JUKI PS-800-12080 User manual

CAUTION :

This Instruction Manual provides instructions for the active tension. When you want to use

your sewing machine with this product attached, refer to the “Safety precautions” in the In-

struction Manual for your sewing machine carefully until you fully understand the included

precautions in prior.

PS-800-12080

Active tension

INSTRUCTION MANUAL

CONTENTS

1. List of parts ............................................................................................................................1

2. Assembling the parts ............................................................................................................ 3

3. Wiring (miscellaneous cover components of the sewing machine) ................................. 5

4. Wiring (inside the electrical equipment rack) ..................................................................... 6

5. Method for adjusting the AT ................................................................................................. 8

5-1. Setting of the parameters ............................................................................................................8

5-2. Adjusting the projection amount of the plunger........................................................................9

6. Method for using the AT...................................................................................................... 10

6-1. Method for setting the AT thread tension.................................................................................10

6-2. Method for changing the thread tension during sewing.........................................................12

6-3. Method for deleting the changes in thread tension setting during sewing ..........................13

– 1 –

1. List of parts

Active tension (asm.)

No. Part number Part name Qty

①40244934 Tension release auxiliary shaft (asm.) 1

①-1 40236683 Tension release auxiliary shaft (1)

①-2 40236685 Tension release auxiliary pin (1)

①-3 26201004 Guide pin (1)

①-4 RE0320000K0 E retaining ring (1)

②40244974 AT solenoid asm. 1

②-1 40236465 Solenoid (1)

②-2 RE0500000K0 E retaining ring (1)

②-3 NM6040000SN Hexagonal nut M4 1 type (1)

②-4 40236686 Solenoid screw (1)

②-5 40236680 Solenoid mounting plate (1)

②-6 40236681 Left AT shaft bushing (1)

②-7 SM1850600SP Countersunk head screw (2)

②-8 SM6040802TP Bolt screw (2)

①40244934 Tension release auxiliary shaft

①-2

①-1

①-4 ①-3

②40244974 AT solenoid

②-4

②-3

②-2

②-1 ②-5

②-6

②-7

②-8

WARNING :

In order to prevent accidents caused by a sudden start of the sewing machine, the following proce-

dure has to be carried out after turning OFF the power supply and air supply to the sewing machine.

– 2 –

③④⑤

No. Part number Part name Qty

③40172470 Thread tension controller (asm.) 1

④40243919 AT spring 1

⑤SM6041402TP Bolt M4 L=14 2

⑥40243045 AT SOL PCB asm. 1

⑦40243046 AT SOL cable asm. A 1

⑧40243047 AT SOL cable asm. B 1

⑨KX000000210 Cable tie mount 2

⑩SM4051601SC Countersunk head screw M5 x 0.8 L=10 2

⑪HX002940000 Fixation base 1

⑫SM6041002TN Bolt M4, L=10 1

⑬EA9500B0200 Cable clip band 6

⑥

⑦

⑧

⑨ ⑪

– 3 –

1) Loosen screw ❶. Detach tension release

solenoid ❷.

2. Assembling the parts

❷❷

3) Detach the face plate. Take out tension disc

releasing solenoid tension release auxiliary

shaft asm. ❺from the solenoid mounting hole.

❹❹

❺❺

❶❶

❸❸

2) Loosen screw ❸. Detach thread tension con-

troller ❹.

Tension disc releasing solenoid

tension release auxiliary shaft asm.

Pull the auxiliary shaft in the direction

of the arrow until it comes off.

WARNING :

In order to prevent accidents caused by a sudden start of the sewing machine, the following proce-

dure has to be carried out after turning OFF the power supply and air supply to the sewing machine.

– 4 –

4) Secure AT solenoid asm ②in the

mounting hole with screws ⑤ (two

pieces).

6) Put the end Aof tension release auxiliary

shaft asm. ①into the thread tension con-

troller mounting hole.

Put spring ④on the end Bof the tension

release auxiliary shaft asm.

Mounting hole

End A End B

E retaining ring Spring

E retaining ring

Retaining ring

of the thread

tension con-

troller asm.

Grease

application

points

5) Put a little amount of grease (white) sup-

plied in the accessory bag on a piece of

cloth. Then, apply a thin coat of the grease

to the AT shaft, reseat spring and tension

release pin with that cloth.

– 5 –

3. Wiring (miscellaneous cover components of the sewing machine)

1) Wire AT solenoid cable ②along the route indi-

cated with the red dotted line as shown in the

figure on the left.

During this procedure, loosen the screw and

tighten fixing base ⑨. Then, secure the cable

with cable clip band ⑬.

2) Wire AT solenoid cable ②along the route indi-

cated with the red dotted line as shown in the

figure on the left.

Insert the termina-side cable through the inter-

mediate-part opening in the cover and pass it

through the sewing machine.

During this procedure, loosen the screw and

tighten fixing base ⑨. Then, secure the cable

with cable clip band ⑬.

Pressing the retaining spring of the AT thread

tension controller asm. against the end surface

of the tension controller mounting hole, secure

it with screw ❸at a position where the stroke of

the thread take-up spring becomes 4 to 5 mm.

If you cannot press the retaining

spring of the thread tension controller

asm. against the end surface of the

mounting hole, loosen bracket screw

❻of the AT thread tension controller.

After pressing the retaining spring

against the end surface of the mount-

ing hole, temporarily tighten bracket

screw ❻.

❸❸

4～5mm

❻❻

⑨⑬⑨⑬

⑬⑬

3) Wire AT solenoid cable ②along the route indi-

cated with the red dotted line as shown in the

figure on the left.

Draw out the cable from the rear opening in

the cover and secure it together with other

cables with cable clip band ⑬.

– 6 –

4. Wiring (inside the electrical equipment rack)

4) Pull AT solenoid cable ②into the electrical

equipment rack through cable entrance of the

rack.

1) Connect AT solenoid cable ②and AT SOL cable asm. A ⑦to the AT SOL PCB asm. ⑥in the elec-

trical equipment rack.

[Standard type and the laser type]

⑥⑥

②②⑥⑥⑦⑦

GND

LOOSE

24V

Pin No. 10

Loose thread

2) Insert the pin contact of the black wire (GND) of AT SOL cable asm. A ⑦into IN6/IN7 connector pin

No. 4.

3) Connect AT SOL cable asm. A connector ⑦to the loose line / LOOSE connector of the electrical

control box.

IN4/IN5/IN6

– 7 –

[ Rotary knife type ]

⑥⑥

②②⑥⑥⑧⑧

GND

LOOSE

24V

5) Connect AT solenoid ②cable and AT SOL cable asm. B ⑧to AT SOL PCB asm. ⑥ in the electrical

equipment rack.

6) Connect terminals of AT SOL cable asm. B ⑧

to the IO PCB.

Refer to the table shown below for the connec-

tion destinations of the respective terminals.

Color of line Cable Connection desti-

nation

Brown -24V +24V

Gray LOOSE Loose thread -

Black GND GND

7) Put the cables together in the duct.

Loose thread -

+24V

GND

4) Put the cables together in the duct. Secure the

PCB with cable clip band ⑬.

⑬⑬

PCB

– 8 –

5. Method for adjusting the AT

1) Press button A.

5-1. Setting of the parameters

2) Press button B.

In the default state, the password that has

been factory-prepared at the time of delivery is

provided.

The factory-provided password is "11111111".

3) Press button C.

D F

4) When you want to enable the AT function,

change the setting of Dfrom "Tension disk

release" to "Thread clamp".

In the case of the sewing machine for light-

weight materials, set correction value Fto

"-10". After you have set the correction value,

press button E.

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