A4E Electric Control Manual PowerMax
A4E Electric Control Manual PowerMax
A4E Electric Control Manual PowerMax
Safety Instruction
· Please read this manual carefully, also with related manual for the machinery before use the controller.
· For installing and operating the controller properly and safely, qualified engineers are required.
· Please stay away from arc welding equipment, in order to avoid electromagnetic interference and malfunction of the
controller.
· Keep room temperature bellow 45°c and above 0°c
· Do not use in humidity below 30% or above 95% or dew and mist places.
· Please turn off the power and unplug the power cord, before install the control box and other components,
· To prevent interference or electric leakage accidents, please make the ground work; the power cord ground wire must
be securely connected to earth by an effective way.
· All parts for the repair provided by the Company or approved before use.
· Please turn off the power and unplug the power cord before any maintenance action. There is dangerous high voltage
control box, you must turn the power off after one minute before opening the control box.
· The symbol in this manual means Safety Precautions, please pay attention to it and strictly follow it, to avoid any
unnecessary damage.
1 Installation Instructions
1.1 Product specifications
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Fig.1-1 Controller Socket Diagram
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1 Pedal socket; ② Presser Foot lifter solenoid socket ; ③ Solenoid socket; ④Auxiliary Solenoid socket;⑤Air suction tube socket
:If it is difficult toinserted plug into socket, please check whether them are matching with each other, or the inserting direction
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or needle insertion direction is correct!
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Fig.1-2 Controller Interface Definition
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We must prepare the system grounding project, a qualified electrical engineer is requested for the construction. Product is energized and
ready for use; you must ensure that the power outlet the AC input is securely grounded. The grounding wire is yellow and green lines, it must be
connected to the grid and reliable security protection on the ground to ensure safe use, and prevent abnormal situation.
:All power lines, signal lines, ground lines, wiring not to be pressed into other objects or excessive distortion, to ensure safe use!
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2 Operation Panel Instructions
2.1 Operation Panel Display Instruction
According to the system working state, the LCD module of operation panel will display the current sewing mode, parameters, start / end back
tacking, and presser foot, needle position, trimming, soft start sewing etc. Function mark of the operation panel is as follows:
Parameter In the boot state, long press key to enter the parameter modes. After modify the parameters,
setting key press key to storage. Then long press key to exit this mode.
Factory reset Long press button for 5 seconds to restore the factory Settings.
1. Short press the “+” key, and the stitch length increases by 0.1mm each time. Long press the “+” key,
adjustment key 2. Short press the “-” key, and the stitch length decreases by 0.1mm each time. Long press the “-” key,
Front reinforcing sewing selection key. Short press it once to switch between Front Reinforcing
Front
Sewing , Front Double-reinforcing Sewing , and Off. The corresponding LCD screen icon lights
reinforcing
up. Select the corresponding key to set the stitch count in segments A and B. The range of stitch count
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sewing key
1~F corresponds to 1~15 stitches.
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Rear reinforcing sewing selection key. Short press it once to switch between Rear Reinforcing Sewing ,
Rear
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Rear Double-reinforcing Sewing , and Off. The corresponding LCD screen icon lights up. Select the
reinforcing
corresponding key to set the stitch count in segments C and D. The range of stitch count 1~F
sewing key
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corresponds to 1~15 stitches.
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Power-on voice
1. Short press key: The power-on voice is disabled. Short press again to enable the power-on voice.
message and
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2. Long press key: The voice function is disabled. Then, long press again to enable the voice function.
voice on/off key
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With error warning: Short press key to broadcast the error code solution directly.
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and trimming 2. Long press key, the thread trimming icon on the LCD screen lights up, and the thread trimming
key function is enabled. Long press key again to disable the thread trimming function.
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Condensed 1. Short press key: Condensed sewing selection key. Short press it once to switch between Rear
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sewing/ Condensed Sewing, OFF, Front and Rear Condensed Sewing, and Front Condensed Sewing. The
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1.Short press to switch between Pattern Sewing Mode and Pattern Sewing Editing.
Pattern sewing
2. Long press key turn off the presser foot lifting function( At the same time, lifting the presser foot in
/ Presser foot
the middle and lifting the presser foot after thread cutting are invalid ), Press it again briefly, and the
key
presser foot lifting function will be turned on.
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W bar tacking 1, Short press key, the icon of LCD is lit, W seam marking function turns on.
/Multi-section 2, Long press key, the icon of LCD is lit, the multi-section constant-stitch sewing function turns
constant-stitch on.
1. Short press key, the thread tension icon on the LCD screen lights up, and the thread tension
Tension/trigger function is enabled. Short press it again to disable the thread tension function.
key 2. Long press key, and the trigger function is enabled. Long press it again, and the trigger function is
disabled (valid in multi-segment sewing mode).
1, Short press key, the icon of LCD is lit, the c sewing after the end of automatic trimming
key 2,Long press Key, the icon of LCD is lit, the cycle sewing midway parking presser foot
Parameter 1. In the Home interface, press key to increase the speed by 50 rpm each time.
increment key 2. In the Parameter Setting, parameter value increment key.
Parameter
1. In the Home interface, press key to decrease the speed by 50rpm each time.
decrement key 2. In the Parameter Setting, parameter value decrement key.
The left Parameters selection toward to left key. ( In constant-stitch sewing mode, long press this key,
The right
Prameters selection toward to right key.
selection key
Normal boot, press key to enter user parameter mode. Press the Left/Right key to move the cursor and the corresponding value digit flashes,
then press the Plus/Minus key to modify the value of the digit. Press key, the parameter number flashes, and save the parameter.
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Press again to exit.
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2.3.2 Needle stop position setting
In the power-on state, press + key to enter the monitor mode (display 024 parameter interface). At this time, turn the hand wheel to the
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upper needle position as required. The displayed value will change with the hand wheel position. Press + key to “set zero” to
parameter value measured after 024 in the interface, confirm the upper needle position is OK, and calculate the lower needle position
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automatically at the same time.
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In the monitoring interface state (press + key to enter), long press to save the current parameters. In the power-on state, long
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2.3.4 Version number query
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In the power-on state, press + key to enter the version display interface, and switch the display of program versions by pressing the
Plus/Minus key, h**-**-** represents the panel program version; A**-**- ** represents the master control program version; V5-**** represents the
voice version; V2-**** represents the recovery code.
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2.3.5 Piece/stitch count setting
In the power-on state, press + key to enter piece/stitch count interface. Use the Left/Right key to switch between the piece/stitch count.
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2.3.6 Step motor “Zero” calibration
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In the power-on state, press key to enter the user parameter mode. Adjust the parameter to item P81, use ordinary A4 paper, and measure at
the speed 4000rmp. Adjust the parameter so that more than 10 stitches are performed by the needle in place. Press the P key to save; (if the
stitch length is at forward feeds, the number decreases; if the stitch length is at reverse feeds, the number increases).
Note: Enter the P81 interface, and the stitch length will automatically become 0 to facilitate debugging. After exiting this interface, the
stitch length will return to normal.
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2.3.7 Stitch length adjustment setting
In the power-on state, press key to enter the user parameter mode. Adjust the stitch length to 5mm and the parameter to P82 (stitch length
compensation at forward feeds). Use ordinary A4 paper, measure at the speed 200 rmp, adjust the parameter to make the stitch length
4.9-5.1mm, and press P key to save; then enter P83 (stitch length compensation at reverse feeds), use ordinary A4 paper, sew a section forward,
at the speed 200 rmp, press and hold the back-tacking switch. Adjust the parameters so that the forward feeds overlap more than 11 stitches, and
press P key to save.
Note: Enter the P82 and P83 interfaces, and the speed will automatically become 200 rmp to facilitate debugging. After exiting this
interface, the speed will return to normal.
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3 System parameters setting list
3.1 Parameter mode
1、In the standby state ,press key to enter the parameter modes.
3 、 When the parameter values have increased and decreased, parameter interface flash. Short press key to save the modified
parameters .Long press key to exit parameter interface, return to standby model.
P01 200~5000 4000 the maximum speed of free sewing (the global maximum speed)
P07 5~720 300 After the motor runs to the target Angle, open the clip-on electromagnet
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0: Press the time control;
P15 0~2 0
1: Compensate for half stitch;
2: Compensate for one stitch
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P18 1~120 15 Stitch balance for start back tacking No.1(Pull in compensation)
P19 1~120 15 Stitch balance for start back tacking No.2(Release of compensation)
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Front reinforcing working mode.
0: Press the pedal gently to start the initial backstitch automatically.
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P20 0~3 0 1: Controlled by the pedal, stop at will.
2: Controlled by [CT] time after the needle stops at the upper position
3: Controlled by [CT] time after the needle stops at the lower position
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Rear reinforcing working mode.
0: Press the pedal gently to start the initial backstitch automatically.
P21 0~3 0 1: Invalid
2: Controlled by [CT] time after the needle stops at the upper position
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3: Controlled by [CT] time after the needle stops at the lower position
W reinforcing working mode.
0: Press the pedal gently to start the initial backstitch automatically.
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P22 0~3 0 1: Controlled by the pedal, stop at will.
2: Controlled by [CT] time after the needle stops at the upper position
3: Controlled by [CT] time after the needle stops at the lower position
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Type of front/rear reinforcing mode (CD is similar to AB)
0: B->AB->ABAB->NONE;
1: B->NONE
P23 0~4 4
2: B->AB->NONE
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3: AB->NONE
4: AB->ABAB->NONE (Panel)
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P24 0~1024 80 Pedal trimming position
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P28 10~150 130 Thread tension start angle during front reinforcing and W sewing
P29 160~359 250 Thread tension end angle during front reinforcing and W sewing
Tension force adjustment, the greater the parameter, the greater the force ( When the parameter is
P33 0~100 2
0, the clamping force is mixnmum )
P40 0~1024 300 Pedal presser foot lift position (greater than the previous parameter value in turn)
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P41 0~1024 500 Pedal back to center position (greater than the previous parameter value in turn)
P42 0~1024 501 Pedal forward running position (greater than the previous parameter value in turn)
P43 0~1024 650 Pedal low-speed running position (upper limit) (greater than the previous parameter value in turn)
P44 0~1024 900 Pedal simulation maximum value (greater than the previous parameter value in turn)
P47 200~360 360 After trimming anti pull (It realizes trimming is pulled back function)
P50 1~500 150 Presser foot lifting electromagnet full output time (ms)
P51 1~100 9 Presser foot lifting electromagnet ON time per cycle (ms)
P54 1~100 15 Presser foot lifting electromagnet Off time per cycle (ms)
P56 0/1 1 Power on automatic upper needle position search: 0: no search 1: search
P57 0~600 100 Presser foot lifting electromagnet protection time 100ms
P60 200~5000 3000 Maximum fixed-length sewing speed (automatic speed test)
P64 0~10 0 Short thread switch (0: off; non-0: condensed stitch count)
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P67 0~359 10 Short thread angle compensation in quick, immediate trimming
Slow release presser foot level adjustment, the smaller the value, the faster the release; (overclock
P71 0~50 2
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On time)
Broken needle prevention (0: off, non-0: press manual backstitch to find the suction angle, open
P72 0~359 90
normal 90)
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P73 0/1 0 Rear reinforcing function before thread trimming halfway of fixed stitch sewing (0: off, 1: on)
Operation mode selection after fixed length sewing is completed
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P74 0/1 0
0: rear reinforcing sewing 1: end sewing and standby (stitch compensation)
P75 0/1 0 Thread trimming switch for each segment of multi-segment sewing (0: off, 1: on)
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Manual backstitch function mode selection
P77 0/1 0 0: Juki mode. Have action during sewing or stop halfway.
1: Brother mode. Have action only during sewing.
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P78 10~150 130 Tension start angle
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P79 160~359 320
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P81 -999~999 45 Zero compensation
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P83 -250~250 0 Reverse stitch length compensation
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P84 200~3000 2000 Pattern sewing speed limit
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P87 0/1 0 Front short thread direction
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P97 0/1/2 0 0 Boot voice and key voice 1 Boot voice only 2 Key voice only
P98 0~4 2 Voice volume adjustment (restore factory default without change)
P99 0/1/2 1 language selection 0: off, 1: Chinese, 2:English, default language 1 Chinese
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013 State of encoder 028 The sampling voltage of interaction
020 DC voltage 029 Software version
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021 Machine speed 02A Analog input 1
022 The phase current 02B Analog input 2
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023 Initial electrical angle 02C Error counter
系 ID
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Alarm code Description Corrective
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Stitch counter alarm The stitch counter reaches the limit. Press key to cancel the alarm and reset the counter.
Trimming counter
The trimming counter reaches the limit. Press key to cancel the alarm and reset the counter.
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alarm
Power is off alarm Please wait for 30 seconds, then turn on the power switch
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Safety switch alarm Adjust the machine to the correct position.
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3.4 Error mode
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If the error code appears, please check the following items first:1.Make sure the machine has been connected correctly; 2. Confirm that the
control box match with the machine head. 3. Confirm factory reset is accurate
Error Code Description Solution
1. Turn off the system power, and turn it on again after 30 seconds.
2. Please enter P62 to check the initial angle of the arm shaft motor.
Arm shaft motor 3. Check whether the arm shaft motor encoder and electronic control are damaged or in other poor
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Err-01
hardware overcurrent conditions. If so, replace them in time.
4. If the system still does not work properly after troubleshooting and restart.
Please contact your local service provider or call 4008876858.
Disconnect the power supply of the controller and check whether the input power supply voltage is
lower than 176V. If so, please restart the controller after the voltage returns to normal. If the voltage
Err-03 System undervoltage
returns to normal, it still does not work properly after the controller starts up.
Please contact your local service provider or call 4008876858.
Overvoltage during Disconnect the controller power and check whether the input power voltage is higher than 264V. If
Err-04
shutdown so, please restart the controller after the voltage returns to normal. If the voltage returns to normal, it
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Overvoltage during still does not work properly after the controller starts up.
Err-05
operation Please contact your local service provider or call 4008876858.
1. Turn off the system power, check whether the electromagnet connection is correct and whether
there is any loose or damaged part. If so, replace it in time.
Electromagnet circuit 2. Unplug the 14-pin plug on the electric control to confirm whether the electric control is normal. If
Err-06
failure the electric control is normal, please check whether the electromagnetic circuits are damaged.
3. If the system still does not work after troubleshooting and restart.
Please contact your local service provider or call 4008876858.
Turn off the system power, and turn on the power again after 30 seconds to see whether it can work
Current detection circuit
Err-07 properly. Try a few times again. If the fault occurs frequently, please contact your local service
failure
provider or call 4008876858.
1. Please check whether there is any foreign object wrapped around the machine head, whether
there is any thread residue stuck in the rotating shuttle, and whether the eccentric wheel of the
machine is stuck.
2. Disconnect the power supply of the controller and check whether the input plug of the arm shaft
Err-08 Arm shaft motor stalled
motor power supply is detached, loose, or damaged.
3. Please enter P62 to check the initial angle of the arm shaft motor.
4. If the system still does not work properly after troubleshooting and restart.
Please contact your local service provider or call 4008876858.
1. Please check whether the connection between the operation panel and the electric control is
drops off, loose, or broken.
Panel communication 2. Please check whether the connection cable of the pedal speed controller is drops off, loose, or
Err-10
failure damaged.
3. If the system still does not work properly after troubleshooting and restart.
Please contact your local service provider or call 4008876858.
1. Check whether the connection between the arm shaft motor encoder and the controller is loose.
2. Replace the arm shaft motor encoder.
Err-11 Head stop signal failure
3. If the system still does not work properly after troubleshooting and restart.
Please contact your local service provider or call 4008876858.
1. Please enter P62 to check the initial angle of the arm shaft motor.
Arm shaft motor initial
Err-12 2. Please try 2-3 times again after power off. If it still fails.
angle detection failure
Please contact your local service provider or call 4008876858.
1. Turn off the power of the system, check whether the arm shaft motor encoder connector is loose,
or drops off. Restore it to normal and restart the system.
Arm shaft motor zero
Err-13 2. Replace the arm shaft motor encoder.
position fault
3. If the system still does not work properly after troubleshooting and restart.
Please contact your local service provider or call 4008876858.
Master control eeprom
Err-14 components read/write
failure
Arm shaft motor Turn off the system power, and then turn on the power again after 30 seconds. If the controller still
Err-15
overspeed protection does not work properly, please contact your local service provider or call 4008876858
Err-16 Arm shaft motor reverse
Master control restart
Err-17
failure
Check whether the arm shaft motor is stalled. If not, please contact your local service provider or call
Err-18 Arm shaft motor overload
4008876858.
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Alarm for oil shortage Check whether the oil level of the machine is sufficient. If the problem is still not resolved after filling
Err-20
every 8 hours up the oil volume, please contact your local service provider or dial 4008876858.
1. Please check whether there is any foreign object wrapped around the machine head, whether
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there is any thread residue stuck in the rotating shuttle, and whether the eccentric wheel of the
machine is stuck.
2. Disconnect the power supply of the controller and check whether the input plug of the arm shaft
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Err-21 Arm shaft motor stalled
motor power supply is detached, loose, or damaged.
3. Please enter P62 to check the initial angle of the arm shaft motor.
4. If the system still does not work properly after troubleshooting and restart.
系 ID
Please contact your local service provider or call 4008876858.
Check whether the bobbin is sufficient. If the bobbin is sufficient but the error still exists, please
Err-24 Bobbin detection alarm
contact your local service provider or dial 4008876858.
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Thread residue detection Restart after cleaning the yarn, if it still fails to work.
Err-26
alarm Please contact your local service provider or call 4008876858.
Password lock shutdown The machine has reached the set time. If further use is required, please contact your local service
识 A
Err-30
alarm provider or call 4008876858.
1. Check whether the backstitch step motor, swing seat, and teeth are stuck. After the normal state
业 OR ES
is restored, restart the system.
Backstitch step motor 2. Check whether the backstitch step encoder is damaged or in other poor conditions. If so, replace it
Err-31
zero position fault in time.
3. If the system still does not work properly after troubleshooting and restart.
企 P IN
Please contact your local service provider or call 4008876858
1. Turn off the system power, and then turn on the power again after 30 seconds
2. Check whether the backstitch step motor, swing seat, and teeth are stuck. After returning to the
Backstitch step motor
Err-32 normal state, restart the system.
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hardware overcurrent
3. If the system still does not work properly after troubleshooting and restart.
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Please contact your local service provider or call 4008876858
Backstitch step motor
Turn off the system power, and then turn on the power again after 30 seconds. If the controller still
Err-33 current A detection circuit
does not work properly, please contact your local service provider or call 4008876858.
failure
Backstitch step motor
Turn off the system power, and then turn on the power again after 30 seconds. If the controller still
Err-34 current B detection circuit
does not work properly, please contact your local service provider or call 4008876858.
failure
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1. Check whether the backstitch step encoder and electronic control are damaged or in other poor
conditions. If so, replace them in time.
Backstitch step motor
Err-35 2. Turn off the system power, and then turn on the power again after 30 seconds
Hall signal failure
3. If the system still cannot work properly after troubleshooting and restart.
Please contact your local service provider or call 4008876858
1. Turn off the system power, and then turn on the power again after 30 seconds
Backstitch step motor 2. Check whether the backstitch step motor, swing seat, and teeth are stuck. After returning to the
Err-36
stalled normal state, restart the system.
3. Check whether the backstitch step encoder and electronic control are damaged or in other poor
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conditions. If so, replace them in time.
4. If the system still cannot work properly after troubleshooting and restart.
Please contact your local service provider or call 4008876858
Digital AC Servo Controller
Packing List
Please check carefully whether the components listed on the packing list are all included. Please
Controller piece 1
User manual 1
Warranty Card
Please fulfill this Warranty Card and fax it to us, purpose for getting a customer servicenumber, only through it
the products maintenance and other technical service could bewarranted. In case of more than one set of product
are once purchased, only one warranty card needed but all product bar code should be enclosed.
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Notice:
1. This card is important evidence with which customer can obtain maintenance service andtechnology support, please keep
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it well.
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2. The warranty period is calculated since the product is selled,if the proof is notprovided,corresponding time will adds one
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3. For those errors which happen in normal condition and without man-made misplay during theperiod, in terms of warranty
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content, with original warranty card and purchasing certification.We will provide free repair service and technology support till
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4. Repair service and technology support under following conditions will charge during warranty period.
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a. Valid warranty card and purchase certification can not be provided.
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c. The fault or damage is caused by unavoidable force.
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e. The fault or damage is caused by unauthorized removing, repairing and/or refitting.
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f. The fault or damage is caused by irrational operation, which does not obey the regulatedmethods in the manual.
INSPECTION
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CERTIFICATE
NAME Digital AC Servo System DATE See bar code
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