This document describes the JK-500/600/700 control system, an energy-saving servo motor system designed for industrial sewing machines.
Function Description
The JK-500/600/700 control system is a modern replacement for traditional clutch motors in industrial sewing machines. Its core mission is energy saving, cost reduction, and environmental protection. The system offers high efficiency, stable performance, and a reasonable price, making it a popular choice in the apparel industry.
The system comprises two main components: a controller and a motor.
Controller
The controller utilizes the newest AVR SCM (System-on-Chip) from ATMEL LIMITED, which enables accurate motor control through an optimized algorithm. The power driver for the motor incorporates an intelligent driver module from Fairchild Semiconductor, providing robust protection against overvoltage, overcurrent, and overheating. The controller's structure is designed for efficiency and reliability. A pedal-driven speed governor is integrated as part of the motor speed controller.
Motor
The motor employs a permanent-magnet AC motor structure. Its rotor is made of permanent-magnet material, contributing to its compact size, high power output, energy efficiency, and environmental friendliness. A Hall position sensor is built into the motor.
The product is available in two types:
- Mounted type: (as shown in picture 2)
- Direct-drive type: (as shown in picture 3)
Accessories
An optional accessory is the positioner, also known as a synchro or detector (as shown in picture 4). This component provides a signal to the controller for needle positioning, making it suitable for applications requiring precise needle control.
Important Technical Specifications
The following table summarizes the key performance and parameters for the JK-500/600/700 Magneto Servo System:
| Parameter |
Specification |
| Controller Model |
JK-500/600/700 |
| Model |
Energy-saving Servo Motor |
| Power Voltage Range |
AC 220±10% V 50HZ |
| Motor Output |
380W/550W |
| Speed Setting |
4000rpm (pensile-type), 6000rpm (direct-drive type) |
| Max Speed |
5000rpm (pensile-type), 7000rpm (direct-drive type) |
| Maximum Torque |
380W/1N/M, 550W/1.5 N/M |
| Needle Up/Down |
Optional (synchronized needed) |
| Transistor Protection |
Yes |
| Package |
Two sets in one carton |
| Gross Weight |
13 KG |
| Packing Dimension |
550×350×260 |
Application
- 380W Motor: Applicable to ordinary lockstitch sewing machines, overlock sewing machines, and other light-load machines.
- 550W Motor: Applicable to ordinary heavy-duty lockstitch sewing machines, double-needle lockstitch sewing machines, heavy-duty overlock sewing machines, and interlock sewing machines.
- Customers should select the appropriate power based on their specific conditions.
Usage Features
Safety Instructions
- Read the manual carefully before installation and adjustment.
- Installation and operation must be performed by professionally trained staff.
- Confirm that the power is safely grounded and that the voltage range matches the technical requirements on the nameplate.
- Keep feet away from the pedal when turning power on or off.
- Always cut off power during the following operations:
- Installing the machine.
- Inserting or pulling out any plug in the control box.
- Threading, changing needles, and rotating the machine head.
- Machine maintenance or when the machine is idle.
- Control system settings and maintenance should be performed by trained staff.
- Allow 5 seconds between power changes.
- The system must be safely connected to the ground.
Installation and Adjustment (Pensile-Type System)
-
Installation of Synchro (non-positioning type can ignore this step):
- Pull down the driver of the machine head.
- Set the synchro into the pre-made mounting hole (as shown in pictures 6 and 7).
- Set the alnico in the fixed position of the driver according to the color mark, using the first positioning screw of the main shaft as a fiducial (counter-clockwise) (as shown in picture 8). The correct installation position is for the upper needle position.
- Install the driver. Adjust the position of the drive in the main shaft so that the distance between the alnico and synchro is 2-3mm. Rotate the driver back and forth to ensure it rotates without friction (as shown in pictures 9 and 10).
-
Installation of Motor Module:
- Insert three lifting screws into the foreseen holes in the sewing machine table and fix the motor to the table.
- Adjust the position of the motor rack so that the motor belt puller is level with the handwheel and belt of the sewing machine.
- Adjustment of elasticity: Press the belt with a force of 1 kg. If the belt sags by one centimeter, it is correctly adjusted. If not, adjust the belt. Install the belt cover back.
-
Installation of Control Box:
- Drill two holes, one centimeter deep, with a Ø3 drill in the right front of the bottom table, with a distance of 195mm between them.
- Fix the control box tightly with wooden screws.
- Insert the plugs of the motor, synchro, and speed controller into the relevant sockets.
- Fix the packed cable conductor to the table, away from the belt (as shown in pictures 12 and 13).
-
Installation of Pedal:
- Ensure the tension rod is perpendicular to the pedal.
- Adjust the angle of the tension rod so that the filter angle to the ground level is 15 degrees.
-
Connection of System:
- Connect the controller power supply wire to a single-phase 220V power supply system, which must have a separate earthing device. The control box must be safely connected to earth.
- Insert the plugs of the motor, speed controller, and synchro into the sockets behind the control box.
- Once everything is ready, check for stable connections and adjust the plastic sheath to cover the plugs completely (as shown in picture 16).
Installation and Adjustment (Direct-Drive Type)
- Decompose the direct-drive motor: Break it into front and back cover, rotor, and stator (as shown in picture 17).
- Make the main shaft cross the front cover and keep it perpendicular to the main shaft, then fix the screw (as shown in picture 18).
- Find the position of the main shaft flat, make the flat face upwards, then cover it to the end with the motor rotor. Position the screw in the rotor shaft to the flat of the main shaft and fix it (as shown in picture 19).
- Install the stator to the fixed front cover of the motor. Be cautious during this operation due to the strong magnetism of the rotor, to avoid finger injury and motor damage. Pay attention to the position and direction of the down-lead wire of the stator before installation. The down-lead wire of the stator is located under the front cover (as shown in picture 20).
- After stator installation, check the distance between the stator and rotor. The standard distance should be 0.5mm per circle. No metal materials should be sucked into this gap (as shown in picture 21).
- Assemble the front and back covers of the motor and fix the screws (as shown in picture 22).
- A blue-marked alnico is installed near the second fixing screw (counter-clockwise), and the other alnico installation position should be red-marked.
- Cover the motor shaft with the handwheel, and align it with the flat in the motor using the first screw in the handwheel, then fix the screw. Be cautious about the distance between the alnico and sensor flat during installation; 2-3mm is appropriate. There should be no friction when rotating the handwheel (as shown in pictures 23 and 24).
- Installation of Control Box: (Same as pensile-type, see point 3 above, and pictures 25 and 26).
- Installation of Pedal: (Same as pensile-type, see point 4 above, and pictures 27 and 28).
- Connection of System: (Same as pensile-type, see point 5 above, and picture 29).
Adjustment of Needle Position (for positioning types)
- Connect to power and turn on the main switch of the control box.
- Rotate the sewing machine driver. When it stops at the upper needle position, the red luminotron in the synchro should light up. Adjust the position of the alnico with the red mark and fix the screw.
- Similarly, rotate the sewing machine driver. When it stops at the lower needle position, the green luminotron in the synchro should light up. Adjust the position of the alnico with the blue mark and fix the screw.
Operation Instruction of Control Panel
The control panel features a nixietube display and buttons (P and S).
- WPS (Working Parameter Setting): The nixietube shows 'P'.
- Speed Setting:
- Press 'P', the nixietube shows 'V' (speed setting interface).
- Press 'S' to adjust the speed from 1-9 (increases in a circle).
- The corresponding speed limitation ranges from 500 to 4500 R/S (revolutions per second), depending on the machine type.
- Rotating Direction Setting:
- Press 'P' again, the nixietube shows 'b' (rotating direction setting interface).
- Press 'S':
- '0' indicates corotation (suitable for lockstitch sewing machines, with a dot below the number lit).
- '1' indicates inversion (suitable for overlock sewing machines, with no dot below the number).
- Conservation of Data:
- After all parameters are set, press 'P'. The nixietube will show 'O' and 'K' separately if data is stored successfully.
- If storage fails, 'Er' will be displayed. If this happens, turn the controller off, then on again, and re-operate from steps 1-4.
- System Recovery Function:
- If the controller is not working regularly, press 'S' on the 'P' interface until the nixietube shows 'O' and 'K'. This will restore the system parameters to the factory settings.
Operational Requirements
- Keep the system away from high magnetic fields and environmental radiation to avoid obstructions.
- Operational temperature must be within 5°C to 45°C.
- Do not use the product near heat sources (heaters, radiators).
- Do not use the product in overly wet circumstances.
- Do not use the product near corrosive liquids or explosive environments.
- Ensure good ventilation where the controller and motor are stored.
- Maintain a steady power supply voltage.
- A qualified connector to the ground is mandatory for safety.
Maintenance Features
Troubleshooting and General Recovery Processing
If the machine malfunctions, maintenance and repair should be performed by professionally trained personnel.
-
No reaction when the controller is turning on:
- Check if the power plug is tightly connected to the socket.
- Check if the protective tube is burnt. If so, replace it. Open the controller cover, locate the protective tube, remove the burnt one, and replace it with a new 5A/250V Ø5mm×20mm protective tube (as shown in picture 34).
-
Controller is connected, but the motor doesn't work when pressing the pedal:
- Check if the plugs of the speed adjustor, motor, and motor signal wire are correctly connected to the sockets in the controller.
- Check if the speed adjustor is broken.
-
The motor's rotation speed is sometimes fast and sometimes slow:
- Check if the belt is too loose, if the belt puller has slipped, or if the pedal and tension rod are loose.
-
The motor stopped during running:
- First, check if the machine load is too heavy or if there is a mechanical issue.
- Then, check if the power socket and plug are well connected to the motor Hall socket and plugs. Do the same for the speed adjustor's socket and plug.
-
The motor runs without stopping when the controller is turned on:
- A: Check if the working model is set to '0'. If it's set to another model without synchro installation, the motor will run continuously.
- B: Check if the position of the alnico within the speed adjustor has changed. To adjust:
- Open the plastic cover of the speed adjustor, and loosen the fixed screw.
- Adjust the position of the swinging arm (picture 35 shows the swinging arm position when working) so that the alnico within the swinging arm is on the right side of the Hall sensor. Generally, the machine should stop. If not, adjust the position again clockwise.
-
Nixietube alternately displays 'E1':
- This indicates an operational failure of the motor. Check if the sewing material is too heavy or if the machine needs lubrication.
-
Nixietube alternately displays 'E2':
- This indicates motor overcurrent or undervoltage. Check if the power supply voltage is normal (should be between 200V and 240V).
-
Nixietube alternately displays 'E3':
- You need to cut off the power and then turn it on again.
-
If the protective tube is burnt on boot-start, and the error still exists after changing a new protective tube:
- Contact the local distributor.
-
If there is any other error not listed above:
- Contact the local distributor.
Setting of Control Box
The control box has two main interfaces: 'P' (user setting) and 'F' (factory setting).
-
Switching from P to F: Press button 'F' first, then press 'P' together with 'F'. The liquid crystal box will show 'F', indicating the factory setting interface.
-
Parameters under 'P' interface:
- V: Speed setting, from 0-9.
- B: Running direction setting. '0' means clockwise running, '1' means inverse hours running.
-
Parameters under 'F' interface (seven parameters):
- M: Working model setting. '0' means ordinary, '1' means upper and lower needle positioning, '2' means upper needle positioning.
- L: Speed limitation setting, from 0-9.
- C: Working current setting, from 0-9.
- N: Start speed setting, from 0-9.
- U: Upper needle positioning setting, from 0-9.
- D: Lower needle positioning setting, from 0-9.
- A: Can store current parameters as Windows default. Press 'F'; it will succeed when 'OK' is shown on the interface, otherwise 'Er' will be displayed.
-
Storing Settings: Press 'P' to store the settings finally.
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