Sankosha DF-100E-V3, Instruction Manual

Page 1: ...this Instruction Manual carefully and understand all instructions before starting operating of the machine If at any time you have any questions please do not hesitate to contact us DF 100E V3 Instruction Manual Instruction Manual ...

Page 2: ...re 0 5MPa Air Pipe 1 4B Steam Pipe Inlet 1 2B Outlet 1 2B Noise Level A Level 72dB A Level 82dB Weight 165kg Dimensions Width Depth Height 1110mm 970mm 2170mm Max Welcome Thank you for choosing our DF 100E V3 Rotary Form Finisher This machine was delivered to you after thorough inspection at our plant Please read this manual carefully for proper usage of this machine ...

Page 3: ...rations 21 Cover Pad Change Instruction 22 1 Lower Body Cover setting 22 2 Upper Body Cover setting 23 3 Mat and cover setting of front and rear clamp left and right side clamp 23 Test Operation 24 Operation Procedures 24 Test Number List 25 Service Menu 26 Trouble Shooting 31 DAILY MAINTENANCE 35 Check Item List 35 Check Item Daily 36 Check Item Annual 38 Maintenance Check List 39 SPARE PARTS LIS...

Page 4: ...ert the user to unspecified prohibition Shock Hazard This is to alert the user to a risk of electric shock in certain circumstances Prohibition of Dismantling This is to alert the user to a risk of injury or shock if the indicated part is dismantled Cut Hazard This is to alert the user to a risk of cutting hands or fingers by a cutter or others May cause physical handicap General Sign for Compulsi...

Page 5: ... personnel Do not dismantle by yourself It may cause electric shock injury fire or accident Shock Hazard Do not touch the electric plug or switch It may cause electric shock Shock Hazard Parts must not get wet when cleaning the machine with water It may cause electric shock Safety Instructions For your safety please follow the instructions below Only qualified trained personnel can operate the mac...

Page 6: ...re due to different electrical supply Cleaning Both the main power switch and the breaker should be off when cleaning It may cause electric shock without power off Check and cleaning Electric plugs and electric sockets need to be checked and cleaned periodically If you find any damage call us or your Sankosha distributor Breakage can cause electric shock and fire Adequate space Adequate space arou...

Page 7: ...ive Area DANGER Control box has terminals with lethal voltage Only maintenance personnel can open the box Turn off the power before opening the box Ignoring this warning will result in serious injury or death due to electrical shock ...

Page 8: ...ING The machine has a certain range of motion Keep your hands away from the moving area during operation Before starting up or checking for maintenance turn off the air and power first Ignoring this warning could result in serious injuries ...

Page 9: ...Area CAUTION The machine has High Temperature Area Never touch these area during operation Do not also touch these areas for 30 minutes after the steam has been turned off Ignoring this warning may result in burns CAUTION ...

Page 10: ...ain residual pressure Cut hazard Keep hands away from the machine Do not touch while operating Pinch hazard Keep hands away from the machine Turn the power off during maintenance or cleaning Pinch hazard Keep hands away from the machine Do not touch while operating Clean filter before operation Center Mark Indicating the center of gravity of the machine Inside Control Box Make sure that each warni...

Page 11: ...Body down Foot Pedal Body up Foot Pedal Multi function Foot Pedal Body Front Clamp Control Box Control Panel Operation Button Solenoid Valve Box Steam Gauge Power Switch Steam Inlet Steam Outlet Filter Regulator Side Vents Clamp Center Vents Clamp Blower Motor Filter Inverter Box Sleever Holder Sleever ...

Page 12: ...ll be displayed If you push the Reset button machine will return to its normal condition Reset Button When you push this button there are four different possible functions 1 If you push this button after power supply ON operation will be possible 2 If you are in the foot pedal process the machine will return to previous process 3 If you are in auto operation each timer will stop 4 If you push this...

Page 13: ...ec Max 8 sec 20 sec Max 30 sec 20 min Max 30 min Long 8 0 sec Max 8 sec 30 sec Max 30 sec 30 min Max 30 min You can change each timer setting Please see page 17 The blower timer shows minutes when the Laundry Button next page at the Control Box is ON Mode Selection Switch You can select following mode along with side expander function Jumper Mode Front clamp moves Center Vents Mode Center vents cl...

Page 14: ...tart the test operation for each function Please see page 24 Test Operation for further details Counter Clear Button Push this button 0 will blink at Display Window Push the Enter Button You can reset the counter at 0 Push this button again The window will show the garment counter Enter Button for Timer Remember The light turns green when the button is ON Push this button after changing the timer ...

Page 15: ... pedal body will move down Body Up Foot Pedal When you keep on pressing this pedal body will move up Multi Function Foot Pedal When you press this pedal you can advance operation process Process number will be displayed on the display window Process is Rear clamp 1 Front clamp 2 Side expander 3 Side Clamp 4 Auto operation Shoulder Expander Foot Pedal Body Down Foot Pedal Body Up Foot Pedal Multi F...

Page 16: ... Up Down Cylinder Low air pressure can cause a malfunction If the pressure does not reach its standard level set the air pressure properly following the procedure below Check Point Check compressor if the main air pressure does not reach 0 5MPa even after the above adjustment Follow the procedure for proper operation Improper operation can cause mechanical failure or injury to operators CAUTION Ho...

Page 17: ... Selection Switch you can select the Steam Timer and the Blower Timer from 3 different modes Short Middle and Long You can change each timer setting Please see page 13 Timer Selection Switch for factor initial setting The setting change method of each timer Select a mode you want to use by Timer Selection Switch Push the Steam Timer Button or the Blower Timer Button The green lamp on the upper rig...

Page 18: ... pedal Rear side of the garments will be clamped 1 is displayed When the Wide Side Vents Selection Switch is ON the side vent clamps opens left and right It is useful for finishing a larger garment You can change how to clamp the center vent and side vent by using the DIP function in the Service Menu Please see 29page Rotation Lever Manual Rotation Button Auto Body down Foot Pedal Body up Foot Ped...

Page 19: ...d If the setting is not correct push the reset button The machine will return to its previous position 11 Press the multi function foot pedal The automatic operation will start Auto operation procedure Steam Injection Body going up while Stretch Selection Switch being ON Steam Blower Blower Dry Time of each process is counted in display window When the finishing process is over the front rear clam...

Page 20: ...sh reset button The machine will return to its previous position 8 Press the multi function foot pedal The automatic operation will start Auto operation process Steam Injection Body going up while Stretch Selection Switch being ON Steam Blower Blower Dry Time of each process is counted in display window When the finishing process is over the front rear clamp the left right clamp and the body stop ...

Page 21: ...played Other Operations How to Reset Emergency Stop When the Emergency Stop Button is pushed E1 shows on the Display Window and the machine safely returns to the initial position from any process of the operations In order to resume normal operation turn the Button clockwise The lock will be released The Display Window shows 1 Push the Reset Button next The normal operation will resume ...

Page 22: ...Body Cover setting Put Lower Body Cover on body and attach both side Velcro tapes which are in the bottom of cover Don t put side vent clamp support inside of the cover in cover setting There are the covers for front and rear clamp support plate and side expander plates inside of the Lower Body Cover Loosen strings of those covers and put the covers on each plate Then tie the strings Pull strings ...

Page 23: ...left and right side clamp Set mats on front rear clamp cover and set them on front rear clamp plate and tie strings so that there is no wrinkle Set mats on left right side clamp cover and set them on left right side clamp plate and tie strings so that there is no wrinkle Upper Body Cover String Steam Cover Pass strings from arrow direction and tie them inside Cover Mat Front Clamp Side Clamp Right...

Page 24: ... number is displayed with order of Test Number List at page 25 Step 3 Push the Enter Button Test mode is now ON and the function starts working The Enter Button is blinking while the test is ON Push the Enter Button again to stop the test operation Please finish the test operation otherwise it will not work for another test Step 4 Push the Test Button when you finish the test The Test Button lamp ...

Page 25: ...zzer sounds 1 3 seconds later when it opens Adjust the speed to the beep o 0 6 Body Up Down Solenoid No 7 No 8 Buzzer sounds 2 5 second later when the Body goes up Buzzer sounds 1 5 second later when Body goes down Adjust the speed to the beep o 0 7 Wide Side Vents Solenoid No 9 Buzzer sounds 0 5 second later when Side Vents spreads right and left Buzzer sounds 0 5 seconds later when it shrunk Adj...

Page 26: ...hows up and the Service Menu is ready to work Counter Clear Button When the Service Menu works this button functions as the return button Landry Button On Input Test 2 the light turns ON when the test is ON The light turns OFF when the test is OFF Enter Button Push this button in order to determine the selected menu or change the setting Dial Turn this Dial to select each Menu or change the settin...

Page 27: ...Button to start the selected Service Menu 4 Work or set on the selected Menu See Service Menu Explanation for further details 5 After completion of the Menu push Counter Clear Button and return to the normal operation Normal operation will resume after a certain period of time goes by without pushing this button Service menu explanation 1 in1 Input Test 1 Display by Operation Procedure 1 Push the ...

Page 28: ...ure 1 and 2 Push the Enter Button to select Turn the Dial Select the number Chart 2 you want to test then push the Enter Button The selected test menu is ready to work Chart 2 Output Test List No Output Name Remarks No Output Name Remarks １Ａ Motor ON Inverter ３Ａ Side Expander Open Solenoid Solenoid No 4 ２Ａ Steam Injection Solenoid Solenoid No 1 ３ｂ Side Expander Closes Solenoid Solenoid No 5 ２ｂ Cen...

Page 29: ...c V 7 The time of interval of process to process while in automatic mode 2 0sec Max 5 0sec 5 diP DIP Setting Display by Operation Procedure 1 and 2 Push the Enter Button to select Turn the Dial Select the number Chart 4 you want to change then push the Enter Button The selected DIP Setting shows up Push the Enter Button The current setting will show up Turn the Dial to change ON or OFF Push the En...

Page 30: ...ough you change the time t 3 Not in Use Nothing happens even though you change the time t 4 Change time to return to the initial display if you do nothing with Service Menu t 5 Change time to return to the initial display if you do nothing with Input Test 7 dEF Default Setting Display by Operation Procedure 1 and 2 Push the Enter Button to select OFF shows up at the Display Window Turn Dial to set...

Page 31: ...sh the Reset Button 2 Wiring may be the cause if E1 displays even after releasing it Check the Button itself or check if the wire is cut E10 1 Inverter Error 2 Something is wrong with Inverter 3 If the machine stops because of an inverter problem turn the power off Then leave the machine until inside of the inverter has cooled More than 2 minutes Turn the machine on again The inside parts of inver...

Page 32: ...hing which is pushing the button If you push the button again the machine will return to its original position 2 Even if the button is not pushed if it is showing E20 error it is a button problem Please check whether the switch is broken or a wire connection is loose or disconnected E21 1 Blower Button error 2 Blower Button stays activated if the button is staying pushed by something when the main...

Page 33: ...error it is a switch FP03 problem Please check whether the switch is broken or a wire connection is loose or disconnected E25 1 Shoulder Expander Foot Pedal Error 2 Shoulder Expander Foot Pedal stays activated if the pedal is staying pressed by something when the main power is ON or the machine is at the original position 3 1 In the case of keep pushing button please release the pedal Also please ...

Page 34: ...nection is loose or disconnected E28 1 Auto Start Button Error 2 Auto Start Button stays activated if the pedal is staying pressed by something when the main power is ON or the machine is at the original position 3 1 In the case of keep pushing the button please release the button Also please remove anything which is pushing the button If you push the Reset button again the machine will return to ...

Page 35: ...ur Sankosha equipment please read and comprehend carefully this Daily Check Manual thoroughly before operation Keep this manual in a safe place for easy access at all times The Checking cycle will differ daily or monthly annually according to the item or area that requires maintenance Use Item Check List for checking the correct service procedures If at any time you have any questions please do no...

Page 36: ...se Counterclockwise Pressure will decrease Pull the knob down 2 Regulator Mist Separator Figure 2 Check if the automatic drain function works properly at the Regulator Mist Separator The drain is automatically discharged when the quantity of the drain reaches over half of the drain case If the drain cannot be discharged even after over half of the drain case is filled it might malfunction Turn the...

Page 37: ...scharge the drain Close the faucet after discharge 5 Cover check Figure 4 Check to see if it is dirty torn or not Body front clamp rear clamp side clamp side vent clamp and lower body cover Dirt and any type of tear can negatively affect finish quality 6 Emergency stop check Figure 4 Push the emergency stop button to ensure that the machine stops Emergency Stop Button Lower Body Cover Steam Pressu...

Page 38: ... quality as well as a decrease in the blower power Start Operation After checking the above items start operation after warming up the machine sufficiently for 15 to 20 minutes after the steam is turned on Check Item Annual 8 Regulator Cleaning Figure 6 Clean the filter of the Regulator Change the Filter Element if any pressure descent frequently takes place Figure 6 Figure 5 Filter Element Blower...

Page 39: ... 4 Steam Trap 5 Cover 6 Emergency stop 7 Blower filter No Item 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 Air Pressure 2 Regulator 3 Steam Pressure 4 Steam Trap 5 Cover 6 Emergency stop 7 Blower filter Check Item Annual No Item 1 2 3 4 5 6 7 8 9 10 11 12 13 8 Regulator filter Photocopy this checklist for ongoing maintenance ...

Page 40: ...40 ...

Page 41: ...41 Spare Parts List Index 1 Front Diagram 2 Rear Diagram 3 Switch Solenoid Valve Diagram 4 Steam Piping Diagram 5 Cover Diagram ...

Page 42: ...42 Front Diagram 1 Front Diagram REV 3 ...

Page 43: ...B6B001 3 Cylinder B1C006 2 Side Expander Cylinder packing set B6H012 2 Cylinder B1C001 2 Side Clamp Cylinder packing set B6H041 2 109 Speed Controller C1A005 4 110 Knuckle Joint B6B006 2 Cylinder B0J010 1 BODY Rotation Cylinder packing set B6H002 1 Cylinder sensor B5A003 2 Sensor band B5B001 2 113 Rod end E5A003 1 114 Rod end E5B006 1 115 Cylinder B2H002 1 BODY Up Down 116 Joint C0C050 1 117 Joint...

Page 44: ...44 Rear Diagram 2 Rear Diagram REV 3 ...

Page 45: ...et B6H012 1 205 Speed Controller C1A002 10 Knuckle Joint B6B001 1 Cylinder B1A016 2 Wide Side Vents Cylinder packing set B6H017 2 Cylinder B1C013 2 Side Vents Clamp Cylinder packing set B6H052 2 209 Knuckle Joint B6B006 2 G0H005 1 No DF100EV3 0011 G0E034 1 No DF100EV3 0012 G0E049 1 No DF100EV3 0062 211 Blower Fan G2B023 1 212 Cable bear K1B039 1 213 Rubber E5V008 2 210 Motor 202 206 204 207 208 ...

Page 46: ...46 Switch Solenoid Valve Diagram 3 Switch Solenoid Valve Diagram REV 3 315 301 ...

Page 47: ...to Start 309 Selection Switch 20O001 1 Mode Selection 310 Selection Switch 20O007 1 Timer Selection 311 Toggle Switch 20L013 3 312 Control Panel 11U417 1 313 Dial 21D006 1 Foot Pedal Unit FP UNT 025 4 Micro Switch 21E003 4 Foot Pedal Spring H0D019 4 315 Filter Regulator D0C004 1 316 Joint C0C019 1 317 Regulator D0E026 3 318 Joint C0C016 10 319 Joint C0C018 1 320 Manifold Valve A0F153 1 Solenoid Va...

Page 48: ...48 Switch Solenoid Valve Diagram 3 Switch Solenoid Valve Diagram REV 3 315 301 ...

Page 49: ... A0E012 1 No 3 Close Front Clamp Valve A0E018 1 No 4 Open Side Expander No 5 Close Side Valve A0E012 1 No 6 Close Side Clamp Valve A0E012 1 No 9 Wide Side Vents Clamp Valve A0E012 1 No 10 Close Side Vents Clamp 326 Manifold valve A0F055 1 327 Valve A0E018 1 No 13 Start Body Rotation No 14 End Body Rotation 328 Manifold valve C1A007 5 329 Pulls E5V051 1 330 Magnetic Catch E5V053 1 325 ...

Page 50: ...50 Steam Piping Diagram 4 Steam Piping Diagram REV 3 ...

Page 51: ... REV 3 No Part Name Part Number Q ty Remark 401 Air Muffler J0A001 2 402 Piston Valve A0G003 1 403 Joint C0E001 1 404 Steam Gauge J0A003 1 405 Y Type Strainer J2M007 1 406 Steam trap J2N001 1 407 Radiator RD180 000 1 ...

Page 52: ...52 Cover Diagram 5 Cover Diagram REV 3 513 ...

Page 53: ... Clamp Mat S1D051 1 505 Wire Fillet Front Clamp Cover S1D058 1 506 Front Clamp Mat S1D035 1 507 Wire Fillet Side Clamp Cover S1D060 2 508 Side Clamp Mat S1D053 2 509 Wire Fillet Side Vents Clamp Cover Left Right S1D061 1s 510 Side Vents Clamp Holder Cover Left Right S1D551 1s 511 Side Vents Mat S1D056 4 512 Tube Cover S1D063 1 513 Wooden Sleever Q0A013 1s Left Right set ...

Page 54: ...54 Attached Diagram Sensor Diagram Electric Connection Diagram 1 4 4 4 Steam Piping Diagram Air Connection Diagram ...

Page 55: ...er Button SW03 Wide Side Vents Select Switch SB03 Body Rotation Button VR01 Blower Power Dial SB06 Auto Start Button SW01 Mode Select Switch SW05 Stretch Select Switch SQ01 Body Rotation End Sensor SQ02 Body Rotation Middle Sensor FP01 Shoulder Pedal FP04 Multi Function Pedal FP03 Body Up Pedal FP02 Body Down Pedal SW04 Stretch Select Switch ...

Page 56: ......

Page 57: ......

Page 58: ......

Page 59: ......

Page 60: ...Steam Piping Diagram Radiator RD180 000 Piston Valve D290A399 Pressure Gauge AMT7 16 60φ 1 6MPa Steel Muffler SBN 38 Y Strainer FC KY 4G4 15A 100Mesh Steam Trap YH 15A ...

Page 61: ......

Page 62: ...DF 100E V3 Rev 6 2019 1 ...