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brother

DC

MOTOR

SERVICE

MANUAL

MD-802

(Single-Phase

Type)

MD-812

(Three-Phase

Type)

BROTHER

INDUSTRIES,

LTD.

KIA^nVA

IADAM

INTRODUCTION

This

service

manual

is

compiled

for

the

technical

staff

who

maintain

and

inspect

the

drive

motor

designed

for

the

auto¬

matic

thread

trimming

machine.

The

manual

describes

the

motor

and

the

control

box

and

also

covers

adjustments.

Read

the

service

manual

carefully

so

that

you

understand

the

right

handling

and

adjustment.

TABLE

OF

CONTENTS

(

tDESCRIPTION

OF

THE

MOTORj

)

1

(

^NAME

OF

EACH

COMPONENT^

).

2

((

JNAME

OF

EACH

PA^f^

).

3

((

configuration")).

4

(

(principle

of

control

system^

)

5

(

(

ADJUSTMENT

(

j)...

7

[T1

DC

Servomotor

.

7

|~2]

Needle

position

detector

(synchronizer).

7

[3]

Control

box.

9

[4]

Treadle.

10

[¥]

Brush

replacement.

10

[6]

Motor

brake

spacing.

11

[7]

Checking

the

lamp

terminal

code.

11

[8]

Standing

work

machine.

12

[9]

Application

to

production

control

system.

13

(j(

OPERATION

INSTRUCTION^)

fT]

Installation

of

operation

box

.

14

[2]

M

otor

and

control

box

(Models

DB2-B737

•

B747

■

B748

•

B791

-

B793

•

B795

•

B798).

14

[|]

Operation

box

(Models

DB2-B737

■

B747

•

B748

•

B791

•

B793-B795

•

B798).

15

(

tBLOCK

DIAGRAM

OF

CONTROL

CIRCUIT^

)

18

Q]

Single-phase/100V

(Models

DB2-B737

-

B747

•

B791

•

B793

•

B795

•

B798)

.

18

[2]

Three-phase/200V

(Models

DB2-B737

•

B747

■

B791

•

B793

•

B795

•

B798)

.

19

[3]

Single-phase/100V

type

#470B

(Model

DB2-B738)

.

20

[4]

Three-phase/200V

type

#470

(Model

DB2-B738).

21

(

f

DETAILS

OF

CONNECTOR

R4N^T7

))

22

[1]

Model

DB2-B737

•

B747

•

B748

•

B791

•

B793

■

B795

•

B798

(Type

300B).

22

[2]

Model

DB2-B738

(Type

#4706).

23

(

(

TROUBLE

SHOOTING

24

C

(CHECKING

THE

MOTOR

J

)

.

25

Q]

Motor.

25

[2]

Brake.

25

t

CHECKING

THE

MACHINE

SOLENOIDS

)

)

26

[~T~1

Solenoid

load

of

the

machine.

26

[j]

Hem

sensor.

26

|~3~1

B737

Machine

control

system

block

diagram..

27

[

4

]

B738

Machine

control

system

block

diagram.

28

[

5

]

B737

•

B738

Motor

drive

control

system

block

diagram.

29

(C

DESCRIPTION

OF

THE

MOTOlT))

★

The

Brother

DC

motor

is

best

suited

for

the

energy

saving

works.

To

save

sewing

labor

and

enhance

the

automation,

advanced

functions

are

installed

with

the

reliable

unit-design.

FEATURES

1.

Energy

Saving

Power

rates

is

saved

about

50%

with

the

DC

servomotor,

as

compared

with

the

clutch

motor

we

have

made.

When

the

sewing

machine

is

stopped,

the

DC

motor

is

also

stopped,

resulting

in

highly

effective

energy

saving.

2.

Quiet

Operation

While

the

clutch

motor

produces

windy

or

idling

sounds

and

vibrations,

the

DC

motor

is

free

from

them

because

it

does

not

run

when

the

sewing

machine

is

stopped.

3.

Easy

Maintenance

The

maintenance

is

easily

done

just

by

adjusting

the

solenoid

brake

spacing.

There

is

no

need

to

replace

the

moving

brake

plate.

4.

Reliability

The

microcomputer

and

hybrid

ICs

are

adopted

with

higher

integration,

so

that

higher

reliability

is

obtained.

5.

Free

Control

of

Sewing

Speed

The

sewing

speed

is

freely

controlled

just

by

the

adjustment

knob.

By

the

high

speed

volume

knob,

the

speed

is

con¬

trolled

from

215

spm

to

the

maximum

speed.

And

by

the

reinforcement

sewing

speed

knob,

the

speed

is

controlled

from

215

spm

to

3,000

spm.

6.

Applicable

to

Standing

Work

and

Automation

The

application

for

standing

works

and

automation

is

secured

just

by

connecting

the

switch

to

the

plug

of

the

control

box.

7.

Lightweight

The

DC

motor

weights

less

10

kg,

as

compared

with

the

clutch

motor.

[DB2-B737]

[DB2-B738]

★

Use

the

DC

motor

for

the

following

sewing

machines.

*The

DC

motor

is

also

applied

to

the

automatic

thread

trimming

machines,

models

DB2-B748,

B795,

and

B798.

[DB2-B793]

[DB2-B791

]

CONTROL

CIRCUIT

UNIT

NOTE:

The

sections

enclosed

by

the

broken

line

indicate

where

high

voltage

is

applied.

Handle

these

sections

with

great

care.

CAUTION:

1.

In

setting

down

the

machine

head

or

touching

the

needle,

be

sure

to

turn

off

the

power

switch

and

confirm

the

pilot

lamp

“OFF”.

2.

Ground

codes

are

provided

for

both

single-phase

and

three-phase

types.

Do

not

fail

to

ground.

(A

ground

code

is

not

Do

not

fail

to

ground.

(A

ground

code

is

not

provided

for

single-phase

110V

type,

however,

ground

the

motor

frame

if

necessary.)

3.

In

adjusting

the

volume

in

the

controi

box,

be

sure

to

turn

off

the

power

switch,

remove

the

front

cover

and

confirm

the

pilot

lamp

“OFF”.

*

It

is

dangerous

to

handle

the

control

box

inside

because

high

voltage

is

applied.

Handle

with

great

care.

4.

Keep

away

from

such

machines

which

make

strong

noise

as

high

frequency

welder

for

usage.

C(

PRINCIPLE

OF

CONTROL

SYSTEM

1.

When

the

power

switch

O

is

turned

on

and

the

treadle

3

is

stepped

on,

the

start

signal

and

the

voltage

correspond¬

ing

to

the

stepping

degree

are

supplied

to

the

control

box

©

by

the

treadle

unit.

The

voltage

is

supplied

to

the

motor

©

by

the

control

circuit

board

in

the

control

box

©

so

that

the

motor

runs

in

proportion

to

the

stepping

degree

to

drive

the

sewing

machine.

2.

When

the

treadle

©

is

returned

to

the

neutral

position

(with

foot

off),

the

neutral

signal

is

sent

to

the

control

box

©

by

the

treadle

unit

©

and

the

brake

command

is

given

by

the

control

circuit

board

to

decelerate

the

motor

©.

Then

the

signal

from

the

synchronizer

©,

mounted

on

the

pulley

of

the

sewing

machine,

is

sent

to

the

control

box

©

and

the

brakes

are

applied

so

that

the

operation

of

the

sewing

machine

is

stopped

at

the

needle

down

stop

position

set

by

the

synchronizer

©.

3.

When

the

treadle

is

stepped

on

again,

the

thread

trimming

signal

is

sent

to

the

control

box

©

by

the

treadle

unit

©

and

the

command

is

given

by

the

control

circuit

board

to

run

the

motor

©

at

the

thread

trimming

speed

(inching

speed).

Then

the

signal

from

the

synchronizer

©

is

sent

to

the

control

box

©

and

the

brakes

©

are

applied

so

that

the

operation

of

the

sewing

machine

is

stopped

at

the

needle

up

stop

position

set

by

the

synchronizer

©.

Drawing

for

Mounting

the

((

ADJUSTMENT

))

★

Set

down

the

machine

head

and

then

hang

the

belt

on

the

motor

pulley

and

the

machine

pulley.

★

The

belt

comes

to

fit

the

machine

pulley

and

the

motor

pulley,

which

happens

to

loosen

the

belt

tension

sometimes.

Check

the

belt

tension.

★

The

machine

rotates

counterclockwise

as

seen

from

the

pulley

side.

★

Adjust

the

belt

O

by

loosening

the

set

screw

0

and

turning

the

nut

0

so

that

it

loosens

about

10

mm

when

pressed

by

finger.

Needle

position

detector

(synchronizer)

Model

DB2-B747

•

B791

•

B793

•

B795

•

B798

★

Take

off

the

synchronizer

cover

for

adjustment.

Synchronizer

detects

the

needle

by

two

hole

IC

and

controls

the

needle

down

signal

and

the

thread

trimming

signal

by

one

hole

IC.

Needle

down

Needle

up

stop

position

stop

position

5

mm

Model

B798

22

~

26

mm

7.5

mm

11

~

1.4

mm

*In

adjusting

each

hole

IC,

do

not

fail

to

turn

off

the

power

switch.

Position

Adjustment

for

Needle

Down

Signal

★

Turn

the

machine

pulley

this

side

and

set

the

needle

5

mm

up

from

the

bottom

to

coincide

the

lower

end

of

the

magnet

O

with

the

upper

end

of

the

thread

trimming

needle

down

hole

IC

0

.

(As

for

the

model

B747

•

B748,

adjust

the

needle

7

mm

up

from

the

bottom

and

as

for

the

model

B798,

7.5

mm

up.)

When

the

lower

end

of

the

magnet

O

does

not

coincide

with

the

upper

end

of

the

thread

trimming

needle

down

hole

IC

0

,

loosen

the

screw

0

and

move

the

thread

trimming

needle

down

hole

IC

for

adjustment.

When

the

thread

trimming

needle

down

hole

IC

0

is

moved

in

the

rotating

direction,

the

needle

bar

comes

up.

And

when

in

the

reverse

direction,

the

needle

bar

comes

down.

Turn

on

the

power

switch

and

stop

the

machine

at

the

needle

down

stop

position

so

that

the

distance

between

the

top

of

the

needle

plate

and

the

lower

end

of

the

needle

clamp

screw

is

18-22

mm.

(As

for

the

model

B798,

the

distance

is

22-26

mm.)

Position

Adjustment

for

Needle

Up

Signal

★

Stop

the

machine

at

the

needle

up

stop

position.

The

needle

point

stops

9-11

mm

away

from

the

top

of

the

needle

plate

for

thin

and

medium

materials,

and

10-12

mm

for

thick

materials.

(As

for

the

model

B798,

the

needle

point

stops

11-14

mm

away.)

When

the

needle

point

does

not

stop

properly,

loosen

the

screw

0

and

move

the

needle

up

stop

hole

IC

0

for

adjustment.

When

the

needle

up

stop

hole

IC

0

is

moved

in

the

rotating

direction,

the

needle

bar

comes

down.

And

when

in

the

reverse

direction,

the

needle

bar

comes

up.

*

Tighten

the

screws

0

and

©by

the

force

of

6-10

kg-cm.

Synchronizer

Model

DB2-B737

•

B748

★

The

synchronizer

detects

the

needle

position

with

two

sensors.

The

thread

trimmer

signal

is

timed

to

the

needle

down

position

signal

and

the

treadle

reverse

signal.

★

When

the

power

is

turned

on

and

the

needle

stopped

in

the

down

position,

the

distance

between

needle

plate

top

and

needle

set

screw

bottom

should

be

18

to

22

mm.

When

the

needle

is

stopped

in

the

up

position

and

the

pulley

reference

line

is

within

the

belt

cover

reference

lines,

the

distance

between

needle

plate

top

and

needle

tip

should

be

10

to

12

mm

with

thin

and

regular

materials,

10

to

14

mm

with

thick

materials.

(As

for

the

Model

B748

the

needle

up

stop

position

10

~

14

mm.)

Adjust

as

follows

when

necessary.

★

Turn

the

power

off.

Needle

up

position

1.

S

lightly

loosen

the

two

screws

O

■

Move

the

set

screws

O

in

the

direction

of

normal

pulley

movement

to

raise

the

needle

bar

©

stop

position.

Turn

the

other

way

to

lower

the

needle

bar.

Needle

down

position

1.

Set

the

treadle

to

reverse

and

then

release

it

to

neutral.

(This

is

the

needle

down

stop

position.)

2.

The

needle

plate

top

to

needle

screw

bottom

gap

should

be

18

~

22

mm.

3.

Loosen

screw

©

and

move

the

synchronizer

©

to

adjust.

*

Check

the

needle

up

stop

position.

*

When

the

machine

pulley

is

removed

once,

provide

0.5

mm

clearance

between

the

pulley

bottom

and

the

synchro¬

nizer

for

installation.

(Improper

clearance

causes

improper

machine

operation)

When

the

Synchronizer

Is

Out

Of

Order

.

.

.

★

Turn

off

the

power

switch

and

pull

out

the

synchronizer

code.

Use

the

machine

with

standard

function

(without

thread

trimming)

until

the

synchronizer

is

replaced.