Clinton AS-892E Bedienungsanleitung

ML892E-4

CLINTON

MODEL AS-892E

VARIABLE SPEED DC SERVO MOTOR

For

UNION SPECIAL

FEED-OFF-THE-ARM MACHINES

PEDESTAL MOUNT

40-0256-01

SERVICE MANUAL

TABLE OF CONTENTS

ML892E-5

SECTION I - INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION II - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BELT GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LCD DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .

CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER AND CABLE CONNECTIONS . . . . . . . . . . . . . . . . . .

MOTOR ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-2

2-3

SECTION III - SYNCHRONIZER TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

SECTION IV - PROGRAMMABLE LCD DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

MAXIMUM SEWING SPEED . . . . . . . . . . . . . . . . . . . . . . . . .

DIRECT ACCESS PARAMETERS . . . . . . . . . . . . . . . . . . . .

HIDDEN PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MASTER RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PULLEY RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEST PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. TREADLE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. SYNCHRONIZER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . .

3. ENCODER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. DIVIDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

4-3

4-4

4-5

SECTION V - CONNECTOR DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SECTION VI - DRAWINGS AND PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

MAJOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR ASSEMBLY, DC SERVO . . . . . . . . . . . . . . . . . . . .

CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAMMABLE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . .

E-PROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-2

6-4

6-5

6-6

6-7

6-8

SECTION VII COMPLIMENTARY ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 7-1

NEEDLE COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THREAD CATCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC EYE MTG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOOTLIFTER ASSEMBLY (U.S. 35800) . . . . . . . . . . . . . . .

FOOTLIFTER ASSEMBLY (U.S. 36200) . . . . . . . . . . . . . . . .

VENTURI ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7-2

INTRODUCTION

Clinton's Model 892E is an electronically controlled variable speed drive for industrial sewing

machines. The system consists of a brushless DC Servo motor, a microprocessor powered

controller, a synchronizer, speed control, and programmable LCD display. No clutches or brakes

are used. All components interact to give a fast accurate and reliable sewing machine drive. The

components of the system are shown in figure below.

The model 892E has outputs for air thread saver, foot lift, needle cooler and stacker. It can be used

to operate all Clinton chain cutters, as well as various make and model chain cutters.

The programmable LCD display is used to select the desired mode. In addition, the display box is

used to select or change all parameters such as Speeds, Timers, Counters, Toggle Switches, etc.

1-1

SECTION I

ML892E-6

MOTOR

ON / OFF SWITCH

CONTROL BOX

SPEED CONTROL

WASTE CONTAINER

PROGRAMMABLE

LCD DISPLAY

SYNCHRONIZER

BELT GUARD

ML892E-7

SECTION II

INSTALLATION

A. MOTOR

Mount the motor to the pedestal base using the plate,

the motor support arms, the spacers, the bolts, and

washers supplied (See Figure 2-1). Install pulley and

belt then check the following:

a. The motor is mounted so that the motor drive pulley

and sewing machine drive pulley are properlyaligned.

b. The V-belt connecting the motor to the sewing machine

should be tensioned properly. It should be possible to

pull a correctly tensioned belt together between two

fingers within approximately 2 cm (3/4"). Excessive

tension may not only shorten the life of the bearings,

but could also affect the operation of the sewing machine.

A loose belt will affect positioning accuracy.

B. SYNCHRONIZER

1. Install pulley adapter is used (see figure below).

2. Now mount and secure synchronizer to pulley adapter.

3. Mount the synchronizer retaining rod assembly as shown in figure below.

2-1

FIG. 2-1

FIG. 2-2

C. BELT GUARD

After aligning belt and pulleys, install the belt guard (see figure 2-3) starting with the standoff A

and bracket B then add bracket C and belt guard D . Centralize and adjust height and

test for proper clearance.

D. LCD DISPLAY

Mount the LCD display to the motor with the

mounting bracket as shown in figure 2-4.

E. CONTROL BOX

Refer to figure 2-5 and install as follows:

1. Mount primary mounting bracket A to the

top plate of the column B with the two

3/8 screws, washers and lock washers.

2. Fasten L brackets C to control box and

to rear panel plate D with the 10-32

screws provided.

3. Mount On-Off switch and adapter bracket E

as shown.

4. Hook and slide assembly onto bracket A

already fastened to column and screw in

place.

5. Add air control assembly F venturi G

as shown to complete installation.

6. Fasten plastic guard H after power and

cable connections are made.

2-2

ML892E-8

Fig. 2-5

FIG. 2-4

FIG. 2-3

2-3

ML892E-9

H. MOTOR ROTATION

Temporarily remove the "V" belt. Turn power on then move the pedal forward and note the direction

of motor pulley rotation. If incorrect, do the following:

1. Turn power off.

2. Refer to section IV-C, Hidden Parameters, and follow the instructions to change motor rotation.

The parameter is in the "**** Toggle Switches" group.

3. Install the "V" belt.

G. POWER AND CABLE CONNECTIONS

Refer to figure below and connect all cables as shown. The system can be operated from 230V,

3 phase or 230V, single phase power.

Caution: It is important that the ground wire be connected between the motor and sewing

machine to prevent a static charge buildup at the sewhead.

F. SPEED CONTROL

The Clinton model 892E is equipped with

a remote speed control. Connect treadle rod

to ball joint assembly with rod and drill/tap 2

1/4-20 holes as shown. Assemble with 1/4

screws, flat washer and split washer.

Fig.2-6

Fig. 2-7

SYNCHRONIZER TIMING

Turn the power off before making synchronizer adjustments. Refer to figure below for all adjustments

and perform the steps below to time the synchronizer.

1. Remove cover from synchronizer, then loosen the disc locking screw.

2. Rotate the handwheel so that the needle is at its highest position.

3. Rotate the UP sensor disc until the notch is centered in the photo interrupter module.

4. Rotate the down sensor disc until the notch is centered in the photo interrupter module.

5. Rotate the trim disc until the notch is centered in the photo interrupter module.

6. Tighten the disc locking screw and replace the cover.

NOTE: After power is turned on a fine adjustment may be necessary and can be made by

positioning the needle under power and noting the actual needle UP and needle DOWN

stopping positions. If any of the positions are not correct, readjust the appropriate disc.

3-1

SECTION III

ML892E-10

PROGRAMMABLE LCD DISPLAY

A. MAXIMUM SEWING SPEED

Maximum sewing speed can be adjusted by changing the "MAXIMUM SPEED" parameter in the

"LCD" display.

The LCD display, shown below is used to program and set the various parameters of the 892 series,

such as; SPEEDS, TIMERS, COUNTERS, and TOGGLE SWITCHES.

Two (2) different modes of operation are available.

They are:

1. Operating Mode

2. Programming Mode

When power is turned on, the display reads

"OperatingMode".

There are two (2) groups of parameters that are accessed in different ways. They are : (1) parameters

with direct access and (2) hidden parameters with indirect access. In addition a master reset is avail-

able to reset all parameters to their default values.

B. DIRECT ACCESS PARAMETERS

The direct access parameters are divided into four (4) groups. They are (1) SPEEDS, (2) TIMERS,

(3) COUNTERS, and (4) TOGGLE SWITCHES. Table 5-1 describes each parameter, shows

the default value and range of adjustment for each parameter.

4-1

SECTION IV

ML892E-11

To change a parameter, follow the sequence described below.

1. Press the key to enter the programming mode. Continue pressing this key until the para-

meter group that is to be changed is displayed. As an alternative; press the key to enter

the programming mode and display the last changed parameter.

2. Press the key to step to the next parameter in the selected group.

3. Press the key to increase or the key to decrease the contents of the displayed para-

meter. Both keys are used to toggle parameters between states in the Toggle Switches group.

Hold the key closed to make the display step automatically.

4. Press the key to return to the operating mode and save the changed parameters.

4-2

ML892E-12

TABLE 4-1

PARAMETER DESCRIPTION DEFAULT RANGE

SPEED GROUP RPM RPM

MINIMUM

SLOW STRT

VENT.SPD

First speed when pedal is moved forward.

Initial speed at start of cycle (after trim).

This speed is maintained for No. of stitches set by soft

start count parameter.

Speed motor runs while venturi is active

180

500

2000

80-250

150-1000

100-9000

TIMER GROUP MS MS

STRT DEL

VENT TIME

WASTE REM

CUT TIME

Delays machine start to allow presser foot to drop.

Delays venturi shut off after stop.

Waste removal turned on in the seam when this function

is selected.

Cutter on time or pulse length

120

300

0-500

10-2500

15-200

10-250

COUNTER GROUP STITCHES STITCHES

SOFTST

FRNT.CNT

END CNT

WASTE REM

Number of stitches sewn at soft start speed after trim

(EOC).

Number of stitches with venturi on and first cut if enabled

after eye is covered.

Number of stitches with venturi on and end cut if enabled

after eye is uncovered.

Number of stitches with venturi on in the seam if the

waste removal function is selected.

1-25

15-200

TOGGLE SWITCHES

PF/SEAM

PF/EOC

SOFT STRT

HEEL 2

POSITION

Pr. Ft. up or down in seam, treadle neutral.

Pr. Ft. up or down after trim, treadle neutral.

Used to turn soft strt "on" or "off".

If on, needle up. If off footlifter up with heel 2.

Selects the needle position in the seam to UP or DOWN.

DOWN

OFF

ENABLED

DOWN

UP/DOWN

ON/OFF

ENABLE/DISABLE

UP/DOWN

SWITCHES VENTURI

1ST CUT

2ND CUT

TREADLE

START EYE

SEAMLEN

POS STOP

PF STOP

WASTE REM

Turns chopper on/off after start venturi stitch count.

Turns chopper on/off after the end venturi stitch count.

Neutral: Position before cycle starts

Continue: Cycle starts without releasing treadle

Uncov: Cycle starts independent of eye

Covered: Cycle starts only if eye is covered

No Stop: Turns function off

Stop: Motor stops after stitch count is finished

Select needle position after stop

Select presser foot position after stop

Enables/Disables waste removal function

OFF

NEUTRAL

UNCOVERED

NO STOP

DOWN

DISABLED

ON/OFF

NEUTRAL/

CONTINUE

COVERED/

UNCOVERED

STOP/NO STOP

UP/DOWN

ENABLE/DISABLE

ML892E-13

C. HIDDEN PARAMETERS

The parameters in this section are separated from the Direct Access parameters because they are

infrequently changed and should not be changed by the operator. The parameters are listed in:

TABLE 4-2

To enable access to Hidden Parameters, follow the sequence described below.

1. Turn power off, if it is on, then wait until the display goes blank.

2. Press the key and the key simultaneously. Keep pressed then,

3. Turn power on. A series of "***" will appear on the display. They will slowly dissapear.

4. Release the keys then press the key before all the stars dissapear.

5. Press the key repeatedly, until the first hidden parameter group (****SPEEDS) is dis

played.Note that 4 stars (*) as described in section "A".

6. Parameters may then be changed by following the procedure described under

DIRECT ACCESS PARAMETERS (Page 4-1).

4-3

PARAMETER DESCRIPTION DEFAULT RANGE

****SPEEDS RPM RPM

TRIM/POS

MAXIMUM

Machine speed during the position trim cycle.

If *** Tgl switch "position" is set to w/ramp the "trm/pos"

speed affects the slope of the ramp. If "no ramp" is

selected, position speed is constant and can be changed

by the "trim/pos" parameter.

Maximum sewing machine speed. The speed cannot go

higher than 3500 times the pulley ratio.

220

4200

100-400

1000-9900

****MISCELLANEOUS

HYSTERESIS

PF DUTY

The amount the pedal has to be moved when going from

one direction to the other before the speed changes.

Average voltage applied to Pr. Ft. solenoid. The voltage

should be high enough to keep the solenoid energized

without overheating.

1-10

2-10

****TOGGLE SWITCHES

DIRECTION

POSITION

AUTO MODE

SAFETY SW

SAFETY SW SEW

VENT.SPD

Direction of motor rotation viewed from pulley.

Select position with ramp or position at constant speed.

Maximum speed until eye is uncovered.

Set to enable only on machine with trimmer safety sw. If

enabled, machine will not run unless safety switch is

properly connected.

Defines operation of safety switch. If "CLS" machine

starts only when the switch is closed. If "OPN" machine

starts only when the switch is open.

Enable/Disable function.

CCW

W/ RAMP

DISABLE

CLS

DISABLE

CCW/CW

W/ RAMP

OR NO RAMP

ENABLE/DISABLE

CLS/OPN

ENABLE/DISABLE

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