PLK-E1008H-2008H

Technical Manual (USA Version) Basic Manual with Touch Screen

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Contents
Software Installation Area Limit
PLK-E1008H-2008H with Touch Screen ------------------------------------------------- 1-3 Area Limit Cancel----------------------------------------------------------------------------- 4-6

Touch Screen

Explanation of Basic Screens and Keys --------------------------------------------------- 7-12

Pattern Data Handling

Pattern Read, Write, and Delete from the Floppy Disk --------------------------------- 13-18 Pattern Read, Write, and Delete from the Internal Memory---------------------------- 19-24 Pattern Read Shortcut from Internal Memory -------------------------------------------- 25

Pattern Making

Basic Pattern Input --------------------------------------------------------------------------- 26-33

Knife Pre-Heat Code Modify Pattern Adjustment Other

Function 4 Code Addition ------------------------------------------------------------------- 34-36 Function 4 Code Deletion ------------------------------------------------------------------- 37-39 Home Position Correction ------------------------------------------------------------------- 40-42 Enlargement/Reduction Scale--------------------------------------------------------------- 43-45 Digital Display Reference ------------------------------------------------------------------- 46 Clamp Up After Pattern is Finished-------------------------------------------------------- 47-49 Pattern Internal Memory Format ----------------------------------------------------------- 50-52

Troubleshooting

Input and Output Troubleshooting Mode ------------------------------------------------- 53-58 Test/Automatic Mode ------------------------------------------------------------------------ 59-60

Reference Information

Solenoid Valves ------------------------------------------------------------------------------- 61 Wiring ------------------------------------------------------------------------------------------ 62-73

SOFTWARE INSTALLATION FOR THE PLK-E1008H-2008H

THIS INSTALLATION HAS 4 FLOPPY DISKS/ THE LCD DISPLAY MUST BE PLUGGED IN FLOPPY DISK 1 (F1) MAIN SYSTEM PROGRAM FLOPPY DISK 2 (F2) LANGUAGE DATA FOR THE LCD DISPLAY FLOPPY DISK 3 (F3) IMAGE DATA FOR THE LCD DISPLAY FLOPPY DISK 4 (F4) FONT DATA FOR THE LCD DISPLAY WITH THE POWER OFF, INSERT THE F1 FLOPPY INTO THE DISK DRIVE 1. WHILE PRESSING AND HOLDING IN THE F KEY, TURN THE POWER ON FIRST DISPLAY WILL SHOW

" H !
2. PRESS THE D KEY NEXT DISPLAY

F
LED1

1.
LED2

S
LED3

Y
LED4

S
LED5

" H !

1
LED1

0
LED2

0
LED3

8.
LED4

b
LED5

THE FIRST MODEL NUMBER THAT APPEARS MAY NOT BE THE MACHINE YOU HAVE SELECT YOUR MODEL BY PRESSING THE ! ARROW KEY SELECT MODEL PLK-E1008. THE SCREEN WILL SHOW 1008.b 3. AFTER YOUR SELECTION, PRESS THE D KEY NEXT DISPLAY

" H !

1
LED1

0
LED2

0
LED3

8.
LED4

P
LED5

THE ABOVE SETTING IS THE STEP SEQUENCE. IF YOUR DISPLAY IS DIFFERENT, PRESS THE ! ARROW KEY UNTIL IT SHOWS 1 0 0 8. P. THIS IS AN IMPORTANT STEP

4. PRESS THE D KEY THE MACHINE WILL LOAD THE F1 FLOPPY WAIT UNTIL THE DISPLAY CHANGES TO:

" H !

F
LED1

2.
LED2

L
LED3

b
LED4

L
LED5

TAKE OUT THE F1 FLOPPY AND PUT IN THE F2 FLOPPY 5. PRESS THE D KEY NEXT DISPLAY

" H !

E
LED1

n
LED2

G
LED3

.
LED4

L
LED5

SELECT THE LANGUAGE USING THE ! ARROW KEY THE ABOVE DISPLAY IS ENGLISH OTHER LANGUAGES ARE: SPANISH, JAPANESE, CHINESE, AND FRENCH 6. PRESS THE D KEY AFTER YOUR SELECTION THE MACHINE WILL LOAD THE F2 FLOPPY WAIT UNTIL THE DISPLAY CHANGES TO:

" H !

F
LED1

3.
LED2

P
LED3

I
LED4

C
LED5

TAKE OUT THE F2 FLOPPY AND PUT IN THE F3 FLOPPY 7. PRESS THE D KEY THE MACHINE WILL LOAD THE F3 FLOPPY WAIT UNTIL THE DISPLAY CHANGES TO:

" H !

F
LED1

4.
LED2

F
LED3

n
LED4

T
LED5

TAKE OUT THE F3 FLOPPY AND PUT IN THE F4 FLOPPY

8. PRESS THE D KEY THE MACHINE WILL LOAD THE F4 FLOPPY WAIT UNTIL THE DISPLAY CHANGES TO:

" H !

M
LED1

LED2

3
LED3

1
LED4

0
LED5

THE MACHINE WILL START BEEPING SOFTWARE INSTALLATION IS COMPLETED TURN OFF THE POWER TAKE OUT THE F4 FLOPPY DISK AND STORE ALL THE SOFTWARE DISKS SO THEY WONT GET LOST YOU MAY NEED THEM AGAIN SOMEDAY NOTE 1: WHEN YOU POWER THE MACHINE BACK UP, THE LCD DISPLAY WILL SHOW THAT THERE IS NO PATTERN IN THE MACHINE. YOU MUST USE THE LCD DISPLAY TO READ A PATTERN STORED ON A FLOPPY OR MAKE A PATTERN. PRESS THE ENTER KEY TO GO TO THE STANDARD DISPLAY

NOTE 2: HOWEVER, IF THE SOFTWARE HAS BEEN RE-INSTALLED AND IF THERE WERE PATTERNS IN THE INTERNAL MEMORY OF THE MACHINE, THEY ARE STILL THERE. READ THEM USING THE PATTERN READ FROM INTERNAL MEMORY PROCEDURE

AREA LIMIT CANCEL STANDARD SCREEN 1. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PROGRAM KEY

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE AREA LIMIT KEY

NEXT SCREEN LOOKS LIKE THIS 4. PRESS THE ALC KEY

NEXT SCREEN LOOKS LIKE THIS 5. PRESS THE ON KEY

6. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 7. PRESS THE X KEY

NEXT SCREEN LOOKS LIKE THIS 8. PRESS THE TOP KEY

THE MACHINE WILL WRITE THE NEW SETTING TO MEMORY AND RETURN TO THE STANDARD SCREEN

BASIC SCREENS AND KEYS STANDARD SCREEN PATTERN NAME PATTERN NUMBER

JOG +

SPEED

JOG -

PATTERN READ SHORTCUT

PRESSER FOOT UP/DOWN

MENU HOME IMAGE DISPLAY NEXT SCREEN TO BOBBIN WINDING AND UP/DOWN COUNTER

SCREEN AFTER THE NEXT KEY IS PRESSED

BOBBIN WINDING BACK TO STANDARD SCREEN HOME POSITION CORRECTION

SCREEN AFTER THE BOBBING WINDING KEY IS PRESSED

RETURN TO PREVIOUS SCREEN WHEN IN THIS SCREEN IF THE CLAMP IS LOWERED AND THE START PEDAL IS PRESSED, THE MACHINE WILL ROTATE WITHOUT SEWING THE PATTERN SO A BOBBIN CAN BE WOUND PRESS THE X KEY TO RETURN TO THE PREVIOUS SCREEN AND THEN THE BACK KEY TO RETURN TO THE STANDARD SCREEN STANDARD SCREEN

SCREEN AFTER THE MENU KEY IS PRESSED

SCREENS THAT CAN BE OPENED IN THE MENU MODE

Reading patterns from the floppy disk and internal memory

Writing patterns to the floppy disk and internal memory

Pattern Input

Pattern Modification These keys appear for B data

Pattern Conversion The keys on the right appear for B data. Home position correcting and scaling are the most used

Program Mode Various Settings About 10 of these settings are normally used

10

Input/Output Checking and Setting Mode

Function Mode Pattern copy and internal memory format are the most used

SCREENS THAT CAN BE OPENED IN THE PROGRAM MODE

1/4
1. Wiper 2. Slow start 3. Clamp 4. Area limit 5. Needle position 6. Thread trimming sensor
Wiper on/off Adjusting the operation timing, etc. Slow start on/off Speed change etc. Clamp on/off delay timer setting 2-stage clamp setting 2-stage clamp link Canceling the area limit. Changing the area limit range Adjusting the reverse run angle, up/down stop position angle, etc. Thread trimming sensor on/off Adjusting the number of delay stitches, speed, etc.

11

2/4
1. Home position 2. Halt 3. Counter 4. Brake 5. Presser foot 6. Bobbin winding
Setting return to home operation for various situations, etc. Setting the related operations for when the HALT switch is operated Setting the count method and counter clearing method Weak brake on/off Adjusting the operation time, etc. Presser foot operation timing Using non-stitch feeding with presser foot lowered after basting Adjusting the bobbin winding operation time and speed, etc.

3/4
1. Feed method 2. Speed 3. Thread trimming timing 4. Step 5. Jog 6. Feed angle
Adjusting according to the clamp weight and fabric thickness. Setting the feed, etc. Adjusting the speed for each stage Adjusting the thread trimming and thread release operation, etc. Setting operation with the step file Setting operation when JOG key is pressed, etc. Feed start and feed end angle setting. (Do not change during normal use.)

4/4
1. LCD panel 2. Other 3. Special
Adjustments related to the LCD panel, etc. Other various settings Do not use!

KEYS MOST COMMONLY USED HOME JOG + JOG ENTER NEXT SCREEN MENU PREVIOUS SCREEN EXIT CURRENT MODE PATTERN READ PATTERN WRITE PATTERN INPUT CLEAR LAST ENTRY

12

READING, WRITING, AND DELETING PATTERNS FROM THE FLOPPY DISK READING A PATTERN FROM THE FLOPPY DISK STANDARD SCREEN 1. PRESS THE HOME KEY AND THEN THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PATTERN READ KEY

NEXT SCREEN LOOKS LIKE THIS THE DEFAULT SETTING IS TO READ A PATTERN FROM THE INTERNAL MEMORY 3. PRESS THE FLOPPY DISK KEY TO CHANGE TO THE SCREEN FOR READING A PATTERN FROM THE FLOPPY DISK

13

NEXT SCREEN LOOKS LIKE THIS THE SETTING CHANGES TO READING A PATTERN FROM THE FLOPPY DISK 4. PRESS THE KEY THAT HAS THE NUMBER AND NAME OF THE PATTERN. IN THIS EXAMPLE, 600 WAS PRESSED 5. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS THE PATTERN NAME BOX_X WITH THE NUMBER 600 WAS READ FROM THE FLOPPY DISK NOTE: IF THE SAME PATTERN NUMBER IS IN THE INTERNAL MEMORY, A SCREEN WILL APPEAR ASKING IF YOU WANT TO OVERWRITE THE PATTERN. IF YOU DO NOT WANT TO OVERWRITE THE PATTERN, PRESS THE X KEY AND THE PREVIOUS SCREEN WILL COME BACK. IF THE PATTERNS ARE DIFFERENT AND YOU WANT TO KEEP BOTH OF THEM, WRITE ONE OF THE PATTERNS TO A DIFFERENT NUMBER

14

WRITING A PATTERN TO THE FLOPPY DISK STANDARD SCREEN 1. PRESS THE HOME KEY AND THEN THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PATTERN WRITE KEY

NEXT SCREEN LOOKS LIKE THIS THE DEFAULT SETTING IS TO WRITE THE PATTERN TO THE INTERNAL MEMORY 3. PRESS THE FLOPPY DISK KEY TO CHANGE TO THE SCREEN FOR WRITING A PATTERN TO THE FLOPPY DISK

15

NEXT SCREEN LOOKS LIKE THIS THE SETTING CHANGES TO WRITING A PATTERN TO THE FLOPPY DISK 4. BY PRESSING THE ABC KEY, THE LETTERS IN THE NAME WILL BE ERASED FROM RIGHT TO LEFT 5. USING THE KEYPAD, PUT IN THE NAME OF YOUR CHOICE USING UP TO 8 ALPHANUMERIC CHARACTERS 6. BY PRESSING THE NO KEY, DO THE SAME THING TO CHANGE THE PATTERN NUMBER IN A RANGE FROM 600-799

NOTE 1: TO WRITE THE PATTERN AS A-DATA TO BE USED IN THE PLK-A SERIES MACHINES, SELECT THE PATTERN NUMBER IN A RANGE FROM 100-249 NOTE 2: IF THE SAME PATTERN NUMBER IS ON THE FLOPPY DISK A SCREEN WILL APPEAR ASKING YOU IF YOU WANT TO OVERWRITE THE PATTERN. IF YOU DO NOT WANT TO OVERWRITE THE PATTERN, PRESS THE X KEY AND THE PREVIOUS SCREEN WILL COME BACK. IF THE PATTERNS ARE DIFFERENT AND YOU WANT TO KEEP BOTH OF THEM, WRITE ONE OF THE PATTERNS TO A DIFFERENT NUMBER. IN THIS EXAMPLE, THE NAME WAS CHANGED TO SQUARE AND THE NUMBER WAS CHANGED TO 601 7. PRESS THE ENTER KEY

A WRITE IN PROGRESS SCREEN WILL APPEAR PLEASE WAIT FOR THE PATTERN TO WRITE TO THE FLOPPY DISK

NEXT SCREEN LOOKS LIKE THIS WRITING COMPLETE

16

DELETING A PATTERN FROM THE FLOPPY DISK STANDARD SCREEN 1. PRESS THE HOME KEY AND THEN THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PATTERN READ KEY

NEXT SCREEN LOOKS LIKE THIS THE DEFAULT SETTING IS TO READ THE PATTERN FROM THE INTERNAL MEMORY 3. PRESS THE FLOPPY DISK KEY TO CHANGE TO THE SCREEN FOR READING A PATTERN FROM THE FLOPPY DISK

17

NEXT SCREEN LOOKS LIKE THIS THE SETTING CHANGES TO READING A PATTERN FROM THE FLOPPY DISK 4. PRESS THE KEY THAT HAS THE NUMBER AND NAME OF THE PATTERN IN THIS EXAMPLE, 601 WAS PRESSED 5. PRESS THE PATTERN DELETE KEY

NEXT SCREEN LOOKS LIKE THIS IN THIS EXAMPLE THE PATTERN NUMBER 601 WILL BE DELETED FROM THE FLOPPY DISK NOTE 1: IF YOU DO NOT WANT TO DELETE THIS PATTERN, PRESS THE X KEY AND THE DISPLAY WILL RETURN TO THE PREVIOUS ONE 6. TO CONTINUE WITH THE DELETE PRESS ENTER

NEXT SCREEN LOOKS LIKE THIS PATTERN 601 WAS DELETED FROM THE FLOPPY DISK

18

READING, WRITING, AND DELETING PATTERNS FROM THE INTERNAL MEMORY READING A PATTERN FROM THE INTERNAL MEMORY STANDARD SCREEN 1. PRESS THE HOME KEY AND THEN THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PATTERN READ KEY

NEXT SCREEN LOOKS LIKE THIS THE DEFAULT SETTING IS TO READ A PATTERN FROM THE INTERNAL MEMORY 3. PRESS THE KEY THAT HAS THE NUMBER AND NAME OF THE PATTERN IN THIS EXAMPLE, 601 WAS PRESSED 4. PRESS THE ENTER KEY

19

NEXT SCREEN LOOKS LIKE THIS THE PATTERN NAME SQUARE WITH THE NUMBER 600 WAS READ FROM THE INTERNAL MEMORY

20

WRITING A PATTERN TO THE INTERNAL MEMORY STANDARD SCREEN 1. PRESS THE HOME KEY AND THEN THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PATTERN WRITE KEY

NEXT SCREEN LOOKS LIKE THIS THE NAME NEW IS DISPLAYED 3. BY PRESSING THE ABC KEY, THE LETTERS IN THE NAME WILL BE ERASED FROM RIGHT TO LEFT 4. USING THE KEYPAD, PUT IN THE NAME OF YOUR CHOICE USING UP TO 8 ALPHANUMERIC CHARACTERS 5. BY PRESSING THE NO KEY, DO THE SAME THING TO CHANGE THE PATTERN NUMBER IN A RANGE FROM 600-799

21

NOTE 1: IF THE SAME PATTERN NUMBER IS IN THE INTERNAL MEMORY A SCREEN WILL APPEAR ASKING YOU IF YOU WANT TO OVERWRITE THE PATTERN. IF YOU DO NOT WANT TO OVERWRITE THE PATTERN, PRESS THE X KEY AND THE PREVIOUS SCREEN WILL COME BACK. IF THE PATTERNS ARE DIFFERENT, WRITE ONE OF THE PATTERNS TO A DIFFERENT NUMBER NOTE 2: TO WRITE THE PATTERN AS A-DATA TO BE USED IN THE PLK-A SERIES MACHINES, YOU MUST WRITE THE PATTERN TO THE FLOPPY DISK IN A NUMBER RANGE FROM 100-249 IN THIS EXAMPLE, THE NAME WAS CHANGED TO SQUARE AND THE NUMBER WAS CHANGED TO 601 6. PRESS THE ENTER KEY

A WRITE IN PROGRESS SCREEN WILL APPEAR PLEASE WAIT FOR THE PATTERN TO WRITE TO THE INTERNAL MEMORY

NEXT SCREEN LOOKS LIKE THIS WRITING COMPLETE

22

DELETING A PATTERN FROM THE INTERNAL MEMORY STANDARD SCREEN 1. PRESS THE HOME KEY AND THEN THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PATTERN READ KEY

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE KEY THAT HAS THE NUMBER AND NAME OF THE PATTERN IN THIS EXAMPLE, 601 WAS PRESSED 4. PRESS THE DELETE KEY

23

NEXT SCREEN LOOKS LIKE THIS IN THIS EXAMPLE THE PATTERN NUMBER 601 WILL BE DELETED FROM THE INTERNAL MEMORY NOTE 1: IF YOU DO NOT WANT TO DELETE THIS PATTERN, PRESS THE X KEY AND THE DISPLAY WILL RETURN TO THE PREVIOUS ONE NOTE 2: IF THE PATTERN YOU WANT TO DELETE IS CURRENTLY BEING USED BY THE MACHINE, THE PATTERN CANNOT BE DELETED 5. TO CONTINUE WITH THE DELETE PRESS ENTER

NEXT SCREEN LOOKS LIKE THIS PATTERN 601 WAS DELETED FROM THE INTERNAL MEMORY

24

SHORT CUT FOR READING PATTERNS FROM THE INTERNAL MEMORY STANDARD DISPLAY USE THE KEYS UNDER THE IMAGE DISPLAY FOR READING PATTERNS QUICKLY FROM THE INTERNAL MEMORY IN THIS EXAMPLE, THE KEY NUMBER 601 WAS PRESSED AND THAT PATTERN WAS READ FROM THE INTERNAL MEMORY THIS FUNCTION WILL GIVE QUICK ACCESS TO THE LAST 20 PATTERNS THAT WERE READ FROM THE INTERNAL MEMORY AND IN THE ORDER THEY WERE READ FROM LEFT TO RIGHT

MOVES TO LAST READ

MOVES TO FIRST READ

NOTE: WHEN THE MACHINE IS TURNED ON, THE LIST WILL DISPLAY IN ORDER OF LAST READ

25

PATTERN DATA INPUT FOR PLK-E SERIES WITH HOT KNIFE SIMPLE PATTERN EXAMPLE
START END

3 (FUNCTION 4) (FOR KNIFE PRE-HEATING)

SEQUENCE 1. FEED Y +20MM TO POINT 1 2. SEW X +20MM TO POINT 2 3. SEW Y 40MM TO POINT 3 (INSERT A FUNCTION 4 CODE) NOTE: DEPENDING ON SPEED, THIS CODE NEEDS TO BE PLACED SO THAT AT TRIM TIME THE KNIFES ARE NOT GLOWING RED. TRY ABOUT 20 STITCHES FROM THE END OF THE PATTERN TO START WITH. THE CODE CAN BE ADDED OR DELETED TO ANY PART OF THE PATTERN WHILE MAKING THE PATTERN. IF THE PATTERN IS ALREADY MADE, YOU MUST USE THE MODIFY CODE FUNCTION. 4. SEW X 40MM TO POINT 4 5. SEW Y +40MM TO POINT 5 6. SEW X +29MM TO POINT 6 TO OVERLAP THE START POINT 7. INSERT TRIM CODE 8. INSERT USTP (UP STOP CODE) 9. RETURN/END STANDARD SCREEN 1. PRESS THE HOME KEY AND LOWER THE CLAMP(S) 2. PRESS THE MENU KEY

26

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE PATTERN INPUT KEY

NEXT SCREEN LOOKS LIKE THIS 4. PRESS THE CLEAR KEY

NEXT SCREEN LOOKS LIKE THIS IF NEEDED, USE THIS SCREEN TO CHANGE THE STITCH LENGTH. LEAVE SPEED AT HIGH 5. PRESS THE ENTER KEY

27

NEXT SCREEN LOOKS LIKE THIS 6. PRESS THE HOME KEY

NEXT SCREEN LOOKS LIKE THIS 7. USING THE ARROW KEYS, FEED Y +20MM TO POINT 1 8. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 9. USING THE ARROW KEYS, MOVE X +20MM TO POINT 2 10. PRESS THE ENTER KEY

28

NEXT SCREEN LOOKS LIKE THIS 11. USING THE ARROW KEYS, MOVE Y 40MM TO POINT 3 12. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 13. PRESS THE CODE KEY

NEXT SCREEN LOOKS LIKE THIS 14. PRESS THE FUN 4 KEY (KNIFE PRE-HEAT) 15. PRESS THE ENTER KEY

29

NEXT SCREEN LOOKS LIKE THIS 16. USING THE ARROW KEYS, MOVE X 40MM TO POINT 4 17. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 18. USING THE ARROW KEYS, MOVE Y +40MM TO POINT 5 19. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 20. USING THE ARROW KEYS, MOVE X +29MM TO POINT 6 TO OVERLAP POINT 1 21. PRESS THE ENTER KEY

30

NEXT SCREEN LOOKS LIKE THIS 22. PRESS THE CODE KEY

NEXT SCREEN LOOKS LIKE THIS 23. PRESS THE TRIM KEY 24. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 25. PRESS THE CODE KEY

31

NEXT SCREEN LOOKS LIKE THIS 26. PRESS THE USTP KEY (UP STOP) 27. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 28. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 29. PRESS THE RETURN/END KEY NOTE: MAKE SURE THE NEEDLE IS UP. THE CLAMP WILL MOVE BACK TO THE START POINT.

32

NEXT SCREEN LOOKS LIKE THIS 30. PRESS THE HOME KEY AND WAIT FOR THE SCREEN TO RETURN TO THE STANDARD SCREEN DISPLAY

NEXT SCREEN LOOKS LIKE THIS CHECK THE PATTERN BY USING THE JOG KEYS IF YOU WANT TO SAVE THE PATTERN, WRITE IT TO MEMORY OR TO THE FLOPPY DISK

33

HOW TO ADD A FUN 4 IN A PATTERN STANDARD SCREEN 1. LOWER THE CLAMP 2. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE MODIFY KEY

NEXT SCREEN LOOKS LIKE THIS 4. PRESS THE CODE KEY MAKE SURE THE CODE ADD KEY IS HIGHLIGHTED. IF IT ISNT, PRESS IT.

5. PRESS THE ENTER KEY

34

NEXT SCREEN LOOKS LIKE THIS 6. PRESS THE JOG PLUS KEY TO MOVE THE CLAMP TO THE LOCATION OF THE FUN 4 CODE.

7. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 8. PRESS THE FUN4 KEY

9. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS

10. PRESS THE ENTER KEY

35

NEXT SCREEN LOOKS LIKE THIS 11. PRESS THE TOP KEY

NEXT SCREEN LOOKS LIKE THIS 12. PRESS THE HOME KEY

THE MACHINE WILL RETURN TO HOME POSITION AND WRITE THE NEW SETTING TO MEMORY.

36

HOW TO DELETE A FUN 4 IN A PATTERN STANDARD SCREEN 1. LOWER THE CLAMP 2. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE MODIFY KEY

NEXT SCREEN LOOKS LIKE THIS 4. PRESS THE CODE KEY MAKE SURE THE CODE DELETE KEY IS HIGHLIGHTED. IF IT ISNT, PRESS IT.

5. PRESS THE ENTER KEY

37

NEXT SCREEN LOOKS LIKE THIS 6. PRESS THE JOG PLUS KEY TO MOVE THE CLAMP TO THE LOCATION OF THE FUN 4 CODE.

7. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS

8. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 9. PRESS THE TOP KEY

38

NEXT SCREEN LOOKS LIKE THIS 10. PRESS THE HOME KEY

THE MACHINE WILL RETURN TO HOME POSITION AND WRITE THE NEW SETTING TO MEMORY.

39

HOME POSITION CORRECTION STANDARD SCREEN LOWER THE CLAMP 1. PRESS THE MENU KEY

THE NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE CONVERT KEY

THE NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE HOME POSITION CORRECT KEY TO HIGHLIGHT THE KEY. NORMALLY THE KEY IS ALREADY HIGHLIGHTED. 4. PRESS THE ENTER KEY

40

NEXT SCREEN LOOKS LIKE THIS 5. PRESS THE ON KEY

NEXT SCREEN LOOKS LIKE THIS 6. USE THE ARROW KEYS TO SELECT THE AMOUNT OF CHANGE TO THE HOME POSITION. UP TO 12.7MM 7. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 8. PRESS THE TOP KEY

41

NEXT SCREEN LOOKS LIKE THIS 9. PRESS THE HOME KEY THE SETTING WILL WRITE TO MEMORY AND RETURN TO THE STANDARD SCREEN

42

ENLARGEMENT AND REDUCTION SCALE STANDARD SCREEN 1. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE CONVERT KEY

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE ENLARGE AND REDUCE KEY

4. PRESS THE ENTER KEY

43

NEXT SCREEN LOOKS LIKE THIS STITCH LENGTH CHANGES STITCH LENGTH REMAINS THE SAME THE X AND Y SCALE CAN BE CHANGED USING THE KEYPAD OR THE ARROW KEYS SCALE AND SHIFT THE PATTERN SCALE FROM PATTERN START SCALE FROM HOME POSITION 5. SELECT SCALE FROM PATTERN START FOR THIS EXAMPLE 6. PRESS THE ENTER KEY NEXT SCREEN LOOKS LIKE THIS 7. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 8. PRESS THE HOME KEY

44

NEXT SCREEN LOOKS LIKE THIS 9. PRESS THE TOP KEY

NEXT SCREEN LOOKS LIKE THIS 10. PRESS THE HOME KEY

THE SETTING WILL WRITE TO MEMORY AND RETURN TO THE STANDARD SCREEN.

45

Digital Display Reference

Numeral Digital display
Characters

Digital display
Characters

Digital display
Characters

Digital display

46

CLAMP UP AFTER THE SEWING PATTERN IS FINISHED STANDARD SCREEN 1. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE PROGRAM KEY

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE CLAMP KEY

47

NEXT SCREEN LOOKS LIKE THIS 4. PRESS THE RPT KEY

NEXT SCREEN LOOKS LIKE THIS 5. PRESS THE OF KEY

6. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS 7. PRESS THE X KEY

48

NEXT SCREEN LOOKS LIKE THIS 8. PRESS THE TOP KEY

THE MACHINE WILL WRITE THE NEW SETTING TO MEMORY AND RETURN TO THE STANDARD SCREEN

49

PATTERN INTERNAL MEMORY FORMAT NOTE: ANY PATTERNS IN THE INTERNAL MEMORY WILL BE DELEATED. SAVE ANY IMPORTANT PATTERNS TO FLOPPY DISK BEFORE YOU FORMAT. STANDARD SCREEN 1. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 2. PRESS THE FUNCTION KEY

50

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE FORMAT KEY

NEXT SCREEN LOOKS LIKE THIS 4. PRESS THE INTERNAL MEMORY KEY

5. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS

6. PRESS THE ENTER KEY

NOTE: TO RETURN TO THE PREVIOUS SCREEN, PRESS THE X KEY.

51

NEXT SCREEN LOOKS LIKE THIS

7. PRESS THE ENTER KEY

NEXT SCREEN LOOKS LIKE THIS

8. PRESS THE X KEY

NEXT SCREEN LOOKS LIKE THIS 9. PRESS THE TOP KEY

THE MACHINE WILL RETURN TO THE STANDARD SCREEN

52

INPUT AND OUTPUT MODE FOR TROUBLESHOOTING STANDARD SCREEN 1. PRESS THE HOME KEY 2. PRESS THE MENU KEY

NEXT SCREEN LOOKS LIKE THIS 3. PRESS THE INPUT/OUTPUT KEY

NEXT SCREEN LOOKS LIKE THIS 4. PRESS THE INPUT TEST KEY

53

THIS SCREEN WILL SHOW THE STATUS OF THE INPUTS IN THIS SCREEN INPUT 2 IS CLOSED IF THE ARROW MOVES OR AN ERROR SCREEN POPS ON WHEN THE INPUT IS SWITCHED FROM OFF/ON OR ON/OFF, THEN THAT INPUT IS WORKING USING THE INPUT REFERENCE INFORMATION BELOW, VARIOUS INPUTS ON THE PLK-E1008H-2008H MACHINES CAN BE CHECKED. MANUALLY ACTIVATING THE VALVES MAY BE HELPFUL 5. AFTER TESTING, PRESS THE X KEY

INPUT REFERENCE INFORMATION

INPUT SENSOR AND AIR CYLINDER STATUS AT HOME POSITION IN THE AUTOMATIC MODE TERMINAL SIGNAL CONDITION FUNCTION CON I/PIN 2 I1 ON/OFF START/GREY FOOT PEDAL CON I/PIN 3 I2 ON/OFF CLAMP/BLACK FOOT PEDAL CON H/PIN 3 I4 ON/OFF EMERGENCY STOP SWITCH TE1-A2/WHITE I5 ON THICKNESS DETECTOR/CYLINDER RE-TRACTED TE1-A4/GREEN I6 OFF UPPER TRIMMER INPUT/CYLINDER RE-TRACTED TE1-A6/YELLOW I7 ON UPPER TRIMMER INPUT/CYLINDER RE-TRACTED TE1-A8/LT. BROWN I8 OFF THREAD PULLER INPUT/CYLINDER EXTENDED TE1-A10/BLUE I9 ON WIPER INPUT/CYLINDER RE-TRACTED TE1-B4/GREY IA OFF WIPER INPUT/CYLINDER RE-TRACTED TE1-B6/LT. GREEN IB ON TENSION RELEASE INPUT/CYLINDER RE-TRACTED TE1-B8/PURPLE IC OFF TENSION RELEASE INPUT/CYLINDER RE-TRACTED TE1-B10/BROWN ID OFF PRESSER FOOT INPUT/CYLINDER RE-TRACTED TE2-A1/PINK IE ON PRESSER FOOT INPUT/CYLINDER RE-TRACTED TE2-A3/WHITE/STRIPE IF OFF LOWER TRIMMER INPUT/CYLINDER RE-TRACTED TE2-B1/RED/STRIPE IG ON LOWER TRIMMER INPUT/CYLINDER RE-TRACTED TE2-B3/WHITE IH ON/OFF ON--AUTOMATIC MODE-------------OFF--TEST MODE CON G/PIN 3 II ON/OFF LOWER TRIMMER DISABLE SWITCH CON G/PIN 4 IJ ON/OFF UPPER TRIMMER DISABLE SWITCH

54

VALVE REFERENCE INFORMATION VALVES LOCATED UNDER LEFT COVER OF THE MACHINE THICKNESS DETECTOR

LEFT CLAMP

RIGHT CLAMP

UPPER TRIMMER

THREAD PULLER

WIPER

TENSION RELEASE

LOWER TRIMMER

PRESSER FOOT

NEEDLE COOLER

NEXT SCREEN LOOKS LIKE THIS 6. PRESS THE OUTPUT STATUS KEY

55

THIS SCREEN WILL SHOW THE CURRENT STATUS OF THE OUTPUTS IN THIS SCREEN THE OUTPUTS THAT ARE LIGHTED WILL BE ON THE OUTPUTS THAT ARE DARK WILL BE OFF

7. PRESS OUTPUT TEST KEY THIS SCREEN IS USED TO CHECK THE SOLENOIDS BY PRESSING AND RELEASING THE OUTPUT NUMBER OR LETTER, THAT SOLENOID CAN BE CHECKED USING THE OUTPUT REFERENCE INFORMATION BELOW, VARIOUS OUTPUTS ON THE PLK-E1008H-2008H MACHINES CAN BE CHECKED. CAUTION: YOU HAVE TO REMOVE THE PRESSER FOOT IN ORDER TO CHECK THE UPPER KNIFE TO PREVENT CRASHING THE KNIFE TIP INTO THE FOOT 8. AFTER TESTING, PRESS THE X KEY OUTPUT REFERENCE INFORMATION OUTPUTS SIGNAL FUNCTION O1 LOWER TRIMMER O2 WIPER O3 TENSION RELEASE O4 LEFT CLAMP O5 PRESSER FOOT O6 HEATER O7 THICKNESS DETECTOR O8 RIGHT CLAMP O9 UPPER TRIMMER OA THREAD PULLER OB NEEDLE COOLER OH BUZZER

TERMINAL CON 7 CON 9 CON 10 CON 8 CON 11 TE2-A4 TE2-A5 TE2-A6 TE2-A7 TE2-A8 TE2-A9 CON-G/PIN 13

56

NEXT SCREEN LOOKS LIKE THIS 9. PRESS THE X KEY

NEXT SCREEN LOOKS LIKE THIS 10. PRESS THE ENCODER/SENSOR/DETECTOR KEY

THIS SCREEN IS USED TO CHECK THE SYNCHRONIZER MOTOR ENCODER X/Y HOMING SENSORS 11. ROTATE THE MACHINE HAND WHEEL TO CHECK THE SYNCHRONIZERS UP AND DOWN POSITION 12. ROTATE THE MOTOR PULLEY TO CHECK THE MOTOR ENCODER 13. MOVE THE CLAMP IN THE X AND Y DIRECTION TO CHECK THE X/Y HOMING SENSORS NOTE: IF THE ARROW MOVES, OR THE WHEEL ROTATES, THAT INPUT IS WORKING

14. AFTER CHECKING, PRESS THE X KEY

57

NEXT SCREEN LOOKS LIKE THIS 15. PRESS THE TOP KEY

NEXT SCREEN LOOKS LIKE THIS STANDARD SCREEN INPUT/OUTPUT TEST COMPLETE

58

USING THE TEST MODE STANDARD SCREEN

1. TURN ON THE POWER 2. PRESS THE HOME KEY THERE IS A TOGGLE SWITCH TO THE LEFT OF THE EMERGENCY STOP PUSH BUTTON ON IS THE AUTOMATIC MODE OFF IS THE TEST MODE 3. SELECT THE OFF POSITION (TEST MODE)

NEXT SCREEN LOOKS LIKE THIS

THIS IS THE TEST MODE SCREEN USED TO CHECK THE FOLLOWING: (A) TO CHECK EACH SOLENOID BY PRESSING A BUTTON OR KEY NUMBER (B) TO CHECK OR ADJUST THE SENSORS THAT ARE MOUNTED TO THE AIR CYLINDERS (C) TO CHECK THE RELAY FOR THE HEATERS (D) TO SET THE HEIGHT OF THE UPPER KNIFE WHEN IT IS EXTENDED TO BURN THE THREAD (E) TO EXECUTE A COMPLETE KNIFE CYCLE TEST

SEQUENCE EXAMPLE OF USING THE TEST MODE NOTE 1: THE PRESSER FOOT, TENSION RELEASE, WIPER, LOWER HEATER AND UPPER HEATER HAVE 2 SENSORS PER AIR CYLINDER. THE THREAD PULLER AND STOPPER HAVE 1 SENSOR PER AIR CYLINDER. WHEN ACTIVATING THE SOLENOIDS WATCH THE LEDS ON THE SENSORS TO MAKE SURE THAT THEY TURN OFF AND ON WHEN EXTENDING AND RE-TRACTING THE CYLINDERS. IF ONE THE SENSORS IS OUT OF ADJUSTMENT THE KNIFE CYCLE WILL NOT COMPLETE WHEN KEY 15 IS PRESSED. BUTTONS PRESS THE PRESFOOT BUTTON TO CHECK THE PRESSER FOOT AND ITS SENSORS PRESS THE RELEASE BUTTON TO CHECK THE TENSION RELEASE AND ITS SENSORS PRESS THE PULLER BUTTON TO CHECK THE THREAD PULLER AND ITS SENSOR PRESS THE WIPER BUTTON TO CHECK THE WIPER AND ITS SENSORS PRESS THE STOPPER BUTTON TO CHECK THE UPPER HEATER HEIGHT AND ITS SENSOR PRESS THE LOW TRIM BUTTON TO CHECK THE LOWER HEATER AND ITS SENSORS PRESS THE UPPER_TRIM BUTTON TO CHECK THE UPPER HEATER AND ITS SENSORS PRESS THE RESET BUTTON TO PUT ALL CYLINDERS BACK TO ORIGINAL POSITION

59

NOTE 2: IN SOME CASES THE BUTTON SEQUENCE MAY NOT WORK REMEMBER THAT: THE PRESSER FOOT MUST BE UP BEFORE THE WIPER CAN EXTENDED THE WIPER MUST BE EXTENDED BEFORE THE STOPPER CAN COME DOWN THE STOPPER MUST BE DOWN BEFORE THE UPPER HEATER CAN BE EXTENDED

KEYS PRESS KEY 08 TO CHECK THE HEATERS FOR 2.5 SECONDS PRESS KEY 09 TO CHECK THE NEEDLE COOLER BY PRESSING KEY 12, THE HEATER BUZZER CAN BE TURNED OFF PRESS KEY 15 TO EXECUTE A COMPLETE KNIFE CYCLE TEST 4. WHEN FINISHED, PRESS THE RESET KEY 5. PUT THE TOGGLE SWITCH BACK TO THE ON POSITION (AUTOMATIC MODE)

60

VALVE REFERENCE INFORMATION VALVES LOCATED UNDER LEFT COVER OF THE MACHINE THICKNESS DETECTOR

LEFT CLAMP

RIGHT CLAMP

UPPER TRIMMER

THREAD PULLER

WIPER

TENSION RELEASE

LOWER TRIMMER

PRESSER FOOT

NEEDLE COOLER

61

Wiring
INPUT SENSOR AND AIR CYLINDER STATUS AT HOME POSITION IN THE AUTOMATIC MODE TERMINAL SIGNAL CONDITION FUNCTION CON I/PIN 2 I1 ON/OFF START/GREY FOOT PEDAL CON I/PIN 3 I2 ON/OFF CLAMP/BLACK FOOT PEDAL CON H/PIN 3 I4 ON/OFF EMERGENCY STOP SWITCH TE1-A2/WHITE I5 ON THICKNESS DETECTOR/CYLINDER RE-TRACTED TE1-A4/GREEN I6 OFF UPPER TRIMMER INPUT/CYLINDER RE-TRACTED TE1-A6/YELLOW I7 ON UPPER TRIMMER INPUT/CYLINDER RE-TRACTED TE1-A8/LT. BROWN I8 OFF THREAD PULLER INPUT/CYLINDER EXTENDED TE1-A10/BLUE I9 ON WIPER INPUT/CYLINDER RE-TRACTED TE1-B4/GREY IA OFF WIPER INPUT/CYLINDER RE-TRACTED TE1-B6/LT. GREEN IB ON TENSION RELEASE INPUT/CYLINDER RE-TRACTED TE1-B8/PURPLE IC OFF TENSION RELEASE INPUT/CYLINDER RE-TRACTED TE1-B10/BROWN ID OFF PRESSER FOOT INPUT/CYLINDER RE-TRACTED TE2-A1/PINK IE ON PRESSER FOOT INPUT/CYLINDER RE-TRACTED TE2-A3/WHITE/STRIPE IF OFF LOWER TRIMMER INPUT/CYLINDER RE-TRACTED TE2-B1/RED/STRIPE IG ON LOWER TRIMMER INPUT/CYLINDER RE-TRACTED TE2-B3/WHITE IH ON/OFF ON--AUTOMATIC MODE-------------OFF--TEST MODE CON G/PIN 3 II ON/OFF LOWER TRIMMER DISABLE SWITCH CON G/PIN 4 IJ ON/OFF UPPER TRIMMER DISABLE SWITCH

TERMINAL CON 7 CON 9 CON 10 CON 8 CON 11 TE2-A4 TE2-A5 TE2-A6 TE2-A7 TE2-A8 TE2-A9 CON-G/PIN 13

OUTPUTS SIGNAL FUNCTION O1 LOWER TRIMMER O2 WIPER O3 TENSION RELEASE O4 LEFT CLAMP O5 PRESSER FOOT O6 HEATER O7 THICKNESS DETECTOR O8 RIGHT CLAMP O9 UPPER TRIMMER OA THREAD PULLER OB NEEDLE COOLER OH BUZZER

62

CHART OF CONNECTING WIRES

63

(1).Outside of control box

Control box Model name PLK-E-CU -20

Other voltage refer to "[15]Several power supply"

CONB Control box main power supply

60-9090-306-108-005 60-9090-0423-99-805

Detector
Pushbutton switch assay
BM090C349G01

To
770361-1 350418-1

CABLE1

60-9090-304-218-006 60-9090-0322-99-805

CONA Main motor

Main motor
Stepping motor X

To
172339-1 172331-1 172339-1 170359-1 170361-1 170359-1

CABLE2

60-9090-304-118-006 60-9090-0322-00-805 640582-1 350689-1

60-9090-304-118-006 60-9090-0322-00-805

X home sensor(E2S-W23)
350779-1 2P-4P 350690-1 1P 350689-1 350780-1 1,2,4P 350689-1 3P 350690-1

CONC Stepping motor

COND Output of solenoid
CONE RS-232C CONF Teaching panel
CONG Input/output

350780-1 2P-4P 350689-1 1P 350690-1 350780-1 1,2,4P 350689-1 3P 350690-1

X
Y

X Stepping motor Y Y home sensor (E2S-W23) Y

Teaching panel (option)

60-8263-3048-15-001 60-8263-0513-00-808

PLK-E-CON P.W.B

CON5

+12V Y home sensor 0V 0V +12V X home sensor 0V I4(Halt) 0V +12V O6(Buzzer) +24V O1(Trim)

1 2 3 4 1 2 3 1 2 3 4 1 2 1 2 1 2 3 1 2 1 2 3

1 2 3 4 1 2 3 1 2 3 4 1 2 1 2 1 2 3 1 2 1 2 3

60-8263-3038-15-000 60-8263-0513-00-808

CON2
CON1
CABLE1
770372-1 350417-1

CON4

CONH Input signal

171822-4 170204-1

CON3

Halt switch
1 2

Control box

CONI Foot switch

To detector
CON7

60-8263-3028-16-000 60-8263-0617-00-808 T
5195-02-BU 5225TL
5197-02 5225TL

1 2

Bz

60-8263-3028-15-000 60-8263-0513-00-808

Buzzer

Foot switch

Trim

CABLE2

172160-1 170362-1

To main motor encoder

CON8
CON9

+24V O4(Clamp) +24V N.C. O2(Wiper) +24V O3(Thread release) +24V N.C. O5(Presser foot)

FU

Clamp Wiper Tread release

TE1

TE2

Terminal1

Terminal2

CON10
CON11

5195-03 5225TL
5196-02-BU 5225TL

PF

Presser foot

Into sewing machine head

5197-03 5225TL

64

(2).Inside of control box

Control box
Model name Grey
CON1

PLK-E-CU -20 Transformer Orange Orange Black Black (BKO-E3160H01)

FDD CON2

Brown Blue

CONB
Control box main power supply

CONA
Main motor

PLK-B-DISP

P.W.B
CON1 CON5 CON4 CON6 CON7

CONC
Stepping motor

CON1
To PLK-B1-PCCON P.W.B CON1

PLK-B1-PMD-E P.W.B
CON3 CON9

CON8

COND
Output of solenoid

CON2

CONE
RS-232C

CON9 CON6 CON5

CON5

CONF
CON7 Teaching panel

CON4

CONG
Input/output signal

CON2

CON4

CONH
Input signal

CON3

CON3 CON1

CON6

CONI
Foot switch

Brake

register MFS30A

CON10

101K 100ohm

CON1

XC-E2-1B-PLK P.W.B

PLK-B1-CPU-E P.W.B

65

60-9090-306-108-002
1. 3phi AC200V -- 240V
Red White Black Green

50/60Hz
Red White 1 2 Black Green 5 Green

OFF ON

3 4 6

To control box CONB

Push button switch assay M090C349G03

Power unit model name 60-9090-306-108-002

2.3phi AC380V -- 415V
Black Brow Blue Green/ Yellow

PLK-B-PUC-B40 60-9090-305-108-005
1 2 3 4 5 1 Brown 2 3 Blue 4 Green/ 5 Yellow
Black

50/60Hz (Except Europe) 2 Blue 3 4 Green 5 Green/ 6

Yellow Black Brown 1

OFF ON

Push button switch assay M090C349G08

1 Brown 2 3 Blue 4 5 6

Black

F1 5A

3-phase transformer 3phi 800VA BKO-E3138H02 60-9090-304-118-006

Black

u v w

Brow V Blue W F2 5A

Blac k Red Blue

Black Red Blue Green/ Yellow

1 2 3 4

1 2 3 4

Blac Brow k Blue Green/ Yellow

60-9090-304-218-006 60-9090-304-118-006

2 3 4 Green/ 5 Yellow Green/ 6

Yellow

Black 1 Brown

To control box CONB

60-9090-306-208-002

Green/ Yellow Green/ Yellow

60-9090-306-108-005

Ground

66

60-9090-306-108-005
3.1phi AC100V -- 120V 50/60Hz

Power unit model name

PLK-B-PUC-A10 60-9090-304-108-005
1 2 3 4 1 Brown 2 Blue 3 Green/ Yellow 4
Black

Single-phase transformer 1phi 600VA BKO-E3140H03 1 2 White Black 3 4 Green 5 6 Green 1 2 Black 3 Brown 4 5 6
Black 100V

60-9090-305-108-005
1 2 3 4 5 1 Brown 2 3 Blue 4 Green/ 5 Yellow
Black Black 1 Brown Blue Green/ Yellow Green/ Yellow

200V

Black

White Black Green OFF ON

F1

20A

0V

0V Red

Push button switch assay M090C350G05

60-9090-304-218-006
Green/ Yellow

2 3 4 5 6

To control box CONB

60-9090-305-208-005

60-9090-306-108-005

60-9090-306-108-005

Ground

Green/ Yellow

60-9090-306-108-005
4.1phi AC200V -- 240V
Blue Brown Green/ Yellow OFF ON

Noise filter unit model name

Ferrite core

PLK-E-NU-20 60-9090-304-118-006
Black Brown 1 Blue 2 PLK-B1-FIL P.W.B Black Brown Blue Green/ Yellow

60-9090-305-108-005
1 2 3 4 5 1 Brown 2 3 Blue 4 Green/ 5 Yellow
Black Black 1 Brown Blue

50/60Hz (Europe)

Push button switch assay M090C433G02

2 3 Green 4 5 Green/ 6
Yellow

Blue Brown 1

1 Brown 2 3 Blue 4 5 Green/ Yellow 6

Black

3 Green/ Yellow 4

1 2 3 4

2 3 4 Green/ 5 Yellow Green/ 6

Yellow

To control box CONB

60-9090-306-208-005

Ground

Green/ Yellow

60-9090-305-208-005

60-9090-306-108-005

60-9090-306-108-005
5.1phi AC200V -- 240V
Blue Brow Green/ Yellow OFF ON

50/60Hz (Except Europe) 2 3 4 Green 5 Green/ 6

Yellow Blue Brown 1

To control box CONB

Push button switch assay M090C433G02

67

Control box connectors layout

Control box main power supply (Connect to push button switch or power unit or noise filter unit)

CONA ! $ " %

CONB ! % $ # " &

Main motor (Connect to motor)

main

Stepping motor (Connect to stepping motoring sewing machine head)

! $ " % # & ' ( !% $ "# ! " # ' 0 0 0 0 0 $ % & ( 0 0 0 0 0

CONC

CONE

RS-232C (option)

CONF

Teaching panel (option)

1 1 ! " # ' 0 0 0 0 0

COND

! $ " % # & ' (

) * + , . /

$ % & ( 0 0 0 0 0

CONG

Input/output signal

Output of solenoid (Connect to dewing machine head)

! " # ' 0 0 0 0 0

!% & ($ ' # "

1 1 1 1

$ % & ( 0 0 0 0 0

CONH

Input signal (Connect to sewing machine head)

CONI

Foot switch (Connect to foot switch)

Rear view of control box

68

Pin No. of connectors

1.Main motor (CONA) Signal

4.Out of solenoid (COND) (Same as PLK-B1-CON P.W.B CON2.) Signal Initial setting Pin No. U 1 O1 1 V 2 Trim W 3 O3 2 Thread release PE 4 Table1-1 O5 3 Presser foot OB 4 Function output 1 2.Control box main power supply (CONB) O9 5 Function output 3 Signal Pin No. O7 6 Virtual output 1 O6 7 1 Buzzer R +24V 8 2 S O2 9 3 Wiper T O4 10 4 Clamp OC 11 5 Clamp2 output E Table1-2 OA 12 6 PE Function output 2 O8 13 Virtual output 1 OSC2 14 3.Stepping motor (CONC) Signal Table1-4 Pin No. +24V 15 XAN 1 6.Foot switch (CONI) XAP 2 Signal Initial setting Pin No. XBN 3 XBP +12V 1 4 YAN I1 Start 2 5 YAP I2 Clamp1 3 6 YBN I3 Nothing 4 7 Table1-3 YBP GND 5 8 GND 6 5.RS-232C (CONE) N.C. 7 Signal Pin No. GND 8 Table1-6 E Body 1 +12V 2 RXD 8.Input signal (CONH) 3 N.C. (Same as PLK-B1-CON P.W.B CIN2.) 4 TXD Signal Initial setting Table1-5 Pin No. 5 GND +12V 1 7.Teaching panel (CONF) +5V 2 Signal Pin No. I4 Halt 3 I5 Nothing 4 1 R0 I6 Nothing 5 2 VP5 IA Nothing 6 3 R1 I7 Nothing 7 4 0V IB Nothing 8 5 R2 I8 Nothing 9 6 0V IC 10 7 Needle up/down R3 8 11 X home sensor X home sensor -9V 9 12 Y home sensor Y home sensor R4 10 13 N.C. E 11 14 I9 R5 12 15 ID R/W 13 16 UP R6 14 17 DN A0/RS 15 18 PG R7 16 19 EA PD8 17 20 EB S0 18 IE 21 Thread trimming protect PD9 19 IG 22 Needle thread sensor S1 20 IF 23 Clamp2 input PD10 21 IH 24 S2 Clamp step forward 22 0V 25 PD11 23 0V 26 +12V 24 PD12 25 OA0 26 PD13 27 OA1 28 PD14 29 OA2 30 PD15 31 OA3 32 DIR 33 VP5 34 NOE 35 N.C. Table1-7 36 N.C. Pin No.

Table1-8

69

How to use the terminal 1,2 and connectors

1.Input/output signal (CONG) Signal Initial setting 0V 0V Jog + II Jog IJ Reset IK Winding IL Trim prohibit IM Wiper prohibit IN Nothing IO Nothing IP 0V 0V OH Nothing OI Nothing OJ Nothing OK Nothing OL Nothing OM Nothing ON Down position OO Error OD OE OF OG +12V +12V
Operation preparation completion Halt in progress Sewing completion

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Switch

Power supply +12V of CONG, Terminal 1,2 maximum 300mA. If you want to more ampere, put on power supply to outside of control box.

Output

Home position

Table2-1 Switch

2.Terminal 1 (Into sewing machine head) Signal 0V I5 0V I6 0V I7 0V I8 0V I9 +12V +12V +12V IA +12V IB +12V IC +12V ID Initial setting Nothing Nothing Nothing Nothing Virtual input 0 Nothing Nothing Needle up/down

3.Terminal 2 (Into sewing machine head) Signal IE 0V IF O6 O7 O8 O9 OA OB OC IG +12V IH +24V +24V +24V +24V +24V +24V OSC2 Initial setting
Thread trimming protect

Virtual input 1

Pin No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Pin No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Switch

Clamp2 input Buzzer Virtual output 1 Virtual output 0 Function output 3 Function output 2 Function output 1 Clamp2 output Needle thread trimming sensor Clamp step forward

Output
Bz

Table2-2

Table2-3

70

Brown Red Black or White Blue Black

Needle thread Trimming sensor

0V IG +12V

Table of connection into control box

1.CPU -- PMD CPU CON10-1 CON10-3 CON10-5 CON10-7 CON10-9 CON10-11 CON10-13 CON10-15 CON10-17 CON10-19 CON10-21 CON10-23 CON10-25 CON10-27 CON10-29 CON10-31 CON10-33 CON10-35 CON10-37 CON10-39 CON10-41 CON10-43 CON10-45 CON10-47 CON10-49 2.PMD -- FDD PMD CON7-1 CON7-2 CON7-3 CON7-4 Z11 +12V +5V ZI11 SOL-OC ZI22

*( Signal

) Initial setting PMD CON3-1 CON3-3 CON3-5 CON3-7 CON3-9 CON3-11 CON3-13 CON3-15 CON3-17 CON3-19 CON3-21 CON3-23 CON3-25 CON3-27 CON3-29 CON3-31 CON3-33 CON3-35 CON3-37 CON3-39 CON3-41 CON3-43 CON3-45 CON3-47 CON3-49 CPU CON10-2 CON10-4 CON10-6 CON10-8 CON10-10 CON10-12 CON10-14 CON10-16 CON10-18 CON10-20 CON10-22 CON10-24 CON10-26 CON10-28 CON10-30 CON10-32 CON10-34 CON10-36 CON10-38 CON10-40 CON10-42 CON10-44 CON10-46 CON10-48 CON10-50 Signal Z12!"# +12V +5V RESERV ZCRS ZI12
O1(Trim) O7(Virtual output 1) O9(Function output 3) OB(Function output 1) O5(Presser foot)

O6(Buzzer) O8(Virtual output 0) OA(Function output 2) OC(Clamp 2 output) O3(Thread release)

Z21 YI22 Y22 YI12 Y12 XI22 X22 XI12 X12 X11 XPD RA GND

O4(Clamp 1 output)

ZI21 Z22 YI21 Y21 YI11 Y11 XI21 X21 XI11 PMD-OC YPD ZPD GND

O2(Wiper)

PMD CON3-2 CON3-4 CON3-6 CON3-8 CON3-10 CON3-12 CON3-14 CON3-16 CON3-18 CON3-20 CON3-22 CON3-24 CON3-26 CON3-28 CON3-30 CON3-32 CON3-34 CON3-36 CON3-38 CON3-40 CON3-42 CON3-44 CON3-46 CON3-48 CON3-50

*CPU..PLK-B1-CPU-E P.W.B *PMD..PLK-B1-PMD-E P.W.B *XC-E..XC-E2-1B-PLK P.W.B *DISPPLK-B-DISP P.W.B *CONB.Control box main power supply *FDDFloppy disk driver

Table 3-1

Signal FD5V N.C. N.C. N.C.

FDD CON2-1 CON2-2 CON2-3 CON2-4

Table 3-2

3.XC-E -- Main motor XC-B CON3-1 CON3-2 CON3-3 Signal U V W PE CONA CONA-1 CONA-2 CONA-3 CONA-4

Table 3-3

4.1 PMD -- XC-B (CON5 connection) PMD CON1-1 CON1-2 CON1-3 CON1-4 Signal W3 W2 W1 XC-B CON5-4 CON5-3 CON5-2 CON5-1

Table 3-4.1

4.2 PMD -- XC-E (CON6 connection) PMD CON1-1 CON1-2 CON1-3 CON1-4 Signal W3 W2 W1 XC-B CON6-4 CON6-3 CON6-2 CON6-1

Table 3-4.2

71

Table of connection into control box

$%&'( ) *++, &'( CON5-1 CON5-3 CON5-5 CON5-7 CON5-9 CON5-11 CON5-13 CON5-15 CON5-17 CON5-19 CON5-21 CON5-23 CON5-25 CON5-27 CON5-29 CON5-31 CON5-33 6.CPU -- DISP CPU CON9-1 CON9-3 CON9-5 CON9-7 CON9-9 CON9-11 CON9-13 CON9-15 CON9-17 CON9-19 Signal +5V +12V Data bass I/O Data bass I/O Data bass I/O Data bass I/O DIR/RD A0/RS 8255-1 GND FDD CON1-1 CON1-3 CON1-5 CON1-7 CON1-9 CON1-11 CON1-13 CON1-15 CON1-17 CON1-19 CPU CON9-2 CON9-4 CON9-6 CON9-8 CON9-10 CON9-12 CON9-14 CON9-16 CON9-18 CON9-20 Signal +5V +12V Data bass I/O Data bass I/O Data bass I/O Data bass I/O R/W/WR A1 8255-1 GND FDD CON1-2 CON1-4 CON1-6 CON1-8 CON1-10 CON1-12 CON1-14 CON1-16 CON1-18 CON1-20 GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND Signal *++ CON1-1 CON1-3 CON1-5 CON1-7 CON1-9 CON1-11 CON1-13 CON1-15 CON1-17 CON1-19 CON1-21 CON1-23 CON1-25 CON1-27 CON1-29 CON1-31 CON1-33 &'( CON5-2 CON5-4 CON5-6 CON5-8 CON5-10 CON5-12 CON5-14 CON5-16 CON5-18 CON5-20 CON5-22 CON5-24 CON5-26 CON5-28 CON5-30 CON5-32 CON5-34 Signal MODE SELECT IN USE DS3 INDEX DS0 DS1 DS2 MOTOR ON H DIR STEP W DATA W GATE TRKO W PRT R DATA H SEL READY *++ CON1-2 CON1-4 CON1-6 CON1-8 CON1-10 CON1-12 CON1-14 CON1-16 CON1-18 CON1-20 CON1-22 CON1-24 CON1-26 CON1-28 CON1-30 CON1-32 CON1-34

Table 3-5

Table 3-6

7.CPU -- XC-B CPU CON6-1 CON6-2 CON6-3 CON6-4 CON6-5 CON6-6 CON6-7 CON6-8 CON6-9 CON6-10 CON6-11 CON6-12 CON6-13 CON6-14 CON6-15 Signal RA IFV IFU WN UN VN BKS ER VP WP UP COM VDC +12V GND XC-B CON1-1 CON1-2 CON1-3 CON1-4 CON1-5 CON1-6 CON1-7 CON1-8 CON1-9 CON1-10 CON1-11 CON1-12 CON1-13 CON1-14 CON1-15

Table 3-7

8.PMD -- Transformer (BKO-E3160H01) PMD CON5-1 CON5-2 CON5-3 Signal AC 6.3V AC 6.3V
Transformer

Black Black

Table 3-8

9.PMD -- Transformer (BKO-E3160H01) PMD CON9-1 CON9-2 CON9-3 Signal AC 24V AC 24V
Transformer

Orange Orange

Table 3-9

72

10.1 XC-E -- Transformer (BKO-E3160H01) PMD CON5-1 CON5-2 CON5-3 CON5-4 Signal AC 210V 0V

(CO5 connection)

Transformer

AC210V / AC230V AC210V AC230V

Table 3-10.1

10.2 XC-E -- Transformer (BKO-E3160H01) PMD CON6-1 CON6-2 CON6-3 CON6-4 Signal AC 230V 0V

(CO6 connection)

Transformer

AC210V / AC230V AC210V AC230V

Table 3-10.2

11.XC-E -- CONB XC-E CON4-1 CON4-2 CON4-3 CON4-4 Signal E T S R PE CONB CONB-5 CONB-3 CONB-2 CONB-1 CONB-4 CONB-6

Table 3-11

12.XC-E -- Break register XC-E CON4-1 CON4-2 Break register 100 ohm 100 ohm

Table 3-12

73