ZOJE WR580, Product Manual

Page 1: ...WR580 PRODUCT MANUAL V1 0 ...

Page 2: ...Application Model Code Hardware Structure Error Solution Catalogue ...

Page 3: ... power W 550W Human computer interface integrated control box Needle bar led connector 4pin connector DC5V 200mA Safety protection Turn up switch Overvoltage and undervoltage protection Overload protection Blocking protection Short circuit protection Needle pole short circuit protection Fault diagnosis function Specification ...

Page 4: ...n one Automatic medium materials Lockstitch 2 WR580 110V Full automatic integrated 110V 3 WR580H Full automatic integrated heavy material machine 80SF90 B3000 K01 ZJ9503ZJ9703All in one Automatic heavy materials Lockstitch 4 WR580H 110V Full automatic integrated heavy material machine 110V Matching models corresponding motor model ...

Page 5: ...Composition of the product ...

Page 6: ...Power outlet Outlet for pedal Outlet for LED fill needle outlet Interface definition Motor outlet Motor coder outlet ...

Page 7: ...YEE SINGER NEUTRAL Product platform No 1 Embroidery machine 5 Single axis platform 6 1 Spindle 1 stepper 7 1 Spindle 2 stepper 8 1 Spindle 3 stepper 9 1 Spindle more than 3 stepper Machine code electric control box The controller platform serial number 0 9 A Z The controller platform serial number 0 9 A Z H Heavy material blank is normal 110V 110V blank is 220V ...

Page 8: ...Machine code pedal Pedal PL 3 02 PL pedal 1 At present using the common pedal With analog and digital signal 2 Vertical pedal 3 Pure analog signal pedal Serial NO ...

Page 9: ...Model description motor Motor model serial number ...

Page 10: ...oducts C control panel E encoder board H HMI board D driver board P Power Board S synchronizer board F pedal PCB M EMC board K key board T Test circuit boards J tooling board Application Year 09 2009 PCB board serial number 01 to 99 PCB version number A0 A9 AA AZ PCB production time Control box code PCB board designer code ...

Page 11: ...re the ground line is well conneted 4 Machine is forbidden to work in high humidity environment 5 when testing machine do not plug or unplug when the power is on 6 For safety considerations please use 80V electric power isolation transformer when repairing Following the above instruction will effectively ensure the life of the machine and ensure staff safety ...

Page 12: ...Structure and composition of the hardware Hardware structure is divided into three parts 1 the main control box control and operation 2 pedal 3 motor ...

Page 13: ... PCB Control PCB mounting plate Press plate Control PCB positioning colum Finish Plastic cover Plastic cover Note Current control box PCB version number SC1203A5 WR Currently operating Box PCB version number SH1203A4 WR Do not forget to plug the socket when installing control box to avoid no power or display error code ...

Page 14: ...talling pedal to avoid no power or display error code Position of magnet will affect the sewing speed and thread cut size to adjust the pedal strength Pedal PCB number SF1001A3 Location column Pedal magnet speed adjustable Pedal connector 5557 2 3 PCB board Pedal Case Pedal magnet Pedal lifting iron ...

Page 15: ...control box with 80V isolation transformer supply power turn the magnet make the sensor output voltage both side of C2 from 2 77V to 2 83V Note When adjust the pedal must use 80V power supply 3 Test each button on the pedal spacing between magnetic and PCBA hall sensor in 1 5mm 1 8mm Voltage for both side of C2 from 2 77V to 2 83V PCBA Hardware structure assembly instructions ...

Page 16: ...e motor after installed the encoder to make sure the Raster not touch the sensor not touch the connect line and the height for raster is just in the center of the sensor 2 Installed the raster will affect the motor angle motor angle is 252 5 3 Installed the pressure line boards put it into the line box otherwise the line skin will easy to broken 4 Encoder PCB number SE1202A3 ...

Page 17: ...nect line Turn over the motor after installed the encoder to make sure the Raster not touch the and the height for raster is just in the center of the sensor Install the motor direction consistent with the picture due to the motor started wheel fixed level above the encoder slot aligned positioning column to the left of painting a 1 9CM long straight line Grating with rectangular foot vertical clo...

Page 18: ... seconds to enter to the monitoring state press keys to change the monitor serial number monitor the value read Specific display contents are press S to enter into specific values press P to exit and return to standby mode Speed Electric current Voltage Angle Versions ...

Page 19: ...252 5 Function Motor Angel Test Model Press S key into the motor Angle test mode the system display Press P key star to test after the finish it show the motor angel ...

Page 20: ...al calibration mode Press to starting up it will display Pdl on the operation box Press P to start check after finish will show the data Normal value between 15 15 It will show error when the value is out of normal ...

Page 21: ...Function Aging mode Press to enter the aging mode Then press to start press again to stop ...

Page 22: ...External interface definition Power outlet Outlet for pedal Outlet for LED fill needle outlet Motor outlet Motor coder outlet ...

Page 23: ...1 2 4 3 6 5 Operation Socket definition 1 2 4 3 6 5 CN3 SW4 SDA SW3 5V 2 SCL PGND SW4 CLK PGND SW1 SW2 5V 2 Operation Panel CN1 8 7 7 8 SW1 SW2 DATA SW3 Internal interface definition operation panel ...

Page 24: ...External interface definition power 1 2 3 4 Ground wire Power Socket definition L N ...

Page 25: ...External interface definition pedal 5 1 6 4 Pedal Socket definition 3 2 PEDAL PGND 5V 2 For Factory use CN8 ...

Page 26: ...1 4 3 2 Needle GND 5V 1 GND External interface definition Light Needle Pedal Socket definition ...

Page 27: ...P PGND ENC_A 5V_2 F 2 ENC_B CN7 Motor encoder Socket definition 1 2 4 3 6 5 7 8 U W V FG HALL_C HALL_B HALL_A UP ENCA ENCB SCL SDA PGND 5V_2 F2 AC servo motor 4 encoder CN4 Ground U V W J1 1 2 3 4 9 10 External interface definition motor encoder ...

Page 28: ...Main board PCBA appearance ...

Page 29: ...Control box theory diagram ...

Page 30: ...her system line voltage over high E4 Under voltage when shutdown Check whether system line voltage too low E5 Over voltage when runtime Check whether system line voltage over high E6 needle position signal error Check the needle position signal and the plug E7 motor HALL signal error Check whether motor plug loosen or not E8 motor stuck running check whether the motor connect well or not whether o...

Page 31: ...t operation of acceleration and deceleration E13 EEPROM error Contact the supplier technical service E14 Current detection circuit error Contact the supplier technical service E15 Pedal Zero position Detection over Limit Pedal Zero position over setting range E16 OZ circuit error Contact the supplier technical service E17 motor rotates inversely check Motor phase sequence and signal line E18 motor...

Page 32: ...ck the impedance of pin 1 pin3 of Q3 Q8 around 10K 4 check the impedance of pin 2 7 to pin12 of U8 of main control board around 0 7M standby voltage 3 8V 5 check the impedance of pin14 15 16 to pin12 of U8 of main control board around 10K standby voltage 0V 6 check the R169 impedance value of U8 of main control board 1K C101 both ends impedance 6 5K standby voltage 3 2V 7 check the impedance of pi...

Page 33: ...tion signal effective U8 IR2136S pin Raster Installation height manually rotate the motor to see whether the grating touch the sensor chip and height is right in the center position of the sensor R169 C101 U20 OPA2377 pin 1 23 Q3 Q8 IGBT pin 1 1 4 28 15 5 4 1 8 interface dj ...

Page 34: ...rrect or not check monitor DJ interface to check if the motor angle in the range of 252 5 if the deviation of motor angle is too big then motor acceleration or scram will cause large current or speed uncontrolled phenomena 4 check the impedance of pin 1 pin3 of Q3 Q8 around 10K 5 Check if the grating loose or if sensors in encoder board rub with each other E2 Software over current soft test motor ...

Page 35: ...with 80V to supply power then detect the both ends voltage of control board s rectifier bridge inlet voltage multiplied by 1 41 C73 ends impedance around12 5K Two terminal voltage means pin3 to pin4 safety line of U9 around 0 56V 4 if the voltage showed in UDC is wrong using Isolation transformer with 80V to supply power then see impedance of R143 of main control board 100Ω C77 Two terminal impeda...

Page 36: ...olation transformer with 80V to supply power then detect the both ends voltage of control board s rectifier bridge inlet voltage multiplied by 1 41 C73 ends impedance around12 5K Two terminal voltage means pin3 to pin4 safety line of U9 around 0 56V 4 if the voltage showed in UDC is wrong using Isolation transformer with 80V to supply power then see impedance of R143 of main control board 100Ω C77...

Page 37: ...lation transformer with 80V to supply power then detect the both ends voltage of control board s rectifier bridge inlet voltage multiplied by 1 41 C73 ends impedance around12 5K Two terminal voltage means pin3 to pin4 safety line of U9 around 0 56V 4 if the voltage showed in UDC is wrong using Isolation transformer with 80V to supply power then see impedance of R143 of main control board 100Ω C77 ...

Page 38: ...rmer standby voltage 5 1V the impedance of foot 1 to pin 2 of Q1 around10K note when the encoder link to main control box the impedance above is different the voltage of U1 responsed to raster notch is around 0V 4 check whether the pin 3 plug J1 4pins of Q1 of encoder connect with the main control plugJ2 4pins E6 needle position signal error when the motor speed over 50rpm UP signal keeps continuo...

Page 39: ... voltage 5 2V 6 Check the U2 49pin or U6 16pin impedance to C4 negative terminal around 3M use 80Visolating transformer to supply power the standby voltage 3 2V U6 chip model 74LVC244 Stitch as above C30 20 11 10 1 C4 negative terminal U2 TMS320F28031 64PIN Stitch as above 1 1 6 17 32 33 48 49 64 ...

Page 40: ... 1 2M the standby voltage switch between 0V with 5 1V with the raster angle is different the impedance of pin 4 to pin 3 ground of U4 about 20K the standby voltage 1 2V whether pin 2 conduct with J1 pin 1 of U4 remarks when encoder is connected with the main control the above impedance is different 4 Check the impedance of pin 2 to pin 3 ground of U5 of the encoder board about 1 2M the standby vol...

Page 41: ... board about 11K Standby voltage 5 1V impedance of U2 52 pin or U6 18 pin to C4 negative terminal around 3M Standby voltage 3 2V 6 Check the two terminal impedance of C41 on main control board about 11K Standby voltage 5 1V impedance of U2 64 pin or U6 7 pin to C4 negative terminal around 3M Standby voltage 3 2V C29 C39 C41 U6 chip model 74LVC244 pin position as picture above U2 TMS320F28031 64PIN...

Page 42: ... voltage 3 8V 5 Check the Impedance between the main control board U8 pin14 15 16 to pin12 around 10K standby voltage 0V 6 Check the Impedance between the main control board U8 pin1 to pin12 around 2 4M standby voltage 15V 7 Check the Impedance between the main control board U8 pin10 to pin12 about 1K standby voltage low frequency when the motor running is high 8 Check the two terminals impedance ...

Page 43: ...Error solution Encoder U6 pin CN4 pin definition The motor power supply interface U8 IR2136S pin 1 15 28 14 1 8 ...

Page 44: ...ngle is too big then motor acceleration or will cause large current or speed uncontrolled phenomena 2 Judging whether the motor is working or not using a multimeter Ω block to measure motor socket pin 4 and pin1 2 3 whether there is short circuit or whether the impedance among motor three phase U 2 V 2 W 1 is same issue E9 Motor overspeed error exceed the designed max speed Interface dj ...

Page 45: ...with 80V to supply power then detect the voltage of control board s bridge rectifier anode to negative terminal inlet voltage multiplied by 1 41 C73 ends impedance 12 5k or so Two terminal voltage means U9 foot 3 to foot 4 safety line 0 56V or so 4 f the voltage showed in UDC is wrong using Isolation transformer with 80V to supply power then see R143 resistance in main control board 100Ω C77 ends ...

Page 46: ...oder board about 1 2M the standby voltage with the grating angle is different switch between 0V with 5 1V U4 pin 4 impedance to pin3 ground about 20K the standby voltage 1 2V U4 2stitchs with J1 1 pin whether conduction remarks when encoder is connected with the main control the above impedance is different 4 Check the U5 pin2 impedance to pin 3 ground which on the encoder board about 1 2M the sta...

Page 47: ...Error Solution E11 HALL initialization signal fault when the power on HALL_A HALL_B HALL_C signal in low level 2 4 3 1 U3 4 5 position and foot 1 10 J1 pin and definition U3 U4 U5 ...

Page 48: ...out 11K Standby voltage 5 1V U2 52 pins or U6 18 pins to impedance on C4 negative terminal 3M detection Standby voltage 3 2V 6 check the C41 two terminal impedance on main control board about 11K Standby voltage 5 1V U2 64 pins or U6 7 pins to impedance on C4 negative terminal around 3M Standby voltage 3 2V C29 C39 C41 U6 Chip Model 74LVC244 foot U2 TMS320F28031 64PIN foot 20 10 1 11 33 3 2 17 16 ...

Page 49: ... the motor angle devia on is too large large current or speed phenomenon will accelerate and quick stop 2 encoder inside is an ash 3 the operator is very frequent pedal this fault is a frequency too frequently lead to can put 2 parameter set to 5 relief work frequency E12 motor motor overload long 2me high current opera2on Error solution ...

Page 50: ... Solu on step 1 restore factory seIngs 2 the main control re entry into a program 3 replace the U2 chip E13 EEPROM error DSP reads the wrong data TMS320F28031 64PIN Error solution ...

Page 51: ...rol board impedance between the ends of 100 C54 C62 80V transformer electric measuring voltage 0V 3 the main control end of the D8 D11 plate lts with a mul meter measuring block two diode resistance Infinity nega ve does not make a mistake when measuring Fault detec2on circuit of E14 current CUR_A or CUR_B signal zero offset value is too large D8 D11 C55 C67 Negative pole Multimeter black pen C54 C6...

Page 52: ...pply power by 80V isolation transformer turn the steel magnet make the output of sensor voltage voltage of C2 between 2 77 2 83V Note When you adjust pedal you must us 80V isolation transformer supply power the output of voltage is strong current 3 Check the every positions of cutting to see whether it is normal E15 Pedal zero point adjust error zero point adjust over size 1 5degree 1 5 Turn screw...

Page 53: ...C21 s resistance in mainboard whether it is 11 5K Standing by 80V insolation transformers to check the voltage whether it is around 2 1V and the resistance of R91 should be 1K 5 running by 80V isolation transfromers Check the resistance between foot1 and foot2 of Q10 in mainboard whether it is around 6 6K standing by voltage should be around 0 28V the resistance between foot3 and foot2 should be 1...

Page 54: ...over current and over speed when motor accelerate and sudden stop 2 Check the grating plate on motor whether it is loose and check whether there is friction between grating plate and sensor 3 To check the encoder whether it is into dust 4 Cable pin of motor power plug 1X4 loose cause mistake of 3 phases The involved repairing pictures reminded before E17 Motor reversion The speed of reversion 100m...

Page 55: ...f motor angle will cause overcurrent or over speed when motor is accelerating or sudden stop Whether the grating is loose or not whether it touch or interfere the sensor on encoder board Check the encoder whether it is dusted Pin of power plug 1X4 is come off it will cause mistake of three phase Other steps same as E8 E18 Error of motor angle testing Motor angle error when running ...

Page 56: ...tal position the mercury switch will be short circuit and the impedance 0Ω Check the impedance of C51 on main board around 10K supply power of 80V by isolation transformer the voltage is 3 2V If the mercury is not working access control box s parameter interface set the parameter No 10 to value 1 E19 Turn over warn turn over switch is effective C51 U5 ERROR SOLUTION ...

Page 57: ...board 100Ω Impedance of C77 around 3 8M Voltage of two sides leg 1 and leg 4 ground of U9 around 0 56 Impedance of R91 around 1K Check impedance of C21 on main board 11 5K supply power of 80V by isolation transformer standby voltage around 2 1V Impedance of R91 around 1K supply power of 80V by isolation transformer Check impedance of leg 1 and leg 2 ground of Q10 which on main board around 6 6K st...

Page 58: ...K Check impedance of T2 s output voltage impedance of D20 around 5 7K Voltage around 7V impedance of C3 C57 around 309Ω Voltage around 5 2V impedance of C5 0 6K voltage around 3 3V impedance of C38 1 6M Voltage 15V Check U37 on main board check impedance between leg 1 leg 2 leg 3 leg 5 and leg 8 ground whether it is in short circuit No power No display ERROR SOLUTION ...

Page 59: ...U37 TNY398 C38 IGBT Rectifier bridge 1 4 5 8 C3 D20 gative Black of muitimeter C5 C57 ERROR SOLUTION ...

Page 60: ...谢 谢 ...