typical GT856D User manual

GT856D
COMPUTER CONTROLLED, DIRECT DRIVE,
ZIGZAG SEWING MACHINE
CONTROL BOX
INSTRUCTION BOOK

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Content
1Control Box Hardware.........................................................................................3
1.1 Inner structure of the Control Box............................................................3
1.2 External Interface of the Control Box.......................................................4
1.3 Power Specification..................................................................................7
1.4 Change the Fuse........................................................................................7
2The Introduction to the Operation Panel and the Sewing Operations............8
2.1 Operation Panel Introduction....................................................................8
2.2 Start up......................................................................................................9
2.3 Sewing of the Standard Patterns .............................................................10
2.4 Sewing of the Left/Right Scallop pattern................................................11
2.5 Sewing of the left/right Bline Stitch pattern ...........................................12
2.6 Sewing of the left/right T Stitch pattern..................................................13
2.7 Sewing of ROM pattern..........................................................................13
2.8 Work zigzag width setting.......................................................................14
2.9 The Work Feed Pitch Length Setting......................................................14
2.10 Sewing Speed Setting .............................................................................14
2.11 Start Condensation Operation.................................................................15
2.12 End Condensation Operation..................................................................17
2.13 Setting the Position of the Sewing Base line..........................................18
2.14 Needle Left/Right Stopping....................................................................18
2.15 Needle Up/Down Stopping.....................................................................19
2.16 Flip operation..........................................................................................19
2.17 Stitch-counted Sew .................................................................................19
2.18 The Enable and Disable of the Presser Foot Lifter.................................20
2.19 The Enable and Disable of the Trimmer and Wiper ...............................20
2.20 Half Stitch Motion ..................................................................................20
2.21 The Use of Reverse Button.....................................................................21
2.22 Restore the Default Setting.....................................................................21
2.23 Use Patterns in U-Disk............................................................................21
3Download Pattern From PC to Machine..........................................................23
4Create Pattern Through Control Panel ............................................................25
5Setting the System Parameter............................................................................28
5.1 The list of the System Parameter............................................................28
5.2 The Setting of the System Parameters....................................................30
5.3 The Description of Specific Parameters .................................................31
6The Test of IO Device..........................................................................................31
6.1 The Test of Input Device.........................................................................32
6.2 The Test of Output Device......................................................................32
7Error Code and Processing Method..................................................................33
8Appendix—ROM Pattern Table........................................................................35

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1Control Box Hardware
1.1 Inner structure of the Control Box
Step Motor Driver
Control Board
Servo Motor Driver
IO board
Fan
5V DC
Pedal switch
Transformer

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1.2 External Interface of the Control Box
RS232 Interface
Operation Panel Interface
Sensor Interface
Servo Motor Encoder Interface
Solenoid Interface
Servo Motor Interface
Zigzag Motor Interface
Feed Motor Interface
Foot lift Solenoid Interface
Control box Power Line
J8
J7
J6
J5
J4
J1
J2
J3
J9

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Control Box’s External Interface Specification:
1. Control Box’s Power Wiring
This interface input AC220V to the Control Box. In the general condition,Power
Wiring is connected to the power button which is under the sewing plate.
The list of the Power wiring
Color Signal
Brown Live line
Blue Neutral line
Yellow/Green Earth line
2.RS232 Interface (J8)
You’ll use the Computer Serial Port line to download the pattern.It is use to connected
to the control box and the computer Serial Port.The Port which is conncted with the
electrical control box is DB9 male connector.And the other Port which is connected
with the computer is DB9 female connector. Computer Serial Port Line is the
common serial port line.We use 2,3,5 three wires in the inner parts.
The list of the J8 Interface Signal
Socket No. Signal
2 PC-RXD
3 PC-TXD
5 GND
Others No Use
3.Control Panel Interface (J7)
Control Panel Interface is used to insert control panel Interface plug.The Plug is DB9
female connector.
4.Sensor Interface (J6)
Sensor Interface is used to connected two step motors’ zero position sensor signal,
machine safe switch and hand switch signal.
The list of the J6 Interface Signal
Signal No. No. Signal
5V 8 1 Reserved Input
GND 9 2 Reserved Input
Hand Switch 10 3 Hand Switch
Machine Safe Switch 11 4 Machine Safe Switch
GND 12 5 GND
Feed Zero Position
Sensor Input 13 6 Zigzag Zero Position Sensor Input
5V 14 7 24V
5.Servo motor encoder signal interface (J5)

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This interface is connected to the servo motor encoder signal plug.
The list of the J5 Interface Signal
Signal No. No. Signal
Up Needle Position
Signal 6 1
Encoder A Phase Signal 7 2 Encoder B Phase Signal
Hall V Phase Signal 8 3 Hall W Phase Signal
GND 9 4 Hall U Phase Signal
10 5 5V
6. Solenoid Interface (J4) The list of the J4 Interface Signal
Signal No. No. Signal
7 1
8 2
Thread Nipper solenoid 9 3 Thread Nipper solenoid
Thread Trimmer solenoid 10 4 Thread Trimmer solenoid
Thread Wiper Solenoid 11 5 Thread Wiper Solenoid
12 6
7.Servo motor interface (J1)
The list of the J1 Interface Signal
No. Signal
1 Earth Wire（Yellow Green）
2 A Phase（Green）
3 B Phase（Yellow）
4 C Phase（Red）
8. Zigzag Motor Interface (J2)
This interface is used to connect to the step motor which drives the motion of the
needle bar. The list of the J2 Interface Signal
Color No. No. Color
Red (A+) 4 1 Green (A-)
5 2 Yellow (B+)
6 3 Blue (B-)
9.Feed motor interface (J3)
This interface is use to connect to the 2 Phase step motor which drives the motion of
the feed dog.

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The list of the J3 Interface Signal
Signal No. No. Signal
5 1 Red（A+）
6 2 Green（A－）
7 3 Yellow（B+）
8 4 Blue（B－）
10 .Foot-lifting Solenoid Interface (J9)
This interface is use to connect to the solenoid which is used to lift the foot.
The list of the J9 Interface Signal
Signal No. No. signal
3 1
Foot Lift solenoid 4 2 Foot Lift solenoid
1.3 Power Specification
Power Voltage: Signal Phase 220V±20％
Supply Current: Average Current is lower than 3 A. Peak Current is lower than 7 A
1.4 Change the Fuse
There are 3 piece fuses on the main control board.
The Capacity and the Usage of the Fuse:
No. Capacity Usage
FP1 10A Protect the Main AC Power
FP2 10A Protect the step motor driver
FP4 10A Protect the Solenoids
In order to avoid the electric shock,When you open the chassis cover,please make sure
to cut off the power and wait 3 minutes at least.

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2The Introduction to the Operation Panel
and the Sewing Operations
2.1 Operation Panel Introduction
No. Key/Display Name Function
1 Basic pattern No. 1 Select basic pattern No. 1
2 Basic pattern No. 2 Select basic pattern No. 2
3 Basic pattern No. 3 Select basic pattern No. 3
4 Basic pattern No. 4 Select basic pattern No. 4
5 Basic pattern No. 5 Select basic pattern No. 5
6 Basic pattern No. 6 Select basic pattern No. 6
7 Basic pattern No. 7 Select basic pattern No. 7
8 Basic pattern No. 8 Select basic pattern No. 8
10 11
13 14
12
19
15
16
17
18
21
20
2322
24
25 26
27
28
28 28

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9 ROM pattern Select ROM-stored pattern
10 Zigzag width Set work zigzag width
11 Baseline position Set baseline position
12 Left/Right Stop Set left stop or right stop option of sewing
13 Start condensation Set parameters for start condensation sewing
14 End condensation Set parameters for end condensation sewing
15 Stitch-counted Sew Set parameters for Stitch-counted sewing
16 Up Down Stop Switch Switch between up needle position stop or down
needle position stop
17 Foot Switch Enable or Disable Foot Lifter
18 Thread Trimmer Switch Enable or Disable Thread Trimmer
19 Thread Wiper Switch Enable or Disable Thread Wiper
20 Speed Control Set Max. sew speed
21 Half Stitch Motion Move needle bar by half cycle
22 Parameter View and set system parameters
23 Set Enter changed mode;Confirm and save all
changes
24 Main Display Show all information except feed pitch
information
25 Reverse Feed Pitch Display Show reverse feed pitch value
26 Normal Feed Pitch Display Show normal feed pitch value
27 Reverse feed switch Switch display between positive reverse feed and
negative reverse feed.
28 Increase(+)/Decrease(-)
keys Adjust value displayed nearby.
The follwing “+” “-” keys have secondary names.
2.2 Start up
The control box will auto start up when its power turns on. During the start
process, after you hear the “Bee Bee” warning tone and the main display show “UP”,
N1+
N1-
N2+
N2-
N4+N3+
N3- N4-

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The operator need to move the hand wheel forward less than one circle by manual
until the warning tone disappear.During the process of the start-up initialization,if the
system find any fault by self check, it will show error code in main display to inform
the user(details please see the chapter 3: Failure Warning and the Processing
method).After Initialization success,the operation panel will enter ready mode, then
you can begin your sewing work.
2.3 Sewing of the Standard Patterns
■Operation steps
1) Turn on the Power.The control panel is at the initial condition. The typical
setting status is as follows.
2) Press one of the basic pattern keys 1 to 8. The indicator nearby that key
will turn on.The system load that pattern and search for step motor origin.
After that, the needle bar move to the start stitch.
3) Press the pedal and beginning your sewing.
4) After finish the sewing, press the pedal backward to trim thread .(Thread
trimmer and wiper is the option item).
■The list of basic sewing patterns:
Pattern
No. Name of pattern Display status Stitch pattern
1 Straight Stitch 1 - - -
2 One step zigzag stitch 2 - - -
3 Two step zigzag stitch 3 - - -
4 Three step zigzag stitch 4 - - -
Main display show
Max.Width(mm) 8.0
Standard pattern 2
indicator ON
Up Down Stop
indicator ON
Foot indicator ON
Trimmer indicator ON
Wiper indicator ON

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5
Left callop
stitch
1 (24 stitch)
5 - 1 -
2 (12 stitch)
5 - 2 -
3 (24 stitch)
5 - 3 -
4 (24 stitch)
5 - 4 -
6
Right callop
stitch
1 (24 stitch)
6 - 1 -
2 (12 stitch)
6 - 2 -
3 (24 stitch)
6- 3 -
4 (24 stitch)
6 - 4 -
7 Left
bline stitch
7 - * *
L-stitch
7 = * *
8 Right
bline stitch
8 - * *
L-stitch 8 = * *
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ROM Pattern P* * * such as P007
2.4 Sewing of the Left/Right Scallop pattern
For example: Sewing Left Scallop No.3 pattern ( 5 – 3 - )
■Operation Steps

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1) Press the Standard Pattern 5 key. The indicator nearby that key will turn
on.At same time the main display area show 5-3- for a second and show
the work width of the pattern after that.
2) If you want to change pattern shape, press “Set” key. The width data in
main display area will blink. At this time you press the Standard Pattern 5
key, the main display will show pattern shape code “5-3-”.
3) Press Increase or Decrease key to change pattern shape code.
4) If you confirm your choice, press “Set” key. Then the main display shows
the work width of the pattern again.
5) Press the pedal and beginning your sewing.
■Note
The sewing of the Right Scallop is similar as aboved.
2.5 Sewing of the left/right Bline Stitch pattern
For example:Sewing the Left Bline Stitch with 5 straight stitch ( 7 – 05 )
■Operation Steps
1) Press the Standard Pattern 7 key. The indicator nearby that key will turn
on.At same time the main display area show 7-05 for a second and show
the work width of the pattern after that.
2) If you want to change pattern’s shape, press “Set” key. The width data in
main display area will blink. At this time you press the Standard Pattern 7
key, the main display will show pattern shape code “7-05”.
3) Press Increase or Decrease key to change straight stitch number. 05
means there is 5 straight stitch between left bline stitch. The straight
stitch number can be set from 1 to 99.
4) Press N2+ key. The main display shows “7=00”. At here you must make
sure the digit equal “7=00”, otherwise the shape will become T stitch
shape.
5) If you press N2- key, the main display show “7-05” again, you can
change straight stitch number again.
6) Press “Set” key to confirm your choice. Then the main display shows the
work width of the pattern again.
7) Press the pedal and beginning your sewing.
■Note
The sewing of the Right Bline is similar as aboved.

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2.6 Sewing of the left/right T Stitch pattern
For example:Sewing the Left T Stitch with 5 straight stitch and 2 repeated T
stitch( 7 =02 )
■Operation Steps
1) Press the Standard Pattern 7 key. The indicator nearby the key will turn
on.At same time the main display area show 7-05 for a second and show
the work width of the pattern after that.
2) If you want to change pattern’s shape, press “Set” key. The width data in
main display area will blink. At this time you press the Standard Pattern 7
key, the main display will show pattern shape code “7-05”.
3) Press Increase or Decrease key to change straight stitch number. 05
means there is 5 straight stitch between left T stitch. The straight stitch
number can be set from 1 to 99.
4) Press N2+ key. The main display shows “7=02”. At here you can set the
repeated time of the T stitch. “02” means the T stitch will be repeated 2
times. The repeated time can be set from 1 to 99. If you set digit to
“7=00”, the shape becomes Bline stitch pattern.
5) If you press N2- key, the main display show “7-05” again, you can
change straight stitch number again.
6) Press “Set” key to confirm your choice. Then the main display shows the
work width of the pattern again.
7) Press the pedal and beginning your sewing.
■Note
The sewing of the Right T stitch is similar as aboved.
2.7 Sewing of ROM pattern
After you press “ROM pattern” key, you can sew the current ROM pattern.
The machine can store up to 1000 ROM patterns, coding from P000 to P999.You
can select one of ROM patterns as current ROM pattern. The operation step to set the
current pattern is:
1) Press “Set” key, the width data shown in the main display blinks.
2) Press “ROM Pattern” key, the main display shows the current ROM pattern
code which is blinking.
3) Press “+”/ “-” key to change the pattern code.
4) Press “Set” key to confirm the change. The display shows the work width data
and stop blinks.

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2.8 Work zigzag width setting
Zigzag width unit: 1.0mm
Max. zigzag width: 8.0mm
Setting precision : 0.1mm
■Operation Steps
Asume the control panel is at the normal condition.
1) Press “Set” key, then press “Zigzag width” key. The width data shown
in the main display blinks.
2) Press “+”/ “-” key to change the width data.
3) Press “Set” key to confirm the change. The display stop blinks.
■Note
The work zigzag width 0 is unchangable for basic pattern 1.
2.9 The Work Feed Pitch Length Setting
The Max. Feed pitch: 5.0mm
Setting Precision: 0.1mm
■ Operation Steps
1) Press corresponding “+” / “-” key to change normal feed pitch data.
2) The data in Normal Feed Pitch Display blinks.Continue to press “+” / “-”
key to change data.
3) Press “Set” key to confirm the change. The data stop blinks.
2.10 Sewing Speed Setting
Asume the control panel is at the normal condition.The main display show
the work zigzag width.
■Operation Steps
1) Press “Speed” key, the main display show the max. work speed .
2) Press “+”/ “-” key to change the speed value.
■Note
The max sewing speed is restricted by the max.zigzag pitch length and the
max.feed pitch length. According to the different stitch structure,the allowed
max.sewing speed is different.You can see the list below.
Max. sewing speed according max zigzag pitch length
No. Max.zigzag pitch length (mm) Max.Speed(spm)
1 0.0 - 2.0 5000
2 2.1 - 3.0 4500

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3 3.1 – 4.0 4000
4 4.1 - 6.0 3500
5 6.1 - 8.0 3000
Max. sewing speed according max zigzag pitch length
No. Max.feed pitch length(mm) Max.Speed(spm)
1 0 5000
2 0.1 – 2.0 3500
3 2.1 - 3.0 3000
4 3.1 - 4.0 2500
5 4.1 - 5.0 2000
2.11 Start Condensation Operation
Panel section concerned with start condensation setting is as below.
■Operation Steps
1) Press “Start condensation” key in the normal state, the indicator nearby
the key will be lit up. The main display will show the number of
condensation stitches in the “A” side. Such as “A-**”
2) Press “Start condensation” key for sencond time, the main display will
show the number of condensation stitches in the “B” side. Such as
“b-**”.
3) Press “Start condensation” key for third time, the main display will show
the width of condensation stitches. Such as “U-**”.The data range is
0.0~8.0mm.If you press “Start condensation” key for fourth time, then
the start condensation operation will be cancelled and the indicator for
start condensation is off and the indicator for pattern width is lit up. Then
reverse feed disp normal feed disp.
rev. feed switch
Indicator for B and C side
Indicator for A and D side

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the main display will show the pattern width.
4) Press “Width” key, the main display will show the pattern width.
5) Press down the pedal to start sewing.If the indicator for start
condensation is on, then the specified numbers of stitches for
condensation is sewed first, then follwed is the normal sewing.
6) After finish the sewing, press the pedal backward to trim thread .
■Note
1) To set feed pitch for A or D side: Press “Reverse feed switch” key to light
up the indicator for A and D side, then the reverse feed display show the
feed pitch for that side. Press corresponding “+”/” “-” key to adjust that
value.
2) To set feed pitch for B or C side: Press “Reverse feed switch” key to light
up the indicator for B and C side, then the reverse feed display show the
feed pitch for that side. Press corresponding “+”/” “-” key to adjust that
value.
■Setting steps for condensation stitches and width
1) Press “Start condensation” key in the normal state, the indicator nearby
the key will be lit up. The main display will show the number of
condensation stitches in the “A” side. You can press the conrresponding
“+”/ “-” key to change this value. The data range is 0~99 stitches.
2) Press “Start condensation” key for sencond time, the main display will
show the number of condensation stitches in the “B” side. You can press
the conrresponding “+”/ “-” key to change this value. The data range is
0~99 stitches.
3) Press “Start condensation” key for third time, the main display will show
the width of condensation stitches.Such as “U-**”.To change this value,
press “Set” key, then the value start to blinks, you can press
conrresponding “+”/ “-” key to change this value. The data range is
0.0~8.0mm.
4) Press “Set” key to save all the changes made.
5) Press pedal to start sewing.
■Note
1) The speed of start condensation: when the work speed is larger than 1200
rpm, the start condensation is sewed by the speed of 1200 rpm.when the
work speed is less than 1200 rpm, it is done as work speed.
2) The condition for start condensation to work is: all of the A,B,U value is
larger than 0 and the indicator for start condensation is on.
3) The start condensation is done before any other sewing operations.
4) To disable start condensation, press “Start condensation” key for four
times. When it is disabled, the indicator is off.

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2.12 End Condensation Operation
■Operation Steps
1) Press “End condensation” key in the normal state, the indicator nearby
the key will be lit up. The main display will show the number of
condensation stitches in the “C” side. Such as “C-**”
2) Press “End condensation” key for sencond time, the main display will
show the number of condensation stitches in the “D” side. Such as
“d-**”.
3) Press “End condensation” key for third time, the main display will show
the width of condensation stitches. Such as “U-**”.The data range is
0.0~8.0mm.If you press “End condensation” key for fourth time, then the
end condensation operation will be cancelled and the indicator for end
condensation is off and the indicator for pattern width is lit up. Then the
main display will show the pattern width.
4) Press “Width” key, the main display will show the pattern width.
5) Press forward the pedal to start sewing.
6) After finish the sewing, press the pedal backward to do end condensation.
If the indicator for end condensation is on, the specified numbers of
stitches for condensation is sewed first, then follwed is the action of
trimming thread .
■Setting steps for condensation stitches and width
1) Press “End condensation” key in the normal state, the indicator nearby
the key will be lit up. The main display will show the number of
condensation stitches in the “C” side. You can press the conrresponding
“+”/ “-” key to change this value. The data range is 0~99 stitches.
2) Press “End condensation” key for sencond time, the main display will
show the number of condensation stitches in the “D” side. You can press
the conrresponding “+”/ “-” key to change this value. The data range is
0~99 stitches.
3) Press “End condensation” key for third time, the main display will show
the width of condensation stitches.Such as “U-**”.To change this value,
press “Set” key, then the value start to blinks, you can press
conrresponding “+”/ “-” key to change this value. The data range is
0.0~8.0mm.
4) Press “Set” key to save all the changes made.
5) Press pedal to start sewing.
6) After finish the sewing, press the pedal backward to do end condensation
and thread trimming.
■Note
1) The speed of end condensation: when the work speed is larger than 1200

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rpm, the end condensation is sewed by the speed of 1200 rpm.when the
work speed is less than 1200 rpm, it is done as work speed.
2) The condition for end condensation to work is: all of the C,D,U value is
larger than 0 and the indicator for end condensation is on.
3) The end condensation is the latest sewing operations.
4) To disable end condensation, press “End condensation” key for four
times. When it is disabled, the indicator for end condensation is off.
2.13 Setting the Position of the Sewing Base line
The default sewing base line is in the center of the zigzag range.The
max.adjustment range is ±4 mm distance from the center.
■Operation Steps
1) Press “Baseline position” key in the normal state, the indicator nearby the
key will be lit up. The main display will show the current base line
position. Such as “L-00”.
2) Press “Set” key to enable the change of the base line position.
3) Press “N1+” key to select the rightward change of the base line.The main
display will show “r-**”. Or press “N1-” key to select the leftward
change of the base line. In that case the main display will show “L-**”.
4) Press the corresponding “+/-” key to change the base line position. The
range of the adjustment range is ( 8.0mm – The work zigzag width) /2.
5) Press “Set” key to save the changes made. The main display show the
current base line position for a second and then show the work width. If
the current base line position is not 0, the indicator for baseline will be lit
up, otherwise, it is off.
■Note
To get rid of the baseline setting, please change the value to 0.
2.14 Needle Left/Right Stopping
When the machine is on the normal state, pressing “Left/Right Stop” key can show the
current stop state on the main display. There are 3 kind of left-right stop state.
Left Stop the display show “三 - - - ”
Right Stop the display show “- - -三”
Free Stop the display show “- - - - ”
End Stop the display show “- -三-”
To set the left-right stop state, operate as following:
1) Press “Set” key. The main display show current stop state and blinks.
2) Press “N1+” key to set to left stop,or press “N4+” key to set to right

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stop,or press “N2+” key to set free stop, or press “N3+” key to set “end
stop” state.
3) Press “Set” key to confirm the change. The display stop blinks.
Note:
“Stitch-counted Sew” will not consider the setting of left/right stopping.
2.15 Needle Up/Down Stopping
When the “Up /Down Stop” indicator lights on, the needle will stop at up position
at the end of sewing. If not, it will stop at down position. Press “Up Down Stop
Switch” key to switch between the two state.
The default set is up stop positioning for the machine.
2.16 Flip operation
For example, in normal state, set down stop position. Then operate as following
steps: 1) Press the “Standard Pattern 5” key. The indicator nearby that key will
turn on.At same time the main display area show 5-3- for a second and
show the work width of the pattern after that.
2) Press “Set” key. The width data in main display area will blink. At this
time you press the Standard Pattern 5 key, the main display will show
pattern shape code “5-3-”.
3) Press “N2+” key to select flip operation, this makes the main display
show “5-3A”.Here you can press “N2-” key to unselect flip function, that
makes the main display show “5-3-“ again.
4) Press “Set” key to confirm you choice.
5) Press pedal to start sewing.
6) Stop sewing, rotate cloth by 90 degree.
7) Press “Reverse Button ” to flip the stitch shape.
8) Press pedal again to start flip sewing.
2.17 Stitch-counted Sew
■Operation Steps
1) Press “Stitch-counted Sew” key in the normal state, the indicator nearby
the key will be lit up. The main display will show the number of stitches
in vertical side.Such as “E-**”. If you want to change this value, press
the corresponding “+”/ “-” key. The biggest stitch number is 99.
2) Press “Stitch-counted Sew” key again, the main display will show the