Global ZZ 1560 Series, Instruction Manual & Instruction For Service Manual

Page 1: ...w w w a e s e w i n g m a c h i n e s c o u k ...

Page 2: ...aintenance inspection repair and or Transport The user also has to assure that only authorized personnel work on the machine The user is obliged to check the machine at least once per shift for apparent damages and to immediatly report any changes including the performance in service which impair the safety The user company must ensure that the machine is only operated in perfect working order Nev...

Page 3: ... training 7 For service or repair work on pneumatic systems disconnect the machine from the compressed air supply system max 7 10 bar Before disconnecting reduce the pressure of the maintenance unit Exceptions to this are only adjustments and functions checks made by appropriately trained technicians 8 Work on the electrical equipment must be carried out only by electricians or appropriately train...

Page 4: ...g of belt guards 13 4 4 Mounting of positioning motor control panel 14 4 5 Mounting of connecting cable 15 4 6 Mounting of lighting lamp 16 5 Machine electric connection 5 1 Machine connection to low voltage network 17 5 1 1 Connection of lighting transformer to network voltage 18 5 2 Grounding 19 5 3 Connection of sewing head to EFKA DC1550 DA321G motor 20 6 Setting of Efka positioning motor 6 1 ...

Page 5: ...For your notes w w w a e s e w i n g m a c h i n e s c o u k ...

Page 6: ... Obligatory components they are always supplied Sewing head 1 Accessories include oil tray 2 yarn stand 3 positioning motor connecting cable if there is any tools and other items Optional components they are supplied on request only Complete motor includes motor 4 V belt pulley positioning motor control box 5 or switch circuit breaker electric cables Positioning motor control panel 6 if there is a...

Page 7: ...wooden slats on machine head and stand safety blocks and straps on sewing drive 3 Stand assembly 3 1 Stand frame assembly Assemble the frame according to the picture Mount the pedal 1 provisionally Its position will be adjusted after the whole machine is complete Adjust the bolt 2 so that the stand is stable 4 1 2 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 8: ...frame to the table top pre drilled holes 7 Then turn the stand to the normal position Mount the yarn stand 8 according to the picture insert it into the hole in the table top and fix it with a nut with washer Fix the machine head support 9 Stick rubber hinge bottoms 10 and rubber corners 11 with a suitable contact glue Stick horizontal fitting surfaces of the hinge bottoms only You can also fix th...

Page 9: ...clamps Screw the stand frame to the table top pre drilled holes 9 Then turn the stand to the normal position Mount the yarn stand 10 according to the picture insert it into the hole in the table top and fix it with a nut with washer Fix the support blinds 11 Stick rubber hinge bottoms 12 and rubber corners 13 with a suitable contact glue Stick horizontal fitting surfaces of the hinge bottoms only ...

Page 10: ...with clamps Screw the stand frame to the table top pre drilled holes 9 Then turn the stand to the normal position Mount the yarn stand 10 according to the picture insert it into the hole in the table top and fix it with a nut with washer Fix the support blinds 11 Stick rubber hinge bottoms 12 and rubber corners 13 with a suitable contact glue Stick horizontal fitting surfaces of the hinge bottoms ...

Page 11: ...n both sides To do so make use of the scale on the stand feet Set the stand height so that it corresponds with the operator s bodily proportions Attention Danger of injury Failure to adjust the stand height to the operator s bodily proportions may result in damage of the operator s locomotive organs Tighten the screws 1 8 1 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 12: ...ccording to the picture 4 1 2 Motor integrated on machine head Tilt the machine head 1 slightly and insert it in the recess in the table top After inserting the machine head 1 into the inserts 2 tilt position loosen the screw 3 and slide the prop 4 up to a stop and tighten the screw 3 9 GB 1 1 2 3 4 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 13: ... that the microswitch must be switched on in the machine working position Loosen the screws 1 the microswitch shifting in the groove 2 until the sound of the switch switching a click is heard Tighten the screws 1 10 2 1 D w w w a e s e w i n g m a c h i n e s c o u k ...

Page 14: ... Fix the V belt 2 loosen the screw 3 and stretch the belt Check the belt tension with force F 10 N 1 kg The belt should bend approximately by 15 mm Adjust the position of the stop 4 on the belt guard to the distance approximately 3 mm from the belt pulley so that it prevents the belt falling out of the belt pulley groove at the machine head tilting 11 GB F 10N 15 mm 3 2 3 1 4 w w w a e s e w i n g...

Page 15: ...48 552 3 motor power frequency 60 Hz motor speed 3360 rpm Data unit 523i 524i 525i 527i operating sewing speed rpm 3880 3880 3880 2580 belt pulley outer diameter mm 80 80 80 55 belt pulley order number S980 000050 S980 000050 S980 000050 S980 000189 Efka DC1550 DA321G positioning motor Data unit 523i 524i 525i 527i operating sewing speed rpm 3500 3500 3500 2000 belt pulley outer diameter mm 84 84 ...

Page 16: ...achine is not equipped with the positioning motor fix the proximity switch 5 which is a part of the motor supply on the pin inside the hand wheel to the stop Make sure that the peg 2 fits to the proximity switch fork Fix the proximity switch with three screws 6 Pull the proximity switch cable 7 under the table top according to the picture and subsequently pull it through the cable canal so that no...

Page 17: ...ol panel has Efka V810 marking Also a more comfortable panel V820 can be mounted on the same holder picture in the spare parts catalog Screw out 2 screws 3 and subseqently screw by them the holder 2 Screw the panel 1 on the holder 2 and pull its cable under the table top and subsequently throught the cable canal to the motor control box 14 1 3 2 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 18: ... The connecting cable is included in the accessories Remove the distribution case cover 2 Install the connecting cable 1 according to the picture Connect the connector 3 and mount the distribution box cover back again Pull the connecting cable 1 under the table top according to the picture and connect it to the motor control box 15 GB 1 2 3 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 19: ...crew the roll 2 with the screw 1 to the machine head fix the lighting lamp on the roll 2 and tighten with a handle 3 The transformer installation is described in section 3 2 16 3 1 2 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 20: ...oil connection must correspond with the local network voltage A low voltage circuit includes the following items supply plug main switch in the minimotor drive the main switch is integrated in the minimotor control box motor lighting transformer optionally cables A part of these items is included in the motor packing The low voltage circuit is to be carried out according to the schedule which is i...

Page 21: ...tructions onto the front side of the main switch B The machine is equipped with Efka DC1550 DA321G motor Pull the network plug form the socket Screw out 4 screws on the front plate of the control box Remove the front plate Pull the cable of the lighting transformer through the canal 1 in the control box Take out the black rubber bushing 2 Pierce the bushing with a screwdriver Pull the lighting tra...

Page 22: ... under the table top Screw the opposite end of the grounding conduit to the respective grounding point of the motor marked Fasten the conduit to the bottom side of the table top with a clamp Attention Ensure that the grounding conduit does not touch the driving V belt if there is any 19 GB 1 2 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 23: ...ontrol panel to the connector 2 Connect the position sensor connector in the motor to the connector B2 Connect the motor connector to the connector 3 Connect the pedal position sensor set value sensor to the connector 4 Connect the proximity switch to the connector B18 20 B2 B18 1 3 4 2 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 24: ...ough autoselect function The motor control system is equipped with the autoselect device identifying which sewing machine was connected to the motor with the connecting cable At the motor switch on the resistance value of the resistor for this purpose located inside the machine head is automatically measured On this base required parameter values are automatically set up If the control system is n...

Page 25: ...Reference position On the needle motion downwards the needle point is at the throat plate level This position is used to carry out the positioning motor basic setting The above mentioned positions are derived from this as well as other positions not mentioned here 6 2 2 Setting of machine positioning for DC1550 DA321G motor For the machine positioning the proximity switch on the hand wheel is used...

Page 26: ...rocess is described in the publication Efka Operation Instructions section 8 26 7 Machine lubrication Before starting up the machine must be properly lubricated with oil according to section 9 2 of the first part of these Instructions 8 Sewing test This test can be performed after the machine completely stops Thread the machine and adjust the thread tension according to sections 7 1 7 2 7 3 7 4 of...

Page 27: ...aintenance inspection repair and or Transport The user also has to assure that only authorized personnel work on the machine The user is obliged to check the machine at least once per shift for apparent damages and to immediatly report any changes including the performance in service which impair the safety The user company must ensure that the machine is only operated in perfect working order Nev...

Page 28: ... training 7 For service or repair work on pneumatic systems disconnect the machine from the compressed air supply system max 7 10 bar Before disconnecting reduce the pressure of the maintenance unit Exceptions to this are only adjustments and functions checks made by appropriately trained technicians 8 Work on the electrical equipment must be carried out only by electricians or appropriately train...

Page 29: ...ot lifting 18 7 7 Foot pressure setting 19 7 8 Stitch length setting 19 7 9 Backtacking reverse feeding closing up 20 7 10 Zig zag stitch width throw and position setting 21 7 11 Starting up of manually controlled machine with clutch motor 22 7 12 Control of machine equipped with clutch positioning motor and solenoid automatic control 23 7 12 1 Control pedal 23 7 12 2 Key control panel 24 8 Efka D...

Page 30: ...For your notes w w w a e s e w i n g m a c h i n e s c o u k ...

Page 31: ...t Subclass 525i Ornamental shape stitching in ready made overgarment and ladies underwear made of elastic materials Ornamental stitching in textile footwear The sewn material must not be thicker than 4 mm when pressed down under the presser foot Subclass 527i Shoe sewing stitching of quarters and linings topstitching of tongues sewing of home slippers ornamental stitching Joining of leather and te...

Page 32: ...arge with knee lever with solenoid without thread trimmer with thread trimmer with hand lever with solenoid 523i 411001 X X X X X 523i 447001 X X X X X 524i 811001 X X X X X 524i 847001 X X X X X 525i 811001 X X X X X 525i 847001 X X X X X 527i 811001 X X X X X 527i 847001 X X X X X w w w a e s e w i n g m a c h i n e s c o u k ...

Page 33: ...25i 847001 Sewing equipment 4 lined feed dog needle size Nm 80 110 stitch length max 5 mm throw width max 10 mm for light and medium weight material S791 124032 35 11 6 x 1 2 S080 811641 1 0 S080 651504 S980 031603 134 80 525 E 033 524i 811001 524i 847001 525i 811001 525i 847001 Sewing equipment 3 lined feed dog needle size Nm 80 110 stitch length max 5 mm throw width max 10 mm for light and mediu...

Page 34: ...080 651509 S980 022839 134 35 110 527 E 061 527i 811001 527i 847001 Sewing equipment for two needle cordin seams with or without filler cord 3 lined feed dog needle size Nm 110 130 stitch length max 5 mm needle gauge 5 mm for medium heavy weight material S791 430061 35 7 x 2 3 S980 022868 1 8 S080 651510 S980 022839 134 35 110 527 E 461 527i 811001 527i 847001 Sewing equipment 3 lined feed dog nee...

Page 35: ... Table top separate S981 069440 Knee lever for mechanical foot lifting S794 222012 Lighting lamp Z 012 S980 035456 Gauge for class 52X S980 000293 Unwinding device A M 293 S980 000294 Unwinding device A M 294 S980 000312 Edge hemming set A M 312 S980 031586 Complete foot ZZ 6MM S980 031652 Complete foot ZZ 10MM S080 811768 Throat plate for soft material sewing S791 235002 Unwinding device S791 630...

Page 36: ...S080 674117 12 3 3 5 6 3800 3400 1 5 4 525 Z 043 S080 674118 12 4 4 6 3800 3400 1 3 525 Z 044 S080 674119 12 6 4 10 3800 3400 1 3 525 Z 045 S080 674120 12 12 2 5 3800 3400 1 5 3 525 Z 046 S080 674121 12 12 2 5 3800 3400 1 5 3 525 Z 047 S080 674122 12 2 3 5 6 3800 3400 1 3 525 Z 048 S080 674123 12 12 4 5 10 3800 3400 1 3 525 Z 049 S080 674124 12 6 4 5 10 4400 3800 1 3 525 Z 050 S080 674125 12 4 2 6...

Page 37: ...th knee lever or solenoid 12 mm Needle number see table of sewing equipment Manually controlled subclass clutch motor 2800 rpm Solenoid controlled subclass DC motor AC servo positioning motor with reverse run after thread trimming Sewing head weight 40 kg FIR motor weight 18 kg Efka DC1550 motor weight 10 kg Stand weight 30 kg Thread length after trimming max 20 mm Machine head clear workspace 265...

Page 38: ...njury Thread when the main switch is switched off and motor stopped Do the threading according to picture A and detail B When trimming the material edges do the threading according to picture A and detail C 12 A B A C w w w a e s e w i n g m a c h i n e s c o u k ...

Page 39: ...pulling in the arrow direction 3 Pull the lever 4 in the arrow direction 5 Start the machine up After the bobbin winding wind the thread round the cutter 2 according to picture B and tear it off by pulling in the arrow direction 3 Fix another bobbin immediately and prepare its winding during the sewing 13 GB 3 1 5 4 2 3 2 A A B w w w a e s e w i n g m a c h i n e s c o u k ...

Page 40: ...rding to the picture 2 Draw the thread end 4 through the slit 5 pull under the spring 6 and pull into the slit 7 Insert the case 2 back in the hook and press it down in the arrow direction 8 till the lock inside the case clicks and secures it against falling out Make one stitch without the sewn material and drawing the thread upper end pull the hook thread end outwards above the throat plate 14 6 ...

Page 41: ...ous trimming when the tensioner 2 is opened switched off The tensioner 1 is never switched off Main tensioner adjustment 2 Regulate the thread tension with the tensioner 2 until you achieve a good interlacing of the threads see below Correct interlacing of threads in the center of the material Increase of the needle thread tension or reduce the hook needle tension Reduce the needle thread tension ...

Page 42: ...ng down on the thread end 6 the case is dropping slowly with its own weight Adjustment of bobbin brake spring at the thread trimming 2 Bobbin braking should be as small as possible because it causes difference of tensions of full and empty bobbin and subsequently of thread interlacing in the stitch defective look of the seam Regulate the bobbin braking with a screw 7 and watch the bobbin unwinding...

Page 43: ...ment when the main switch is switched off and motor stopped Loosen the screw 1 and remove the needle 2 Fix a new needle and turn it so that the needle scarf 3 is oriented according to detail D Tighten the screw 1 17 GB 1 3 2 D w w w a e s e w i n g m a c h i n e s c o u k ...

Page 44: ...hread Foot lifting with a knee lever if there is any The foot is lifted by pressing the lever 2 the foot is lowered by releasing the lever Automatic foot lifting with solenoid with pedal applies to subclasses with the positioning motor and automatic control Tread the pedal 3 in position 1 see section 7 11 The foot is lifted Automatic foot lifting after trimming can be pre selected see section 7 11...

Page 45: ...ing in the arrow direction and vice versa The foot pressure should be as small as possible but strong enough so that the feeding is reliable even at a high sewing speed 7 8 Stitch length setting Turn the knob 1 so that the number 2 indicating the required stitch length in mm is opposite the screw 3 19 GB 1 3 2 1 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 46: ...Automatic backtacking bar sewing bartacking On machines equipped with the positioning motor and automatic control the automatic backtacking can be pre selected with a pre selected number of reverse stitches both at the beginning and at the end of the seam At the beginning of the seam after previous thread trimming after the pedal treading forwards the machine will sew the pre selected bar and cont...

Page 47: ...gainst the arrow direction A Setting of zig zag stitch position Press the lever 1 in the arrow direction A until it strikes the lever 2 the lever arrest is released 3 Make sure that the lever setting does not change at the arrest switching off 2 Press the lever 3 and turn it at the same time up to the stop inside the machine against the respective symbol indicating the zig zag stitch position Only...

Page 48: ... the pedal 3 The drive friction clutch switches in this way and the sewing machine starts running Regulate the sewing speed by pressure on the pedal 3 The friction clutch slip changes and thus also the machine speed changes in dependency on the pressure Release the pedal 3 The sewing machine will stop 2 1 3 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 49: ...n See note 1 Slightly forwards Command for foot lowering 2 Further forwards Sewing at minimum speed 1gear 3 Further forwards Sewing 2 speed gear 13 Fully forwards Sewing at maximum speed 12 gear Note The needle position can be pre selected for the neutral position needle down up as well as for the foot position down up at the seam stop by putting the pedal in the neutral position and for the foot ...

Page 50: ... pressed at sewing the sewn material is fed backwards 2 Needle positioning in upper or bottom position By the parameter F 242 DA321 the key function can be defined 1 needle up down 2 needle up 3 one stitch factory setting is 1 2 1 w w w a e s e w i n g m a c h i n e s c o u k ...

Page 51: ...mming is not enabled To the machine control also control panels V810 and V820 can be connected which are available as an attachment By means of V820 control panel it is possible to program the sewing A detailed description of the control is included in the Instruction for Use supplied with the machine by the EFKA DC1550 DA321G drive manufacturer see also www efka net w w w a e s e w i n g m a c h ...

Page 52: ...titch number forwards ornamental bar stitch number forwards standard bar stitch number backwards ornamental bar stitch number backwards End bar single double standard bar stitch number backwards ornamental bar stitch number backwards standard bar stitch number forwards ornamental bar stitch number forwards Thread trimming on off Automatic foot lifting foot lowered at seam stop foot lifted at seam ...

Page 53: ...uble bar thread trimming on foot lowered at seam stop foot lifted at seam finishing Operator s operation Machine work Machine is at standstill Needle is in upper position Foot is lifted in accordance with pre selection Sewn material inserting Pedal treading to position 1 Foot lowering Pedal releasing to position 0 Foot lifting Material position correcting Pedal treading to position 1 Foot lowering...

Page 54: ...clean with compressed air Re lubrication of hook path with oil and washing of dirt out of the path 1 week Spraying the unnecessary oil out of the hook at the machine high speed operation Check of oil reserve in oil tanks see section 10 2 Cleaning of mechanisms in the base plate Cleaning vacuuming wiping out 1 month oil tray Cleaning of ventilator grid on the motor Check of bobbin case 4 fitting cl...

Page 55: ...onment Prevent oil leakages For this sewing machine lubrication use solely the lubrication oil DA 10or oil of the same properties with the following specification viscosity at 40C 10 mm 2 s inflammation point 150C The oil DA 10 is supplied by the companyDRKOPP ADLER AG in different packings Volume Order number 250 ml 9047 000011 1 l 9047 000012 2 l 9047 000013 5 l 9047 000014 To lubricate feed sha...

Page 56: ...ark Add oil into tank 3 through the hole 4 at least once a week until the oil starts flowing from the terminal 5 Add several drops of oil in holes 6 and 7 once a month Grease lubrication Add grease in grease cups 8 and 9 by means of a lubrication press once a year 30 1 2 6 3 5 4 7 8 9 w w w a e s e w i n g m a c h i n e s c o u k ...