FINISHING EQUIPMENT BY FUJISTAR

DOUBLE BODY MANUAL

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            Double Body Shirts Presser DX FDB-002 
                           Instruction Manual
             Manufacturer : Y. A. Co. Co., Ltd. (Japan)
 
 
 
FDB105A-OE-01

 
Table of Contents:
 
1 Introduction...........................................................................................1-1
1.1 Precautions for Using Manuals.................................................................................................1-1
1.2 Warranties................................................................................................................................1-2
2 Safety Precautions................................................................................2-1
2.1 Classification of Dangers and Cautions...................................................................................2-1
2.2 Warning Labels.........................................................................................................................2-3
3 System Configuration............................................................................3-1
3.1 Specifications...........................................................................................................................3-1
3.2 Accessories..............................................................................................................................3-1
3.3 System Overview and Unit Configuration.................................................................................3-2
3.4 Applicable Garments................................................................................................................3-5
4 Operation Procedure.............................................................................4-1
4.1 Startup......................................................................................................................................4-2
4.1.1 Supply of Steam, Air and Power.......................................................................................4-2
4.1.2 Confirmation and Adjustment of Various Setting Values...................................................4-4
4.1.3 Mirror Setting.....................................................................................................................4-4
4.1.4 Preheating for Dummy and Collar Lock............................................................................4-4
4.1.5 Water Supply to the Spray Water Tank.............................................................................4-5
4.1.6 Switch Box.........................................................................................................................4-6
4.2 Operation.................................................................................................................................4-9
4.2.1 Manual mode operation.....................................................................................................4-9
4.2.2 Auto mode operation.......................................................................................................4-10
4.2.3 Machine shutdown...........................................................................................................4-11
5 Maintenance..........................................................................................5-1
5.1 Preventive Maintenance Check List.........................................................................................5-1
5.2 Hints to keep fine finish.............................................................................................................5-2
5.2.1 Air Bag..............................................................................................................................5-2
5.2.2 Pad...................................................................................................................................5-2
5.2.3 Prevention from Stain........................................................................................................5-2
5.2.4 Air Bag Reducing Valve Adjustment..................................................................................5-2
5.2.5 Air Bag Stand-by Timer.....................................................................................................5-3
5.3 Replacement of Air Filter and Mist Separator..........................................................................5-3
5.4 Checking and Cleaning for Steam Related Areas....................................................................5-4
5.5 Other Check Points...................................................................................................................5-5

 
5.6 Adjustment of Each Unit...........................................................................................................5-7
5.6.1 Air Cylinder Cushion Adjustment......................................................................................5-7
5.6.2 Rotation Cylinder Rod Adjustment....................................................................................5-9
5.6.3 Heat Plate Tie-rod Adjustment........................................................................................5-10
5.6.4 Sensor Switch Adjustment..............................................................................................5-11
5.6.5 Unit Change of Timer......................................................................................................5-14
5.6.6 Dummy Related Parts Replacement...............................................................................5-14
5.6.7 Filter Element..................................................................................................................5-22
5.6.8 PLC.................................................................................................................................5-23
6 Machine Errors and Countermeasures..................................................6-1
6.1 Error Detecting.........................................................................................................................6-1
6.2 Error without error indication....................................................................................................6-1
6.3 Machine Failures and Countermeasures.................................................................................6-2
6.3.1 Machine does not work at all.............................................................................................6-2
6.3.2 The failure on the fan or vacuum......................................................................................6-2
6.3.3 Dummy Rotation................................................................................................................6-3
6.3.4 Air Leakage from the solenoid valves related to the rotation............................................6-4
6.3.5 Pressing failure..................................................................................................................6-4
6.3.6 Heat Plates do not heat up................................................................................................6-6
6.3.7 Bad cloth finish..................................................................................................................6-7
6.3.8 Failure on Collar Lock and Sleeve Extender.....................................................................6-8
7 Function Check of Electrical Component and Replacement..................7-1
7.1 Timer and Power Relay............................................................................................................7-1
7.2 Solenoid Valves........................................................................................................................7-3
7.3 Foot Switch..............................................................................................................................7-4
7.4 Push Switches.........................................................................................................................7-4
7.5 The Treatment when Thermal Relay works..............................................................................7-5
7.6 How to Attach / Detach Air Tubes.............................................................................................7-6
8 Installation.............................................................................................8-1
8.1 Installation................................................................................................................................8-1
8.1.1 Carry-in.............................................................................................................................8-1
8.1.2 Installation.........................................................................................................................8-1
8.2 Power.......................................................................................................................................8-2
8.3 Compressed Air........................................................................................................................8-2
8.4 Steam.......................................................................................................................................8-3
8.5 Water........................................................................................................................................8-5
8.6 Exhaust Duct............................................................................................................................8-5

 
9 Proposed Machine Layout by the Required Throughput........................9-1
9.1 120 Shirts / hour........................................................................................................................9-1
9.2 120-200 Shirts / hour................................................................................................................9-2
10 Installation Procedure for “Double-Sleeve Presser” (Option)..................10-1
11 Assembling and Mounting of PLC........................................................11-1
12 Drawings.............................................................................................12-1
12.1 Air Piping Diagram..............................................................................................................12-1
12.2 Steam Piping Diagram........................................................................................................12-2
12.3 Circuit Diagram (FDB-002).................................................................................................12-3
12.4 Over View (Double-Body Shits Presser DX).......................................................................12-4
12.5 Over View (Double-Body Sleeve Presser)..........................................................................12-5
13 Parts List.............................................................................................13-1
 
 

1 Introduction
 
1.1 Precautions for Using Manuals

This document describes the operation procedure of the “Double-Body Presser
FDB-105A” and the related notes for safer and effective operation.
 
Please carefully read out the applicable manual before starting handling and operation
of this system for effective use and to avoid dangers.
And keep this manual beside the machine for your easier and prompt referring at any
time.
 
 
If there is something difference between the description in this manual and the actual
machine, the actual machine takes priority.
 
 
All the copyrights of this document belong to Y. A. C. Co., Ltd. (“YAC” herein after), and
the copying of whole or part of this document without prior written approval by YAC is
prohibited.
 
 
 


 

1.2 Warranties

The warranty system of this system is as shown below;
 
1) Warranty Period
Parts ------- One (1) year after on-site acceptance
 
2) Exceptions of warranty
Even in the warranty period, warranty is not applied in the following cases.

a. The damages and failures caused by user’s wrong handling or improper
operation
b. The damages and failures caused by reasons belong to user’s facility.
c. The damages and failures caused by natural calamities and any other
reasons on which vendor is not liable.

2 Safety Precautions

This chapter presents safety precautions to ensure safer operation of FDB-105A.
 
2.1 Classification of Dangers and Cautions

These general safety precautions presented here shall be observed whenever using
this machine.
 
In this manual, danger level is classified into three (3) levels as, “Danger”, “Warning”,
and “Caution”, and the indication “Danger” is defined as the highest level precaution,
and “Warning” and “Caution” follow it. (DANGER > WARNING > CAUTION)
 
The operator to understand the above precaution level difference and to handle and
operate the machine carefully at any time.
 
In case of you encounter unexpected failure that is not described in this manual,
contact the person who is in charge of service or maintenance immediately.
 
 
Danger!
The danger message is indicated wherever an incorrect handling or operating will
result in serious injuries or death of persons.
As the preventive method is mentioned, handle or operate the machine by following
such instructions.
 
 
 
Warning!
The warning message is indicated wherever the neglect of the correct method may
leads to serious injury or death of persons and an accident.
As the preventive method is mentioned, handle or operate the machine by following
such instructions.
 
Caution!
The message is indicated wherever the neglect of the correct method may lead to
minor or moderate injury of persons, or damage or worse performance of the machine
itself.
As the preventive method is mentioned, handle or operate the machine by following
such instructions.
 
Other symbol in the manual
 
You shall pay careful attention to the messages marked like the followings as well as
the warning messages in the manuals.
 
 
The description with this symbol shows the key point for the handling and operating for
the useful / helpful functions or an incorrect action operator / maintenance person may
often takes, which shall be avoided.
 
2.2 Warning Labels

Following symbols are labeled on the warning locations where the potential dangers
exist.
 
Warning!
Understand the meaning of all safety-warning labels and heed the prohibited items and
countermeasures. Do not peel off, scrape nor cover the safety warning labels. Confirm
the labeled locations before starting running.
 
MECHANICALLY DRIVEN
AWAY FROMDANGERKEEP HANDSMACHINERY

HIGH VOLTAGE
RISK OFWARNINGELECTRIC SHOCKDO NOT TOUCH

HOT SURFACE
HOT SURFACEDO NOT TOUCHCAUTION

Text Box: This is labeled on the area where the electric devices with high voltage, which may injure the operator, exist.
The operator to turn off the main power before accessing this area.
Text Box: This is labeled on the area where the moving mechanisms, which may injure the operator, exist.
The operator to turn off the main power before accessing this area or to give full attention to avoid injury to access this area.
Text Box: This is labeled on the area with heater which may cause burn.
Do not touch this area with bare hand, or touch this area after turning off the heating source and cooling down to the ambient temperature.

DO NOT OPEN THE COVER WHILE RUNNING
DO NOT OPEN THE COVER WHILE RUNNING.
CAUTION

Text Box: This is labeled on the safety cover, which is accessed by operators.
Do not open the covers with this label while machine running even if the safety interlocking system is provided.

3 System Configuration
 
3.1 Specifications
 
FDB-002
FDB-002S/L
Power
Source
200V AC, 3-Phase
Vacuum Fan Power Consumption
750W
Steam
Pressure
 = 0.8 MPa ( = 110psi / = 8kgf/cm2)
Consumption
35kg/hr
Fitting
Rc 1/2 B
Compressed Air
Pressure
0.5 MPa (75psi / 5kgf/cm2)
Capacity
61 Liters/time (2.2KW Compressor)
Hose
.12mm, Nylon hose
Fitting
Rc 1/2 B
Drainage
Fitting
Rc 1/2 B
Water
Fitting
Rc 1/4 B
Option (Rc 1/4 B)
Dimensions
4.4(W) x 5.8(D) x 5.3(H) : ft
1320(W) x 1770(D) x 1600(H) : mm
Weight
1060 lbs / 480kgs
 
The model number for the system consists of “Double-Body Presser” and “Sleeve Presser”
is “FBS-200”.
 Dual-Site Shirts Presser: FDB-002S
 
Single-Site Shirts Sleeve Presser: FSP-601S
 
3.2 Accessories

Items
FDB-002
FDB-002S/L
Air Bag
2
N/A
Pad
2 sets
N/A
Air Tube (N12-B, 0.5m)
1
Air Tube Fitting (TS12-04)
1
Steel Liner Plate
4
Anchor Bolt (C1290)
4
Mirror
1
Mirror Bracket
1
 
Text Box: Dual-Site Shirts Presser: FBS-200
 
3.3 System Overview and Unit Configuration
 
 
 << Front View >>
 
Fig. 1-1
Text Box: (6-1) Air Bag Holder PlateText Box: (44-3) PackingText Box: (24) Foot SwitchText Box: (23) Switch BoxText Box: (5) DummyText Box: Sleeve LifterText Box: (6) Collar Lock AssemblyText Box: (23-5) CounterText Box: (32) Mirror
<< Switch Box >>
 
Fig. 1-2
Text Box: = Top View (Operation Panel) =Text Box: (23-1) [STOP] Push Switch (Red)Text Box: = Front View (Timer Panel) =Text Box: (23-3) [Shirts (S)] Push Switch (Yellow)Text Box: (23-4) [Shirts (L)] Push Switch (Black)Text Box: (23-11) Circuit ProtectorText Box: (23-11) [Power OFF]Text Box: [AUTO][MANUAL]Text Box: (23-9) [Cotton 100%][Polyester Mixed Cloth]Text Box: (23-9) Spray [ON / OFF]Text Box: *Option for “FDB-002S/L”Text Box: Changing Toggle SwitchText Box: (23-2) [Shirts (M)] Push Switch (Green)Text Box: (23-6) [Polyester Mixed Cloth] TimerText Box: (23-6) [Cotton 100%] TimerText Box: (23-6) [Spray] TimerText Box: *Option for “FDB-002S/L”Text Box: (23-6) [Cloth Change] TimerText Box: (23-20) IndicatorText Box: (23-6) [Shirts (M)] Air BagText Box: Stand-by TimerText Box: Stand-by TimerText Box: (23-6) [Shirts (S)] Air Bag
<< Air Unit >>
 
 
Text Box: Fig. 1-3 = FDB-002L =Text Box: Fig. 1-4 = FDB-002S =Text Box: (19-11) Pressure GaugeText Box: (19-19) MufflerText Box: (6) 3-Port Solenoid Valve
(for Rotation)
Text Box: (17) ManifoldText Box: (19-14) T-Shape Bracket
Text Box: (19-9) Distributor
Text Box: (19-16) Piping AdaptorText Box: (19-11) Pressure GaugeText Box: (19-4) Reducing ValveText Box: (19-3) Mist FilterText Box: (19-1) Air Filter with Auto-DrainageText Box: (19-20) Ball ValveText Box: (13) 3-Port Solenoid Valve
(for Left Vacuum)
Text Box: (13) 3-Port Solenoid Valve
(for Right Vacuum)
Text Box: (14) 5-Port Solenoid Valve
(for Right Collar Lock)
Text Box: (14) 5-Port Solenoid Valve
(for Left Collar Lock)
Text Box: (15) ManifoldText Box: (19-19) MufflerText Box: (19-6) Reducing ValveText Box: (19-15)
Joiner Set
Text Box: (19-11) Pressure GaugeText Box: (19-19) MufflerText Box: (17) ManifoldText Box: (6) 3-Port Solenoid Valve
(for Rotation)
Text Box: (19-14) T-Shape Bracket
Text Box: (19-9) Distributor
Text Box: (19-10) Distributor
Text Box: (19-5) Reducing ValveText Box: (19-11) Pressure GaugeText Box: (19-15)
Jioner Set
Text Box: (19-6) Reducing ValveText Box: (19-19) MufflerText Box: (15) ManifoldText Box: (14) 5-Port Solenoid Valve
(for Left Collar Lock)
Text Box: (14) 5-Port Solenoid Valve
(for Right Collar Lock)
Text Box: (13) 3-Port Solenoid Valve
(for Right Vacuum)
Text Box: (13) 3-Port Solenoid Valve
(for Left Vacuum)
Text Box: (19-20) Ball ValveText Box: (19-2) Air Filter with Auto-DrainageText Box: (19-3) Mist Filter
 
3.4 Applicable Garments
 
 
Items
Specifications
Type of garments
Shirts
Materials
100% Cotton, Cotton & Polyester mixed
Size
Girth
37.8” - 58.2” (960 - 1480mm)
Body Length
34.2” (870mm) Max.
 
 
 
Shirt Back View
 
 
 
Text Box: GirthText Box: Body Length
 
4 Operation Procedure

This chapter describes the procedure for the operation of this machine.
For the safer and effective operation, please follow this procedure.
 
Danger!
Do not put fingers, hands, part of the body, tools, clothes or any other foreign materials
during operation to avoid injury.
 
 
 
Danger!
Do not put any tools or articles on/in the machine.
 
4.1 Startup
 
4.1.1 Supply of Steam, Air and Power

1) Steam
 
Caution!
Do not supply the steam with the pressure higher than exceed 0.8 MPa (110psi /
8kgf/cm2).
 
 
Slowly open the Steam Inlet Valve, and fully open.
 
Text Box: CloseText Box: Open
 
2) Air
 
Fully open the Air Inlet Valve slowly.
And adjust the pressure using each Reducing Valve as below:
 
A. Main Air Reducing Valve: 0.5 MPa
B. Rotation Air Reducing Valve: 0.38 MPa
 
Do not adjust the Rotation Reducing Valve pressure higher than 0.38 MPa, otherwise
the cushion adjustment becomes very difficult due to the shock at the completion of
dummy rotation .
 
 
C. Air Bag Air Reducing Valve: 0.01 – 0.03 MPa
 
When the air bag is new, set the pressure as 0.01 – 0.02 MPa, and when the air bag is
old, set the pressure as 0.03 MPa. However, because the performance of the
compressor and the air consumption are different by the users’ facility, please
understand that the above values are just for your reference and adjust them to the
suitable values based on the users’ conditions.
 
 
Make the above pressure adjustment with pressing the dummy by pressing the [START]
button.
 
3) Turn ON the primary power switch. And then, turn the toggle switch on the operation box
to [MANUAL] or [AUTO].
4.1.2 Confirmation and Adjustment of Various Setting Values
 
Timer
Timer#
Standard Value
Remarks
Pressing Timer
Polyester
mixed cloth
TL1
11 sec.
Adjustment required
according to the
steam pressure and
dryness of each cloth
100% Cotton
TL5
14 sec.
Cloth Change Timer
TL6
20 sec.
Adjustment required
according to the
operators’ skill.
Air Bag Stand-by
Timer
Shirt (L)
TL2
0.1 sec.
Adjustment required
according to the
conditions of air
supply conditions of
user’s facility.
Shirt (M)
TL3
0.5 – 0.8 sec.
Shirt (S)
TL4
1.0 sec. (Note)
Spray Timer
TL7
1.0 sec.
Adjustment required
for the fine finish.
 
(Note) The value for Shirts (S), TL4, is PLC setting value and is not user programmable.
 
4.1.3 Mirror Setting

Adjust the position and angle for easier viewing.
 

4.1.4 Preheating for Dummy and Collar Lock

Caution!
If cloth pressing is done before heating up of Dummy and/or Collar Lock, the cloth may
get stains. To avoid such stains, press the [START] button after heating up of the
heater plate, and make pressing several times (without cloth) and start operation after
the confirmation of heating up of both Dummy and Collar Lock.
 
4.1.5 Water Supply to the Spray Water Tank

Check the balance of the water in tank before starting operation.
If the balance is small, replenish the water with the following procedure.
 
1) Close the air inlet valve.
2) Open the water-pouring valve slowly till the reducing valve gauge shows “0”.
3) Pour the water using hose. (Refer to 9-5 Water)
4) After water pouring, close the water-pouring valve.
5) Open the air inlet valve.
 
Text Box: 57 Water-Pouring ValveText Box: (58) Air Inlet ValveText Box: (19-7) Reducing ValveText Box: (19-12) Pressure GaugeText Box: (59) Water Purging Valve
 
4.1.6 Switch Box

 
1) Operation Panel
 
 

POLYESTERMIXED CLOTH100% COTTONSHIRTS (L)SHIRTS (S)
SHIRTS (M)STOPAUTOMANUALPOWEROFFSPRAYONOFF

 
.1 3-position toggle switch
[POWER OFF] (Center) : The main power for the machine is shutdown.
[AUTO](Rear) / [MANUAL] (Front) : Power is supplied and fan starts working.
 
Warning!

Operator shall not turn this switch to [MANUAL].
Please call maintenance person or serviceman when manual mode operation
is required.
 

.2 [SHIRTS (L)] When this switch is pressed, the dummy at the setting position
rotates to the pressing position, and presses the dummy. At this time, the air
bag stand-by time set on the SHIRTS (L) TIMER is applied
This switch is effective only when the switch .1 is at [AUTO].
.3 [SHIRTS (M)] When this switch is pressed, the dummy at the setting position
rotates to the pressing position and presses the dummy. At this time, the air
bag stand-by time set on the SHIRTS (M) TIMER is applied
This switch is effective only when the switch .1 is at [AUTO].
.4 [SHIRTS (S)] When this switch is pressed, the dummy at the setting position
rotates to the pressing position and presses the dummy. At this time, the air
bag stand-by time set on the SHIRTS (S) TIMER is applied
Text Box: ?1Text Box: ?2Text Box: ?3Text Box: ?4Text Box: ?5Text Box: ?6Text Box: ?7
This switch is effective only when the switch .1 is at [AUTO].
.5 [POLYESTER MIXED CLOTH / 100% COTTON] The toggle switch to select
applied pressing time by cloth type. When this switch is turned to
POLYESTER MIXED CLOTH, the preset pressing time for POLYESTER
MIXED CLOTH is applied, and this switch is turned to 100% COTTON, the
preset spraying time for 100% COTTON is applied.
.6 [STOP] The switch to stop machine. (The power is remained.)
.7 [SPRAY ON/OFF] When this switch is turned OFF, spraying is not made.
.8 Circuit Protector
 

1) Timer Panel
 
 
POLYESTERMIXED CLOTH100% COTTONCLOTH CHANGESPRAYSHIRTS (L)SHIRTS (M)
READYCaution!
SHUTDOWNPOWER, AIR &
STEAM BEFOREMAINTENANCE

.1 POLYESTER MIXED CLOTH : The timer to preset the pressing time for
polyester mixed clothes.
.2 100% COTTON : The timer to preset the pressing time for 100% cotton
clothes.
.3 CLOTH CHANGE : The timer to preset the time for cloth change.
(Note) This timer value is to be longer than the preset pressing time.
Otherwise, the machine starts pressing before completion of cloth change.
.4 SPRAY : The timer to preset spraying time.
.5 SHIRTS (L) : The timer to preset the air bag inflating time for shirts (L).
.6 SHIRTS (M) : The timer to preset the air bag inflating time for shirts (M).
.7 READY : The indicator which turns ON during power is being supplied.
When something error is occurred on the machine, it brinks and
machine operation cannot be done.
Text Box: ?7Text Box: ?6Text Box: ?5Text Box: ?4Text Box: ?3Text Box: ?2Text Box: ?1
 
4.2 Operation
 
4.2.1 Manual mode operation
 
1) Turn the power switch to [MANUAL] on operation panel.
2) Wear a shirt on the dummy inserting one sleeve to the Sleeve Expander.
3) Set a collar onto the Collar Lock.
4) Viewing the back of the shirt through the mirror, expand the back of the shirt by both
hands.
5) Fix the front part of the shirt, and then pedal the Foot Switch to turn ON the
vacuum.
6) Fax each part to eliminate wrinkles.
7) Choose POLYESTER MIXED CLOTH or 100% COTTON according to the
materials of the cloth.
8) Press Shirts (L), Shirts (M) or Shirts (S) according to the size of the shirt.
9) By the above operation, the dummy with the shirt rotates to the pressing position.
(At the same time, the other dummy rotates to the setting side.)
10) The air bag inflates and the heat plate starts pressing. (Pressing time is
programmable through the timer on timer panel.)
 
 
The preset air bag inflation starting timing is applied by the selected cloth size.
i.e.) When the air bag stand-by timer for shirts (L) is set as 0.1 sec., the air bag starts
inflating 0.1 sec. later after pressing the [RUN] switch. The stand-by time is
programmable through each timer on timer panel. On the other hand, for the smaller
cloth, longer stand-by time is to set to get better finish and to avoid distortion of
buttoned placket.
 

11) During pressing, wear the next shirt on the dummy at setting side.
12) When the pressing timer reaches the preset time, the heat plate opens and the air
bag deflates, and the machine stops.
13) When the cloth change at the setting side had been already finished, press the
[RUN] switch for the applied cloth, and then the dummy rotates to the pressing
position and pressed.
14) Repeat the above operation

If cloth change is finished before compression of pressing, you can press the applied
[RUN] switch at any time. In this case, the dummy at setting side rotates to the
pressing position upon the completion of the pressing at pressing position.
 
4.2.2 Auto mode operation

In case Manual mode operation, the machine stops when the pressing is finished as
far as the [RUN] switch is not pressed.
In case Auto mode operation, the dummy at setting side rotates automatically when
the pressing at pressing side is finished.
 
Note:

1) In case of Auto mode, for the next cloth, the air bag stand-by time for the Shirts (M)
is automatically applied. When you prefer to change the stand-by time, press the
preferable [RUN] button, Shirts (L) or shirts (S), between the completion of
pressing and completion of dummy rotating. This stand-by time change is effective
only for one time and the time for Shirts (M) is applied again for the following
pressing operation as far as the [RUN] button, Shirts (L) or shirts (S), is not
pressed between the completion of pressing and completion of dummy rotating.
2) When you want to stop operation, press the [STOP (RED)] button.
3) Do not press the [STOP (RED)] button during dummy rotating. Otherwise the
rotating stops on the half way. In this case, rotate back the dummy to the setting
position by hand.
4) When you change the mode between [AUTO] and [MANUAL], locate the toggle
switch lever at the OFF position for 1 sec., and then turn the switch to the
preferable mode. Otherwise, the counter may back to “0”.

Operation Timing Diagram
Press [RUN] within this time framewhen the applied shirt size is not (M) in AUTO modePress [RUN]Preset TimePress [RUN]
(for MANUAL mode)
01234123Setting PositionPedal SW ONVacuum ONDummyChangePedal SW ONVacuum ONDummyChangePedal SW ONVacuum ONPressing PositionVacuum OFFAir Bag InflatingClosePressingOpenProcessDummyHeat PlateContinued

 
When foot switch is pedaled, the vacuum system for the dummy in pressing turns off,
and only the vacuum system for setting side works.
 
4.2.3 Machine shutdown

When the daily operation is finished, please shutdown the machine with following
procedure.
 

1) Turn OFF the power switch on operation panel.
2) Turn OFF the primary power switch.
3) Surely close the steam inlet valve.
4) Surely close the air inlet valve.
5) Inspect the whole machine, and make maintenance work if you find any abnormal
referring to next chapter.
6) Open the Drainage valve, and Drainage the liquid.

5 Maintenance

Please carry out the Preventive Maintenance to keep the good condition of the
machine.
 

5.1 Preventive Maintenance Check List
 
 
 
#
Items to check
Frequency
Remarks
Daily
Weekly
Monthly
Every
2 months
Every
3 months
1
Cleaning for the
mechanical areas
..
 
 
 
 
Especially the dust
cleaning on moving
parts
2
Abnormal sound
and Vibration
..
 
 
 
 
Check the
abnormal sound
and vibration
different from
normal ones.
3
Dirt check in cup of Air
filter, Mist separator
..
 
 
 
 
Check whether the
cup is filled with
Drainage.
4
Releasing of Drainage
in air tank
..
 
 
 
 
Open the Drainage
outlet and release
the Drainage.
5
Water supply
..
 
 
 
 
Supply clean water
into the spray water
tank.
6
Looseness check for
lock nuts, bolt nuts and
piping
 
 
..
 
 
When looseness is
found tighten it.
7
Checking of Steam
trap strainer
 
 
 
..
 
Unplug and clean
the screen.
8
Replacement of
consuming parts
 
 
 
..
 
Replace pad and
others if necessary.
9
Adjustment for each
area
 
 
 
 
..
Adjust the cushion
and others if
necessary.
 
 

 
5.2 Hints to keep fine finish
 
5.2.1 Air Bag

If the air bag is broken or come unsewn, the air bag may not be fully inflated and you
cannot get good finish especially on shoulder or side areas of the shirt.
In such case, darn or replace the air bag.
(Referential air bag life : 20000 - 25000 presses)
 

5.2.2 Pad

Repeated pressing lowers the elasticity and the breathability of the pad in the air bag,
and it carries the lower vacuuming and wrinkles.
When the pad is harden, replace it with new one.
(Referential pad life : 20000 - 25000 presses)
 

5.2.3 Prevention from Stain

1) Minimizing of the spraying time.
As over spraying makes bag or pad wet, and it causes the insufficient drying and
stains, minimizing of the spraying time, considering the operation flow is
recommended.
 
2) Make Pre-Heating before operation
When the cloth is pressed before heating up of the dummy and collar lock, the
dummy and collar lock get dew and it cause the stains on the shirt. To avoid the
stains, try to press without shirt for several minutes after heating up of the heat plate
to heat up the dummy and collar lock before starting operation.
 

5.2.4 Air Bag Reducing Valve Adjustment

When the air bag is new, set the pressure as 0.01 – 0.02 MPa, and when the air bag is old,
set the pressure as 0.03 MPa. However, because the performance of the compressor and
the air consumption are different by the users’ facility, please understand that the above
values are just for your reference and adjust them to the suitable values based on the
users’ conditions.
 
 
 


5.2.5 Air Bag Stand-by Timer

The standard setting value for each shit size is as shown below.
 
1) Shirts (L) (TL2) 0 - 0.2 sec.
2) Shirts (L) (TL2) 0.5 - 0.8 sec.
3) Shirts (L) (TL2) 1.0 sec. (Fixed)
 
The above values are just standard and fine tuning is required to get better finish
according to the various conditions.

5.3 Replacement of Air Filter and Mist Separator

1) Element Inspection
 
Clogging up of air filter and/or element of mist separator lower the pressure of pressing
air cylinder, and the gauge of the reducing valve shows lower pressure and it takes
longer time to back to the original pressure. In this case, observe the air filter and/or
element of the mist separator. If they got serious clogging up, replace the filter
element.
(Recommended replacing frequency : 1 - 2 years)
For the filter element replacement, refer to 5.6.7 Filter Element.
 
2) Drainage Inspection
 
As the air filter and mist separator equips the auto-Drainage, Drainage is automatically
discharged, however please check whether Drainage is accumulated in the case for
safe.

5.4 Checking and Cleaning for Steam Related Areas

Caution!
Before maintenance and inspection work;

1) Turn OFF the main power,
2) Close the main air valve and purge out the remained pressure,
3) Close the steam valve,
4) Wait until heating element is cooled down.

Clean up the strainer on the steam inlet and the steam filter on the strainer of the
steam trap every 2 months.
 
Text Box: (21-1) Steam StrapText Box: * Unplug, and then take out the screen.

5.5 Other Check Points

Caution!
When you operate the pressing mechanism area for maintenance purpose, operate
the pressing mechanism not by pressing the [RUN] switch but by operating manual
switch on the valve to lock the movement.
Otherwise, the mechanism may move against your will and may injure you.
 
 
1) Screw Looseness
 
Though looseness free system (such as lock nuts) is taken for the important areas,
carry out daily checking for the following portions.
 

a. Lock nut on the pressing cylinder rod
b. Lock nut on the rotation cylinder rod.
c. Lock nut on the tie-rod for the heat plate parallel link
d. Lock nut for the rubber stopper for rotating
 
 
2) Heat Plate Parallel Link (Refer to Fig. 3-1)

The parallel link for the heat plate is adjusted so that the heat plate locates parallel with
the dummy juts before pressing. And there must not be any overload during pressing.
If the pressing is made with the bad tuning of the above area, the overload to the
parallel link causes the damage on the tie-rod of the parallel link and/or rod-end.
Inspect the heat plate parallel link with the following procedure:
 

a. Open the heat plate, and rotate the rod-end by catching it by spanner. And
remind the feel.
b. Lock the pressing mechanism by using manual switch on the valve for
pressing.
c. After pressing, try to rotate the rod-end by catching it by spanner again. If the
feel is different from the one on the above a., it is abnormal. Adjust the tie-rod
immediately referring to 3-4 C Adjustment of heat Plate Tie-rod.
 
 

 
Fig. 3-1
 
 
Fig. 3-2
 
 
 
Text Box: (5) Dummy AssemblyText Box: (1) Heat Plate (Front)Text Box: (2) Heat Plate (Rear)Text Box: (44-1) Bearing PackingText Box: (29) Narrow Pillow UnitText Box: (27-2) Rod EndText Box: (33-2) Heat Plate Parallel Tie-RodText Box: (33-1) Heat Plate Parallel Tie-Rod (Rear)Text Box: (27-3) Rod EndText Box: (Front)Text Box: (27-2) Rod EndText Box: (27-3) Rod EndText Box: (28) Round Flange Type UnitText Box: (28) Round Flange Type UnitText Box: (35) Rotation LeverText Box: U(26-7) Oil-Less Bush
Text Box: (26-5) Oil-Less Bush
Text Box: (26-1) Spherical Bush
 
Text Box: (26-5) Oil-Less Bush
 
 

5.6 Adjustment of Each Unit

Though the machine had properly adjusted before shipment, additional adjustment
may be required after long time running. In such case, please adjust each area with
following procedure.
 

5.6.1 Air Cylinder Cushion Adjustment

The bad cushion adjustment of the cylinder causes the malfunction or damage on if it
is too strong or too weak. Please check and adjust them with following procedure.
If it is not adjustable, replace the cushion packing with new one.
 
1) Pressing Cylinder
 
Refer to Fig. 3-3.
The cushion mechanism is located at the head side end, and it functions to absorb the
shock when the heat plate is opened. If the cushion is too hard, the heat plate opens
suddenly at the end of movement, movement becomes slow or heat plate does not
fully open. As the result, the heat plate open detecting sensor does not work and the
dummy does not rotate.
From the above, the cushion is to be adjusted so that the heat plate opens smoothly
with no shock by cushion adjustment screw.
Clock-wise: Strong (Hard)
Counter-clock-wise: Weak (Soft)
 
 
Fig. 3-3
 
 

Text Box: (8) Pressing CylinderText Box: Cushion Adjustment Screw
 
2) Rotation Cylinder & Exhaust Adjustment
 
When you find any shock at the end of rotating of the dummy, check the air pressure
first. (The standard pressure : 0.38MPa) If the pressure is not proper value, effect of
the cushion changes and cushion adjustment becomes difficult.
Besides, if the machine does nor sit horizontally, you may find the similar symptom.
When you find the shock even all the above are normal, adjust the cushion with
following procedure.
 

a. The cushion adjustment for the rotation cylinder is done by using allen-key. Rotate
the adjust screw on the rod side.
Clock-wise: Strong (Hard)
Counter-clock-wise: Weak (Soft)
Adjust the screw little by little running the machine.

b. Because the cushion for the head side is not required, keep that screw 2.5 rotating
from fully closed position so that the cushion does not effect.
c. Speed Controller Adjustment

In case you cannot get preferable result by the above cushion adjustment, try to adjust
the speed controller on the cylinder rod side. (Refer to Fig. 3-4)
When the rotating speed is to high, loosen the lock nut on the speed controller and
rotate the adjustment screw clock-wise little by little to reduce the airflow.
When the rotating speed is too slow, rotate the adjustment screw anti-clock-wise little
by little to reduce the airflow.
After finding the preferable adjustment point, lock the adjustment screw by tightening
the lock nut.
 
Fig. 3-4
 
 
 

Text Box: ?Head Side? Cushion Adjustment ScrewText Box: (Rod Side) Cushion Adjustment ScrewText Box: (19-7) Speed Controller
 

5.6.2 Rotation Cylinder Rod Adjustment

If the lock nut on rotation cylinder is loosened, and screwing depth of the screw which
fixes the rod and the cylinder tip bracket is changed, the rotation mechanism does not
work properly and it may cause the serious machine failures. Therefore, the immediate
adjustment of this area is required.
 
1) Too deep screwing
 
This situation carries the shortage of the rotating angle, and when the dummy rotates
to the pressing side, the cylinder itself obstructs the rotating, and the dummy stops
rotating before reaching pressing position.
If this situation is left as it is long time, the heat plate may break the collar lock.
Immediate adjustment is required.
 
- How to Adjust -

a. Turn OFF the power.
b. Put a spanner on the flat area of the cylinder rod.
c. Rotate the rod to the left pressing the dummy to the pressing side. Then the
dummy moves to the pressing side. Stop rotating the rod when the rubber
stopper touches rotation ring, and surely tighten the lock nut.
 
 
2) Too shallow screwing

This situation carries the shock when the dummy stops at pressing position, and the
cushion adjustment becomes not effective. Adjust the screwing on this stage.
Otherwise, if the screwing becomes more shallow, the dummy gets strong shock when
the it rotates to 90 position, and cylinder and the cylinder fulcrum area may be
damaged.
 
- How to Adjust -

d. Turn OFF the power.
e. Put a spanner on the flat area of the cylinder rod.
f. Rotate the rod to the right pressing the dummy to the pressing side. Then the
rod extends from the cylinder. Stop rotating the rod when the rod fully extended,
and surely tighten the lock nut.

 
 
 
 


 
 

3) Adjustment of Rotation Cylinder Rod

Adjust so that the cylinder rod is fully extended when the dummy is located at proper
pressing position and the rotation ring is touching the rubber stopper. (This area is
adjusted like this when shipped.)
 

5.6.3 Heat Plate Tie-rod Adjustment

Caution!
When you operate the pressing mechanism area for maintenance purpose, operate
the pressing mechanism not by pressing the [RUN] switch but by operating manual
switch on the valve to lock the movement.
Otherwise, the mechanism may move against your will and may injure you.
 
When you find something abnormal, adjust the area with following procedure.
 
Key Point
Once reduce the pressure to 0 MPa, and then slowly higher the pressure with pressing
to 0.5 MPa. During this process, check whether there is no overload at each pressure
on the tie-rod.
 
Preparation:

1) Loosen all the screw on the tie-rod. Note there are right-hand thread and left-hand
thread.(Refer to Fig. 3-1)
2) Turn the toggle switch on operation panel to [MANUAL] and the set the timer as
maximum.
3) Turn the lever on the main reducing valve to left till it becomes loose.
4) Press the Green button on the operation panel, then the dummy rotates and heat
plate presses the dummy lightly.
5) Press the push switch on top the valve for
pressing using screw driver, then rotate it
clock-wise with pressing to lock this button.
(Refer to Fig. 3-5)
 
Text Box: Text Box: Fig. 3-5
(Note) This operation is to be finished between pressing the Green switch and the
completion of the set pressing time.

6) Turn OFF the toggle switch to [POWER OFF].
Adjustment:
 
1) Try to rotate tie-rod by hand. If it is tight due to overload, try to rotate right or left
and find the smoothest position.
2) Turn the handle on reducing valve to right to higher the pressure a little more.
3) Repeat the above 1) and 2) several times till you find the smooth position at
0.5MPa pressure, then surely tighten the lock nut.
(Note) The air pressure is to be adjusted as just 0.5 MPa. Otherwise the cylinder
cushion does not function properly.
 
5.6.4 Sensor Switch Adjustment

The sensor switches work to detect each cylinder’s movement and to transmit the
signal to the controller.
This machine equips 3 sensors.
 
Caution!
Before maintenance and inspection work;

1) Turn OFF the main power,
2) Close the main air valve and purge out the remained pressure,
3) Close the steam valve,
4) Wait until heating element is cooled down.
 
 
Because all the 3 sensor switches had been adjusted before shipment, do not touch
such sensors except the cases re-adjustment is required.
When you need to replace the sensor, mark the original sensor position, and then
install the new one on the same position.

Sensor #
Location
Input Condition
Output
LS1
Head side of
Rotation Cylinder
Turns ON when dummy
comes to 90 rotation
position.
Movement of the
rotation cylinder
switches from “pull” to
“extend”.
LS2
Rod side of
Rotation Cylinder
Turns ON when dummy
comes to pressing position
Transmits “press start
signal”.
LS3
Head side of
Pressing Cylinder
Turns ON when the heat
plate fully opens.
Transmits “dummy
rotation start signal”.
 
Installation Procedure of LS1 & LS2
 
1) Turn the toggle switch on the operation
panel to OFF to shutdown the power.
2) Install the sensor switch to the indicated
position in the right figures, and then turn
the toggle switch on the operation panel
to [AUTO] or [MANUAL].
3) Rotate the dummy by hand and confirm
the LED on the sensor switch turns ON
at each dummy position referring to the
chart in the previous page. And locate
the sensor position at the mostly
sensitive position (Just center position
between the turning ON position and the
turning OFF position).
4) For the cylinder rod side, turn OFF the
power after confirmation of LED ON, and
shift the sensor switch 2mm away from
the cylinder rod cover edge, and then fix
it. If the sensor LED does not light ON
after 2mm shifting, once turn OFF the
power, and locate the sensor just next to
the cylinder rod cover edge, and then
shift it little by little to find the position
LED starts lighting. After finding that
position, shift the sensor switch 2mm
away from that position.
5) After the completion of installation, turn
the toggle switch on the operation panel
to [AUTO] or [MANUAL]. And then,
rotate the dummy by hand and confirm
the LED on the sensor switch turns ON
at each dummy position again.

Text Box: Text Box: Cylinder Head CoverText Box: Cylinder Head CoverText Box: Cylinder Rod CoverText Box: Cylinder Rod CoverText Box: Cylinder Rod CoverText Box: Cylinder Rod CoverText Box: LED ON PositionText Box: Center PositionText Box: LED OFF PositionText Box: LED OFF PositionText Box: Center PositionText Box: LED ON Position
 
5.6.5 Unit Change of Timer

As the unit shown on the timer is universal (from 0.1 sec to 300 hours), when the timer
is replaced, set the unit without fail referring to 7.1 Timer and Power Relay.
 
 

5.6.6 Dummy Related Parts Replacement

The dummy unit consists of Dummy body, Wire Nets (at front and rear of the dummy),
Pads and Air Bag. When the parts replacement is required, follow the procedure
shown below:
 
 
Air Bag (Part code : 62016)
 
Caution!
Before maintenance and inspection work;

1) Turn OFF the main power,
2) Close the main air valve and purge out the remained pressure,
3) Close the steam valve,
4) Wait until heating element is cooled down.
 
 
Do not install the air bag other than the one with specified part code.
 
1) How to remove Air Bag
a. Unlock the Collar Lock
b. Disconnect the air tubes from the fitting and disconnect cable connecters.

(Refer to 7.6 How to Attach / Detach Air Tubes)

c. Untie the strings
d. Remove Air Bag holder plates at both sides.
 
e. Remove the air bag from the air inlet pipe.
 
f. Fully open the all the zippers. (Both shoulders and side)
 
g. Take out the Air Bag with closing the Sleeve Extender.
 
 
 
Text Box: 1) Insert the suitable allen-key into the screw top, and fit the suitable spanner to the nut.
2) Loosen the nut with holding the allen-key, and then take out the nut and spring washer.
3) Remove all of 3 nuts.
4) Take out the Air Bag Holder. (L-shape plate)
Text Box: 1) Loosen the screw on the tie-ring which fixes the Air Bag air inlet.
2) Remove the Air Bag from the pipe.
3) Make the same thing for the other side.

 2) How to install Air Bag
The air bag is designed as tight good and effective finish. Therefore, the air bag
(especially new one) may be tight to install. For your installation work, please
follow the following procedure.
 

a. Install the air bag onto the dummy shoulders first.
b. Pull up the zipper tab to the top position, and hold the zipper tab and air bag by
both hands, and strongly pull down.
c. With keeping pulling the air bag, change the holding finger to the thumb of left
hand. At this time, locate the zipper 20mm away or more from the pad edge.
d. Hook the zipper ends by the right hand. (If it is difficult, start from the above b.
again.)
e. Fully close the zipper keeping the zipper vertical and holding it by the left hand
thumb.
f. Hold the air bag by both hands, and pull out to the left or the right lightly to
make the dummy and both sides of air bag the same position.
g. Pull down the hem of the air bag strongly.
h. Fix the air bag to the dummy by air bag fixture, and tie the rubber string on the
air bag fixture.
 
 


 3) Installation of Collar Lock

Connect all the air tubes and cables. (Take care not to bend them.)
(Refer to 7.6 How to Attach / Detach Air Tubes)
(Note) Take care not to bend them and not to touch them to the collar lock when
collar lock moves. If necessity, fix the cable or tube by using tie-band. If
you operate the machine with touching cable / tube with the collar lock, it
may cause air leakage or short circuit.
 

4) How to Disconnect / Connect Cables and Air Tubes
 
a. Make sure power is turned OFF and
steam, air are not supplied.
b. Loosen the cap nut and remove the
collar lock.
c. Disconnect the air tube that is
connected to the cylinder for collar lock.
d. Holding the collar lock, disconnect the
connector by pressing the both sides of
the connector.
e. Because the Teflon tube end
(connected part) is damaged if once
removed, when you connect the same
tube, cut off the damaged tip part, then
connect it.
f. When you replace the Teflon tube, putting something mark on the upper side of
the tube and the air fitting is recommended to avoid wrong connecting.
 
 

Text Box: Text Box: Teflon TubeText Box: Round NutText Box: Air FittingText Box: Press the both sides,
And then pull out.

 g. Though the collar lock and the sleeve extender is connected by the above
operation, please check whether the sleeve extender smoothly works when
collar lock push button is pressed.
h. When smooth working of the sleeve extender is confirmed, fix the collar lock by
cap nut. Screw-in the cap nut taking care to equalize right and left.

Pad (Part code : 62037)

Caution!
Do not install the pad other than the one with
specified part code.
 
1) Removing Pad
 

a. Remove the collar lock.
b. Remove the air bag referring to 5.6.6 Dummy Related Parts Replacement.
c. Remove the pad.
(In case of the front/back-unified pad, fully open all the zippers to remove it.)

2) Installation of Pad
 
a. Put the pad on the dummy and insert the collar lock fixture bolt, and pass the
collar lock air tubes and the cable for switches through the designated
openings on the pad.
b. Close the zipper. As the pad is designed as tight, if closing o f the zipper is
difficult, pull the pad to the zipper side.

 c. When side zipper is closed, adjust the pad position by pulling up and down so
that the upper zipper comes to the top of the dummy. At this time take care not
to be caught by the wire net. If wire net catches the pad, you cannot adjust the
pad position.
d. Close the left-top zipper followed by the
right-top zipper. (You can close
right-top zipper first.) After closing the
zippers, turn back the tag to inside as
shown in the right photo.
e. When the installation of pad is finished,
operate the machine and let it fit the
heat plate, put spray to moisten and
press to make installation of the air bag
easy. (Spray and press till the space
between 2 heat plates becomes 7.5mm
or smaller.)
f. When the pad is softened and fit to the
dummy and the space between the
heat plate and the pad becomes 7.5mm
or smaller, surely install the air bag, the
collar lock, the air bag holder plate and
the air bag fixture.
 
 
Text Box: Rounded Rectangular Callout: Turn back the zipper tab.Text Box: Text Box: 7.5mm or smaller

 Wire Net (Part code : [Front] 62109, [Back] 62110)
 
Caution!
Do not install the pad other than the one with specified part code.
 
1) Removing Wire Net
 

a. Remove the air bag. (Refer to 5.6.6 Dummy Related Parts Replacement)
b. Remove the pad. (Refer to 5.6.6 Dummy Related Parts Replacement)
c. Cut off the tie-band that connects the wire net and dummy spring holder plate.
 
 
2) Installation of Wire Net
 
a. When the wire net is prepared by user, please refer to the following drawing.

Wire Material: Stainless Steel
Wire Size: 1mm dia.
Mesh: 30
Connecting wire: 1mm dia, Cupper (Enamel finish)
 
Text Box: (Turning-up)Text Box: (Turning-up)Text Box: Wire Size : 0.3mm
Mesh : 30
Text Box: Wire Size : 0.3mm
Mesh : 30

b. Bend the shoulder part at right angle to
inside as shown in the right drawing. And
then, install onto the dummy by using the
connecting wires.
c. After the above work, install the pad, the air
bag, the collar lock and others referring to
5.6.6 Dummy Related Parts Replacement.

Dummy Cover Cloth (Part code : 62014)

Caution!
Do not install the dummy cover cloth other than the one with specified part code.
 
The dummy cover cloth is located between the wire net and the pad on the dummy
back side, and is prepared to make the vacuum effect to the back side and to avoid
wrinkles on the shirt back.
Inspection of the dummy cover cloth when pad replacement is done is recommended,
and id you find any damage, tear or rip in the cover, replace it with new one.
 
You can fix it using stapler or thread.
 
 
Text Box: Text Box: Turning-up at right angleText Box: Pass the wire through these holes, and tie to the dummy spring.Text Box: FrontText Box: Rear
 

5.6.7 Filter Element
 
a. Rotate the bowl guard with pressing the lock to meet the symbol (.) on the lock to
(V) on the body, and then you can take out the bowl guard and the bowl.
b. Insert the allen-key to the bottom of the baffle, and loosen the screw to take out the
baffle and filter element.
c. Install the new filter element and assemble with the opposite way of the above
procedure.

Applicable Filter Elements
 
Air Filter FDB-002: (CKD) 5m Filter Element for F-3000 (YAC Code: 21908)
 FDB-002S: (CKD) 5m Filter Element for F-4000 (YAC Code: 21937)
Mist Filter (Common): (CKD) 0.3m Filter Element for F-4000 (YAC Code: 21909)
 
Text Box: Main BodyText Box: O-RingText Box: Filter ElementText Box: BaffleText Box: BowlText Box: Bowl Guard
 
 

5.6.8 PLC

This system is controlled by PLC and it consists of following units.
 

- CPU Unit
- Extended I/O Unit
 
 
1) Input / Output Configuration

 
Input
Output
CPU Unit
(0 ch.) 00 - 07 terminals
(1 ch.) 00 - 07 terminals
(10 ch.) 00 - 07 terminals
(11 ch.) 00 - 07 terminals
Extended I/O Unit
(2 ch.) 00 - 15 terminals
(12 ch.) 00 - 15 terminals
 
Each terminal has LED display to indicate the I/O status.
 
Numbering:
CPU Unit
Input
0ch. row : 00 – 07
1ch. row : 00 - 07
0CH00 0CH01 0CH07
1CH00 1CH01 1CH07
Output
10ch. row : 00 – 07
11ch. row : 00 - 07
10CH00 10CH01 10CH07
11CH00 11CH01 11CH07
Extended I/O Unit
Input
2ch. row : 00 - 15
2CH00 2CH01 2CH15
Output
12ch. row : 00 - 15
12CH00 12CH01 12CH15
 
 
0CH000102030405071CH0001020304050710CH0001020304050711CH000102030405072CH00010203040507080910111213141512CH00010203040507080910112131415InputInputOutputOutputCPU UnitExtension I/O Unit

Cable Color Definition
 
Basic Definition
Red : .+
Black : .-
From the above basic definition, Red is always.+ and the black is
always.-.
For example, in case the combination of Red & White, it is defined as:
Red : .+
White : .-
and incase of the combination of White & Black, it is defined as:
White : .+
Black : .-
 
2) Program and PLC Digital Switches
 
Program
 
Flash memory is equipped with the CPU unit.
When the replacement of the CPU unit is required, use the one labeled as:
 
The number 47258 shows the program code number.
PLC Main Unit Code No. 47007
Program Code No. 47258
When the user purchase the CPU unit, the information of the above both code
numbers are required.
 
Caution!

Turn OFF the main power before replacing of the CPU Unit
 
Text Box: Double-Body Sleeve
STSD108
NO. 47258

 
PLC Digital Switches
 
Caution!

Do not change the setting of PLC Internal Digital Switches. Otherwise the
machine may not work properly, and there may be serious problem on the
machine.
 
 
Default Setting
SW1
OFF
SW2
OFF
 
 
 
3) I/O Unit Initial Status
 
The initial indicator status (the status just after turning ON the power) of PLC is as
shown below:
 
. Input Unit Indicators
 
ON 0CH05 0CH06 1CH04 1CH06
OFF All the other indicators, except when;
[AUTO] is selected: 0CH03 ON
Dummy is located at setting position: 0CH07 ON
Spray switch is turned to [ON]: 1CH05 ON
 
If the indicators show the different status from the above, there may be
something abnormal.
 
. Output Unit Indicators
 
ON 10CH02 10CH06 11CH07
OFF All the other indicators 
 
6 Machine Errors and Countermeasures
 
6.1 Error Detecting

This machine detects the errors by monitoring the status of the sensor switches (LS2,
LS3).
* When the machine detects ON when it should be OFF, the machine considers error.
(Note) The error is not always monitored but for the specified time only.
 
Portion
(Sensor)
Sensor Status
Signal
Tower
Machine Status
Recovery
Pressing
Position
(LS2)
The sensor turns
ON before the
dummy reaches the
pressing position.
Blinks
Machine Stops
upon detecting
the error
Turn OFF the
power.
(In case the
system
configured with
Sleeve Presser,
turn OFF the
power after
making sure the
machine is at
initial status.)
Heat Plate
Open
(LS3)
After the completion
of pressing, the
sensor turns ON
before the
completion of the
heat plate opening.
Machine Stops
after pressing
 
 
 
6.2 Error without error indication

When pressing position detecting sensor turns OFF (after the dummy rotates to the
pressing position and pressing start signal is transmitted) by bounding due to cushion
failure or other reasons, machine backs to the initial status (see Note) with no error
indication.
In this case, eliminate the cause of the bounding, and then operate again.
 
6.3 Machine Failures and Countermeasures
 
6.3.1 Machine does not work at all
 

Symptom
Cause
Countermeasure
Machine does
not work at all
Power is not
supplied
Tripping of the circuit
protector in the operation box
Press [Reset]
switch on the circuit
protector.
Blowing of the fuse on the
primary power line or,
Tripping of the circuit breaker
on the primary power line
Fuse replacement
or Resetting of the
circuit breaker
Contact failure of the knife
switch on the primary power
line
Scrub the knife
switch
Air is not
supplied
Main air reducing valve is
closed.
Adjust as 0.5MPa.
The failure on [STOP (Red)] switch circuit
Refer to 7.4.
 
 
6.3.2 The failure on the fan or vacuum

Symptom
Cause
Countermeasure
a
The fan does
not work
The thermal relay (th) is working due to
single-phase operation or overload.
Refer to 7.5.
Failure on the electro-magnetic switch
(M)
Replacement
Breakdown of fan motor
Repair or
replacement
b
The fan woks
with abnormal
sound
The damage on the shaft for fan or for
fan motor
Disassembling and
replacement
Foreign body in the fan
Disassembling and
removing of the
foreign body
c
Weak vacuum
power
Damage on the pad
Replacement
Fan is rotating to the reversed direction
(refer to the arrow mark indicated on the
casing.)
Exchange 2 cables
of 3 cables
Damage on the air hose connected to
the inlet
Replacement
Damage on the packing (oil seal) for the
shaft, or
Damage on the dumper
Replacement
d
Vacuum does
not turn OFF
Failure on the valve for the dumper
(SOL7, 8)
Replacement
LED of IN2 does not
turn ON even foot
switch is pedaled.
Failure on the
foot switch
Replacement 
 
6.3.3 Dummy Rotation

Symptom
Cause
Countermeasure
a
Dummy does
not rotate
The sensor (LS3) does
not turn ON because
the heat plate does not
fully opened.
Over-cushion
of pressing
cylinder
Adjust the cylinder
head side cushion.
(Refer to 5.6.1.)
Improper sensor position (LS3)
(Refer to 5.6.4.)
Breakdown of the sensor (LS3)
Replacement or
adjustment
Failure of the solenoid valve (SOL1)
(Refer to 7.2.)
b
Dummy does
not rotate even
the heat plate
fully opened.
Over-cushion of pressing cylinder
Adjust the cylinder
head side cushion.
(Refer to 5.6.1.)
c
One (some) of
the press
switches
(black, green,
yellow) does
not work
The LED of PLC which applies to the
switch does not turn ON.
Black (PB2) 1CH00
Green (PB3) 1CH01
Yellow (PB4) 1CH02
Replacement
d
Slow dummy
rotating
Foreign body in the solenoid valve for
rotation
Check the air flow
(Refer to 7.2.)
Foreign body in the air hose for rotation
related area
Removing of the
foreign body
Rotation shaft was burned.
(When rotate the dummy by hand after
disconnecting the rotating area and the
cylinder)
Repair by vendor
required.
Contact the vendor.
e
Dummy does
not rotate to
the pressing
position
Over projecting of the rubber stopper
Adjustment of the
rubber stopper
Over cushion of the rod side of the
rotation cylinder
(Refer to 5.6.1.)
Too shallow screwing of the rod of
rotation cylinder
(Refer to 5.6.2.)
f
Shock when
dummy
completes
rotating
(For both
dummies)
The machine does not sit horizontally
Sit the machine
horizontally.
Too high or low pressure of rotation
reducing valve
Adjust as just
0.38MPa.
Wrong adjustment of the cushion for the
rotation cylinder
(Refer to 5.6.1.)
Failure of the cushion packing for the
rotation cylinder
Replacement of the
cushion packing
Wrong adjustment of the speed
controller for rotation
Adjustment
Too shallow screwing of the rod of
rotation cylinder
(Refer to 5.6.2.)
 
 

Symptom
Cause
Countermeasure
g
Shock when
dummy comes
to 90 area
Too shallow screwing of the rod of
rotation cylinder
(Refer to 5.6.2.)
h
Shock when
dummy
completes
rotating
(For one
dummy only)
The fulcrum of the rotation cylinder is
not in position.
Contact the vendor.
 
 
6.3.4 Air Leakage from the solenoid valves related to the rotation

Symptom
Cause
Countermeasure
a
Air leakage
from (SOL1)
while pressing
Damage on the piston packing of
rotation cylinder
Replacement of the
piston packing
b
Air leakage
from (SOL1) or
(SOL2) while
machine
stopping
Air leakage from (SOL1) or (SOL2)
Replacement of the
solenoid valve
 
 
6.3.5 Pressing failure

Symptom
Cause
Countermeasure
a
Heat plate
does not make
press even
dummy comes
to the pressing
position
Damage on the solenoid valve (SOL3)
(Refer to 7.2.)
Rusting in the pressing cylinder
(in case long time idling)
Call the vendor
 
Too short pressing time
Longer the setting
time
The sensor (LS29)
does not work
when dummy
comes to pressing
position
Dummy does not
reach the pressing
position due to the
rotation failure
(Refer to 6.3.3.)
Wrong position of
sensor switch
(LS2)
(Refer to 5.6.4.)
Breakdown of the sensor switch (LS2)
Replacement
 

 
Symptom
Cause
Countermeasure
b
The space
between 2
heat plate is
too big (normally
3-5mm) and bad
shoulder finish
Too low pressing
air pressure
Lower primary
pressure
Adjust the primary
air pressure as
0.6MPa or more
Wrong position of
the sensor switch
(LS2)
Adjust the sensor
position
(Refer to 5.6.4.)
Pad is too thick
(In case the failure occurred just after
pad replacement)
Replace with the
specified pad
Damage on the piston packing for the
pressing cylinder
Replacement
Contact the vendor
Air leakage from the solenoid valve
(SOL3)
Replacement
As the screw for the toggle stopper is
loosened (the screw head came up),
heat plate does not fully press.
Screw-in the screw
of the toggle
stopper
c
Slow
open/close
movement of
heat plates
Slow opening
movement
Too much reducing
of speed control
valve
Turn the knob to the
left.
Lower air supply
Consider to higher
the air capacity
Foreign body in
the hose
Remove the foreign
body
Primary air hose
(pipe) is too small
or too long
Consider the hose
(pipe) arrangement
Others
Foreign body in
the silencer
Remove the foreign
body, or filter
replacement
(Refer to 5.6.7.)
Foreign body in
the valve for
pressing
Carry out the flow
check
d
Air leakage
from the rod
area of the
pressing
cylinder
Damage on the packing of pressing
cylinder
Replacement of the
packing
Call the vendor.
e
Shock when
the heat plate
opening
completion
Wrong adjustment of the cushion of
head side of the pressing cylinder
(Refer to 5.6.1)
Damage on the cushion packing of the
pressing cylinder
Call the vendor.
 
 

 
6.3.6 Heat Plates do not heat up

Symptom
Cause
Countermeasure
a
Heat plates
are not heated
at all
No steam
Supply steam.
Stem inlet valve is closed
Fully open the
valve.
b
Temperature of
the heat plates
is lower, or it
takes long time
to heat up.
Steam pressure
gauge shows
lower value.
Shortage of steam
pressure
Consider to improve
the steam supply
system to be able to
supply the steam
with 0.7-0.8MPa
pressure
Steam pressure
gauge shows
fluctuation.
Shortage of steam
supply
Consider to improve
the steam supply
system to be able to
supply enough
volume
The pipe of steam
strap (Inlet side)
does not heat up.
Breakdown of the
steam strap
Replacement
Drainage pipe is
frozen
(Winter season)
Heat up to melt
(In the cold season,
purge out the
drainage after work
everyday.)
Drainage is
cumulated in the
collecting pipe
(In case the height
difference
between drainage
tank and drainage
pipe.)
Purge out drainage
till heating up of
heat plates.
Others
Foreign body in
the Drainage
(especially, the
seamless tube
area)
Cleaning
Use of wrong type
of steam strap
Replacement with
the disk type steam
strap
 
 

 
6.3.7 Bad cloth finish

Symptom
Cause
Countermeasure
a
Oil stain
Air gab get dirt by
oil, and also inside
of mist separator
get oil
The filter element
of the mist
separator get dirt
and oil is not
separated.
Cleaning of the
filter element, or
replacement
(Refer to 5.6.7.)
Mist separator get
oil again within a
short period even
taking the above
countermeasure
Air from primary
includes much oil.
Installation of mist
separator between
the primary
compressor and
the machine is
required.
b
Stain other
than oil
Stain on the
dummy
Dirt in water for
spray
Use clean water
Dirt on the heat
plates
Cleaning
(Take care not to
make scratch on
the heat plate.)
Steam leakage
from the dummy
Call the vendor.
Stain on the collar
Pressed without
preheating
Carry out
preheating before
starting work
without fail.
(Refer to 4.1.4.)
c
Wrinkles on
clothes
Shortage of the air
pressure for the air
bag
Too low air
pressure setting
New air bag:
 0.01-0.02MPa
Old air bag:
 0.03MPa
Breakdown of the
reducing valve
Replacement
Wrong timing to
start inflating
Wrong timer setting
(Refer to 4.1.2.)
Breakdown of the
timer
Replacement
(When the timer
adjustment cannot
be made.)
Wrinkles on the air bag
Try to press
without spraying
and cloth to
eliminate wrinkles.
The air bag does not inflate.
Repair or
replacement
(Bag life :
20K-25K times)
The pad is hardened.
Replacement
(Pad life :
20K-25K times)
 

 
Symptom
Cause
Countermeasure
d
Warpage of
buttoned
placket
Wrong cloth setting
Set cloth properly.
Air bag stand-by time is to short
(Refer to 4.1.2.)
Too high air bag
pressure
Wrong pressure
setting
Adjust the
pressure
Breakdown of the
air bag air reducing
valve
Replacement
Vacuum failure
(Refer to 6.3.2.)
The air bag inflates at setting position.
(Abrasion of rotation metal)
Replacement of
the metal at
dummy rotation
center
e
Small wrinkles
at shoulder,
side of the
cloth (the area
the edge of the
heat plate
touches.)
The shoulder and side area are not
pressed well due to too bid space
between 2 heat plates. (to be 3-5mm)
(Refer to 6.3.5.)
 
 
6.3.8 Failure on Collar Lock and Sleeve Extender
 
 
Symptom
Cause
Countermeasure
a
Collar Lock, or
Sleeve
Extender does
not work
The LED on PLC
applied to the
Collar Lock does
not turn ON
Left Lock 0CH00
Right Lock 0CH01
Breakdown of the
switch
Replacement
Breakdown of the
heat-resistant cable
in dummy
Replacement
The LED on PLC
applied to the
Collar Lock is
always ON
Short-circuit of the
heat-resistant cable
in dummy
Replacement
b
Too slow
movement of
Sleeve
Extender
Bending of cylinder rod for Sleeve
Extender
Replacement
Damage on the air tube
Replacement
 
 

 
7 Function Check of Electrical Component and Replacement
 
7.1 Timer and Power Relay

Timer and Power Relay can be check by the measuring of the voltage however, the
checking procedure is complicated and it is dangerous. Therefore, keeping the spares
and check by replacing the old one with new one.
When you install the new timer, setting change of the time unit is required. Do not
forget this operation.
 
1) How to change the graduation and time unit
 
The graduation and time unit is user programmable on the employed time so that this
component can be used for various purposes.
 
The graduation and the time unit can be changed by rotating the switching screws
using screw driver (Flat-tip) Refer to following Fig. 5-1, Fig. 5-2.
 
Caution!

a. Turn off the power before changing the setting. The setting change while working of
the timer causes the damage on the component.
b. When you change setting, rotate the screw so that the graduation / unit come out in
the center of the opening. Incomplete change carries the damage on the
component.
 
 
 
[Fig. 5-1 ] Change of graduations [Fig. 5-2 ] Change of time unit
 
 
 
 
Text Box: Graduation WindowsText Box: Screwdriver
(Flat)
Text Box: Graduation Change SwitchText Box: Screwdriver
(Flat)
Text Box: Unit WindowText Box: Unit Change Switch
Timer
Graduation
Time Unit
Pressing
Timer
 0 - 5 - 10 - 15 - 20 - 25 - 30
sec
Cloth Change
Timer
 0 - 5 - 10 - 15 - 20 - 25 - 30
sec
Air Bag Stand-by
Timer [Shirts (L)]
 0 - 0.2 - 0.4 - 0.6 - 0.8 - 1.0 - 1.2
sec
Air Bag Stand-by
Timer [Shirts (M)]
 0 - 0.2 - 0.4 - 0.6 - 0.8 - 1.0 - 1.2
sec
 
 
. Operation mode change switch
 
Operation mode is to be set as “A” mode. Otherwise, it may cause the malfunction of
the timer. Confirm the indication of “A” displayed on the operation mode indication
window.
 
2) How to take out Timer Unit
 
Caution!

Before maintenance and inspection work;
1) Turn OFF the main power,
2) Close the main air valve and purge out the remained pressure,
3) Close the steam valve,

Wait until heating element is cooled down.
 
a. Turn OFF the main power, and remove the front panel of the switch box.
b. Pull out the socket.
c. Loosen the screws of the mounting adaptor on the back side of the timer unit. (Fig.
5-3)
d. Push out the timer unit with opening the lock on the mounting adaptor.

 
Fig. 5-3 Fig. 5-4
Text Box: Mounting AdaptorText Box: ScrewText Box: Timer UnitText Box: Lock
 
7.2 Solenoid Valves

1) Circuit Check
 
Disconnect the connectors, and measure the resistance between 2 terminals.
(The direct current resistance of the magnetic valve coil is to be 60O. When you cannot
find any electric current, try to exchange (+) and (-) and then measure again.
If you cannot find any electric current even such probe exchange, is must be the
breakdown with the valve.
 
2) Airflow Check
 

a. Remove the air tube on “OUT” side, and prepare the DC24V power source. (Do not
use the power line from the switch box.)
b. Try to plug and unplug, and check whether the airflow from “OUT port (A, B)”
switches.

(Note) When you cannot check the airflow due to the direct connecting with the other
valve or air cylinder, remove the air fitting and tale out the valve, and connect the air
line to the “IN port” on the valve, then check.
 
 

 

7.3 Foot Switch

Caution!
Before maintenance and inspection work;

4) Turn OFF the main power,
5) Close the main air valve and purge out the remained pressure,
6) Close the steam valve,

Wait until heating element is cooled down.

The circuit for the Foot Switch is check by using a circuit tester.
 

a. Turn OFF the primary power, and open the switch box.
b. Measure the resistance between the terminal “4” and “23” (“a” contact), when the
foot switch works normally, you get following resistances.

When pedaled: 0O
When released: approx. 4KO
 
 
 

7.4 Push Switches
 
a. Turn OFF the primary power, and open the switch box.
b. Measure the resistance between the terminal shown below respectively, “4” and
“23” (“a” contact), when each switch is normal, you get following resistances.
 
 
 

Switch
Contact
Terminals to
measure
Press
Release
Red Switch
(PB1)
b
4 - 37
Approx.4KO
0O
Black Switch
(PB2)
a
4 - 30
0O
Approx.4KO
Green Switch
(PB3)
a
4 - 31
0O
Approx.4KO
Yellow Switch
(PB1)
a
4 - 32
0O
Approx.4KO
 
 

 
7.5 The Treatment when Thermal Relay works

Caution!
When you find any abnormal on the machine, do not use the machine as it is and carry
out the necessary maintenance work following this manual.
When it is beyond your control, please contact the vendor.
 
When the Thermal Relay detects the overload or single-phase power, thermal relay
works and shutdown the electric current to the motor to protect the motor and the
circuit.
(The thermal Relay is located in the switch box.)
 
Recovering procedure:

a. Find out the cause of the overload or single-phase power.
b. Eliminate the cause referring to the following chart.
 
 
Cause
How to determine the cause and countermeasure
Overload
Remove the flange of the fan inhalation and try to
rotate the fax by hand. If the fax does not rotate
smoothly, there may be overload.
Further checking with disassembling is required.
Single-phase operation
due to:
a) Failure on the
primary power switch
b) Blown out of the fuse
on the primary power
line

c) Contact failure of the
magnet switch

Disconnect the cables for the fan motor, and press the
reset switch on the thermal relay, and then turn ON the
toggle switch on the operation panel and measure the
voltages on the portions shown in the left one by one to
determine the cause.
If you find something abnormal, replace the applied
part.
 
 
c. Press the Reset switch on the thermal relay after eliminating the cause.
 


 7.6 How to Attach / Detach Air Tubes
 
 
 
 
 
Text Box: Tube StopperText Box: Air TubeText Box: Releasing RingText Box: l Tube Detaching
Pull out the air tube with pressing the Releasing Ring
l Tube Attaching
Insert the air tube till the tube tip reaches the stopper

 

8 Installation

When install this machine, please follow the instruction shown below for the good
finish and long machine life.
 
 

8.1 Installation

Danger!
While machine transferring, do not enter the area just under the machine.
It is very dangerous when the machine is dropped.
 

8.1.1 Carry-in
 
1) Hook the crane hook on the hook hole located on top of the pressing arm of the
machine.
2) When rollers are used to transfer the machine, pay attention to the size and length
of the rollers not to loose the balance.
3) When the machine is pressed to move, do not push the covers and other fragile
areas.
 
 
8.1.2 Installation
 
1) When the machine is installed on the floor, fix the machine surely using the
attached 4 anchor bolts.
2) When there is some opening between the
floor surface and the machine bottom,
eliminate such opening by inserting the steel
plate or other way, and then tightly fix the
anchor bolts.
3) Keep the 60cm (approx. 2 feet) or more
clearance between the machine and the
other equipment or wall.
 
 
 
 
 
Text Box: Machine
Text Box: 60mmText Box: 60mmText Box: 60mm
 If the above installation is poor:
 
. There may be something position difference and it carries the bad finish on the
clothes.
. The cushion adjustment may get difficulty.
. I may cause the shorter machine life and unexpected accident due to the abnormal
overload from the vibration.
 
 
 

8.2 Power
 
a. Arrange the power following the applied laws and the regulations.
b. The rating voltage for this machine is 3-phase, 200V. Please prepare the enough
capacity of the power so that the other machine can be run in parallel.
c. For the easier maintenance work, preparation of the designated Power Switch,
such as “Non Fuse Breaker” out side the machine is recommended. (Capacity: 5
amps. Wire = 3.5mm2, Recommended Breaker : Fuji Electric : EA33M/5)
d. Grounding is the mandatory to avoid the electric shock when insulation failure.
However, do not connect the grounding cable to water pipe, gas pipe, the
grounding line for the telephone nor to the righting rod.
e. Confirm the direction of the fan rotation referring to the arrow mark indicated on the
fan casing.)
 
 
8.3 Compressed Air
 
1) To supply the necessary airflow and pressure indicated on the serial number plate,
follow the item shown below:
 
a. Supply the air from the primary to the machine using F12mm Nylon tube with
the fitting to avoid the overstress on the air related units.
b. The pipe diameter for the primary line is to be 1/2B or larger, and install the
valve on the machine side end. To avoid pressure reducing, using the larger
size of pipe is recommended.
c. Take note there is not pressure reducing when multiple machines are run at the
same time
d. 70 – 80% loading ratio (20 – 30% Idling ratio) of the air compressor is
preferable.
 
 
 
 
 
 

2) The air supplied from the compressor contains the moisture, dirt and foreign
particles, and they can be the cause of the failure of the valves and cylinders. To
avoid such problems, supplying of the clean and dry air by installing of the
equipment is recommended.
 
a. Installation of “After Cooler” onto the air compressor.
b. Installation of air tank and drainage filter in the primary air line.
c. Installation of Drainage Strap in the primary air line, and etc.
 
 
3) Clean out the air pipe, air hose and fittings to eliminate the foreign particles, dust,
oil and others before connecting to the machine.
4) Do not use the rubber hose for the compressed air supply line. The corrosion of the
rubber obstructs the airflow, and carries the damage on the air related equipment.
 
 
8.4 Steam
 
1) Supply the steam with 0.8MPa pressure to the machine. (Do not exceed 0.8MPa.)
 
a. When the required pressure for the other machines are different from the above,
installation of the reducing valve is required to adjust the pressure.
b. When the primary are is shared by many equipments, or length of the primary
pipe is longer, the pressure reached the machine may be lower that the primary
pressure, and this may cause the bad finish of the clothes, drying failure and
etc. To avoid such problem, use the 1/2B or larger pipe size for the primary. In
case of the longer pipe line, using the pipe with 3/4 or larger is recommended.
 
 
2) For energy saving and to avoid burning, insulation of the pipe is required.
3) To avoid drainage flowing into the machine and to purging out the drainage,
arrange the pipe referring to Fig. 2-1.
4) Arrange the Drainage so that drainage can be purged out easily with lower
pressure.
 
 
 


 
 
(Note) Fully open the drainage valve to purge out the drainage remained in the pipe
after work. (It is mandatory in the cold season or cold area.)
 
Fig. 2-1
 
Danger!
Notes for the pressure-resistant parts for steam
When the machine is not used for one year or more, surely check whether each
pressure-resistant part is effective.
 
 
 
 
 
 
Text Box: Flow up to avoid inflow of drainageText Box: Steam Main Pipe
(Bigger Pipe
with Inclination)
Text Box: OpeningText Box: Drainage
Collecting Tank
Text Box: Steam Inlet ValveText Box: UnionText Box: Main UnitText Box: Steam StrapText Box: Check ValveText Box: Steam StrapText Box: Check ValveText Box: Union
Text Box: Exhaust Drainage at the system endText Box: UnionText Box: Drainage Main ValveText Box: (Bigger)Text Box: Drainage Exhaust Valve
Text Box: (Not required if drainage collecting is not needed.)Text Box: Other Machine
 
 

8.5 Water
* For the machine provided with the spraying system.
 
Do not connect the water pipe to the water tank directly.
Arrange the pipe just beside the water supply valve, and supply the water by
connecting the hose when the water is exhausted.
 
 

8.6 Exhaust Duct

The pipe diameter of the vacuum fan exhaust is F76mm. To avoid the noise and the
air blow into the working room, building of the duct is required. When the duct is built,
design it as:
1) Corners: 3 portion or less
2) Length: 3 meters or less
3) No vertical portion to go down to the ceiling
to minimize the airflow resistance.
 
 
 


 
 
 
 
9 Proposed Machine Layout by the Required Throughput
 
9.1 120 Shirts / hour

. 3 operators (100 – 120 shirts / hour)
 
Capacity of the compressor: 3.7KW
Steam: 70kg/hour
Power Consumption: 200V, 1575W
Working Area: 118sqft (11m2)
 
(Operator A) Rotary Collar Cuffs Presser .. Single Sleeve Presser
(Operator B) Double-Body Presser .. Button Hooker
 .. Single Sleeve Presser (Detaching)
(Operator C) Shirt Folder
 
 
 
 
 

Machine
 
 
 
 
 
Throughput
Shirts
Folder
Rotary Cuffs
Presser
Single Sleeve
Presser
Double-Body
Presser
Button Hooker
Press: 30sec
Press: 8sec
Press: 12sec
Rotate: 4sec
Time to change
Cloth
Rotate: 4sec
 
Time to change
Cloth
Time to change
Cloth
120 shirts/hr
30sec
15 + 15sec
13 + 3sec
17sec
7sec
100 shirts/hr
36sec
18 + 18sec
16 + 4sec
21sec
8sec
 

Text Box: WagonText Box: Table
 

9.2 120-200 Shirts / hour

. 3 - 5 operators (120 – 200 shirts / hour)
 
Capacity of the compressor: 5.5KW (Max.)
Steam: 80kg/hour
Power Consumption: 200V, 1610W
Working Area: 155sqft (14.4m2)
 
a. 3 operators (100 - 120 shirts / hour)
 
(Operator A) Rotary Collar Cuffs Presser .. Double Sleeve Presser
(Operator B) Double-Body Presser .. Button Hooker
 .. Single Sleeve Presser (Detaching)
(Operator C) Shirt Folder
 
b. 4 operators (150 - 160 shirts / hour)
 
(Operator A) Rotary Collar Cuffs Presser
 .. Single Sleeve Presser (Left Sleeve)
(Operator B) Double-Body Presser .. Button Hooker
 .. Single Sleeve Presser (Right Sleeve)
(Operator C) Shirt Folder (Left) .. Double-Body Presser (Left Detaching)
 .. Button Hooker
(Operator D) Shirt Folder (Right) .. Double-Body Presser
 
b. 5 operators (180 - 200 shirts / hour)
 
(Operator A) Rotary Collar Cuffs Presser
(Operator B) Double Sleeve Presser
(Operator C) Double-Body Presser
(Operator D) Shirt Folder .. Button Hooker
(Operator E) Shirt Folder .. Button Hooker
 
 
 
 
 
 
 


 
 

 
 
 

Number
of
operators
Machine
 
 
 
 
 
 
Throughput
Shirts
Folder
Button
Hooker
Double-Body
Presser
Double
Sleeve
Presser
Rotary Cuffs
Presser
Press: 12sec
Press: 13sec
Press: 30sec
Rotate: 3sec
Time to
change Cloth
Rotate: 4sec
Time to
change
Cloth
Time to
change Cloth
3
120 shirts/hr
30sec
7sec
17sec
(3)+13sec
15+15sec
100 shirts/hr
36sec
8sec
21sec
(4)+16sec
18+18sec
4
160 shirts/hr
(R)28sec
7sec
18sec
(R)17sec
27sec
(L)32sec
(3)+15sec
(L)16sec
150 shirts/hr
(R)30sec
8sec
19sec
(R)18sec
29sec
(L)34sec
(3)+16sec
(L)17sec
5
200 shirts/hr
27sec
7sec
15sec
18sec
32sec
180 shirts/hr
31sec
8sec
17sec
20sec
36sec
 
Text Box: WagonText Box: Table
 

10 Installation Procedure for “Double-Sleeve Presser” (Option)

Connect the “Double-Body Shirts Presser” and “Double-Sleeve Presser” with following
procedure.
 
1) Air Piping
 
Connect the branch fitting (A) and the reducing valve fitting with F12 Nylon tube
(2m : Accessory)
 
 
2) Cables
 
Connect “Body Presser” and “Sleeve Presser” with the designated as shown below.
 
 
 
 
 

Text Box: Sleeve PresserText Box: Body PresserText Box: Body Presser BoardText Box: Sleeve Presser BoardText Box: Body Presser
Connecting Cable
Text Box: 15-pin ConnectorText Box: 12-pin ConnectorText Box: 6-pin ConnectorText Box: 4-pin ConnectorText Box: PLC I/O Extension Unit for
Sleeve Presser

 

11 Assembling and Mounting of PLC

1) Assembling of CPU Unit and Extension I/O Unit
 
Simply connect each facing connector, and then slide the lock to connect 2 units.
 
 1 Remove the connector cover on the UPU unit or Extension I/O unit.
When it is tight to remove, use screwdriver (flat).
 
 2 Put the hooks (top and bottom) on the side surface into the socket holes on the
other unit, and then connect the connectors each other by pressing from both
outer sides.
 
 3 Slide the 2 lock levers (top and bottom) to the “Lock” side to fix 2 units each
other. Put the connector cover on the extension I/O unit which was being used
on the CPU unit.
 
 
 

Text Box: Connector
Cover
Text Box: Connector
Cover
Text Box: Lock
 
2) Mounting on the DIN Rail
 
 1 Pull down the hook at the bottom, and hook the upper hook on the DIN rail, and
the press the lower part of the units to hook the lower hook. After that press the
lock at the bottom.
 
 2 Pull down the hook at the bottom by using screwdriver (flat), and lift it up.
 
 
 
 

Text Box: (1) Pull own the hookText Box: (2) Hook
onto
the rail
Text Box: (3) Press the unitText Box: (4) LockText Box: Screwdriver (flat)
 

12 Drawings
12.1 Air Piping Diagram
 

 

Text Box: Air FilterText Box: Reducing Valve
Text Box: Reducing ValveText Box: Reducing Valve (Rotation)
Text Box: Spray UnitText Box: (Option)Text Box: ManifoldText Box: Rotation CYLText Box: ManifoldText Box: (R) Dummy Vac. StopText Box: (L) Dummy Vac. StopText Box: Sleeve Lift CYL (R, R)Text Box: Sleeve Lift CYL (L, R)Text Box: Sleeve Lift CYL (L, L)Text Box: Sleeve Lift CYL (R, L)Text Box: Collar Lock CYL (R)Text Box: Collar Lock CYL (L)Text Box: Mist SeparatorText Box: Reducing Valve (Air Bag)Text Box: Air
Bag
Text Box: Air
Bag
Text Box: Switching
Valve
Text Box: Pressing CYL

 

12.2 Steam Piping Diagram

 

Text Box: DummyText Box: DummyText Box: DummyText Box: DummyText Box: Seamless TubeText Box: Seamless TubeText Box: CodeText Box: CodeText Box: Drainage TankText Box: Ball ValveText Box: CodeText Box: CodeText Box: Steam StrapText Box: CodeText Box: Check ValveText Box: CodeText Box: Pressure GaugeText Box: Max. Stem Pressure
 

12.3 Circuit Diagram (FDB-002)

 

Text Box: Steam ONText Box: CounterText Box: PressText Box: Air Bag InflationText Box: ManualText Box: AutoText Box: (L) Collar Lock SWText Box: (R) Collar Lock SWText Box: Dummy Vac. SWText Box: Auto Press TimerText Box: Dummy 90 ONText Box: Dummy Press Position ONText Box: HT Plate Open ONText Box: L Dummy Set Position ONText Box: Shirt (L) ButtonText Box: Shirt (M) ButtonText Box: Shirt (S) ButtonText Box: Cotton/Mixed TimerText Box: Cotton/Mixed SWText Box: Spray On/Off, TimerText Box: StopText Box: Stand-by Timer (L)Text Box: Stand-by Timer (M)Text Box: Stand-by Timer (L)Text Box: Stand-by Timer (M)Text Box: Mixed TimerText Box: Cotton TimerText Box: Pressing TimerText Box: Spray Valve ONText Box: Spray TimerText Box: IndicatorText Box: (L) Collar Lock CloseText Box: (R) Collar Lock CloseText Box: (L) Dummy Vac OffText Box: (R) Dummy Vac OffText Box: Rotation Cyl PullText Box: Rotation Cyl ExtendText Box: Pressing Valve OnText Box: Air Bag Valve OnText Box: (Note) Number in circle slows the connector pin number on PLC.
 
 

12.4 Over View (Double-Body Shits Presser DX)

 
 
Text Box: Machine CenterText Box: Pressing CenterText Box: Max. RadiusText Box: Air InletText Box: Steam InletText Box: Steam OutletText Box: Pressing CenterText Box: Machine CenterText Box: Anchor BoltText Box: UInstallation Base
 

12.5 Over View (Double-Body Sleeve Presser)
 
 
 

Text Box: Steam Inlet 1/2BText Box: Air Outlet 1/2BText Box: Steam Inlet 1/2BText Box: Air Inlet 3/8BText Box: Steam Outlet 1/2BText Box: Air Exhaust F76
 
 

13 Parts List
 
 
 << Front View >>

 
Fig. I-1
 

Text Box: (23-5) CounterText Box: (6) Collar LockText Box: Sleeve ExtenderText Box: (5) DummyText Box: (24) Foot SwitchText Box: (6-1) Air Bag Holder PlateText Box: (32) MirrorText Box: (23) Switch BoxText Box: (44-3) Packing
<< Side View >>
 
Fig. I-2
 
 

Text Box: (18) Solenoid Valve for Spray
* Option for “FDB-002S/L”
Text Box: (1) Heat Plate (Front)Text Box: (2) Heat Plate (Rear)Text Box: (30-1) Banner HoseText Box: (30-2) Hose ClipperText Box: (25) Fan MotorText Box: (11) Solenoid ValveText Box: For Pressing
Switch Box Details
 
 
Fig I-3
 

Text Box: (23-1) Press SW (Red)Text Box: (23-9) Toggle SWText Box: (23-4) Press SW (Black)Text Box: (23-2) Press SW (Green)Text Box: (23-3) Press SW (Yellow)Text Box: (23-11) Circuit ProtectorText Box: (23-10) Toggle SWText Box: (23-10) Toggle SW
* Optional
Text Box: (23-6) Timer (* Optional)
Text Box: (23-7) Timer Mounting Adaptor
(* Optional)
Text Box: (23-6) Timer Text Box: (23-7) Timer Mounting AdaptorText Box: (23-20) IndicatorText Box: (23-21) Power Relay (* Optional)
Text Box: (23-14) PLC CPU UnitText Box: (23-15) PLC I/O Extension UnitText Box: (* for FBS-200 model only)Text Box: (23-12) DC Power UnitText Box: (23-6) Timer Text Box: (23-7) Timer Mounting AdaptorText Box: (23-8) Timer Front CoverText Box: (23-13) Magnet SWText Box: (23-21) Power RelayText Box: << Switch Box Inside >>Text Box: << Top View >>
Air Inlet Details
 
 
 

 
Text Box: Fig. I-4 (for FDB-002/L)Text Box: (19-11) Pressure GaugeText Box: (19-19) MufflerText Box: (17) ManifoldText Box: (16) 3-Port Solenoid Valve
(For Rotation)
Text Box: (19-14) T-Bracket
Text Box: (19-14) T-Bracket
Text Box: (19-9) Distributor
Text Box: (19-16) Piping AdaptorText Box: (19-11) Pressure GaugeText Box: (19-4) Reducing ValveText Box: (19-11) Pressure GaugeText Box: (19-19) MufflerText Box: (17) ManifoldText Box: (16) 3-Port Solenoid Valve
(For Rotation)
Text Box: (19-9) Distributor
Text Box: (19-10) Distributor
Text Box: (19-11) Pressure GaugeText Box: (19-5) Reducing ValveText Box: (19-6) Reducing ValveText Box: (19-15)
Joiner Set
Text Box: (19-19) MufflerText Box: (15) ManifoldText Box: (14) 5-Port Solenoid Valve
(For Left Collar Lock)
Text Box: (14) 5-Port Solenoid Valve
(For Right Collar Lock)
Text Box: (13) 3-Port Solenoid Valve
(For Left Vacuum)
Text Box: (13) 3-Port Solenoid Valve
(For Right Vacuum)
Text Box: (19-20) Ball ValveText Box: (19-2) Air Filter
with Auto Drain
Text Box: (19-3) Mist SeparatorText Box: Fig. I-5 (for FDB-002S)Text Box: (19-6) Reducing ValveText Box: (19-15)
Joiner Set
Text Box: (19-19) MufflerText Box: (19-3) Mist SeparatorText Box: (19-1) Air Filter
with Auto Drain
Text Box: (19-20) Ball ValveText Box: (13) 3-Port Solenoid Valve
(For Right Vacuum)
Text Box: (13) 3-Port Solenoid Valve
(For Left Vacuum)
Text Box: (14) 5-Port Solenoid Valve
(For Right Collar Lock)
Text Box: (14) 5-Port Solenoid Valve
(For Left Collar Lock)
Text Box: (15) Manifold
Arm Bracket Area
 
 
Fig I-6
 
 
 
 
 
 
 
 
Text Box: (39) Arm Bracket Main ShaftText Box: (3) Insulation AText Box: (4) Insulation BText Box: (44-1) Bearing Packing
Pressing Area
 
Fig I-7
 
Fig I-8
 

Text Box: (27-3) Tie-RodText Box: (33-1) Heat Plate
Parallel Tie-Rod (Rear)
Text Box: (33-2) Heat Plate
Parallel Tie-Rod (Front)
Text Box: (28) Round Flange Type UnitText Box: (21-3) Seamless TubeText Box: (43) Arm Bracket Fixture BoltText Box: (34) Pressing ArmText Box: (40) Pressing Cyl. Head PinText Box: (41) Pressing Cyl. Head PinText Box: (35) Rotation LeverText Box: (38) Rotation Lever ShaftText Box: (42) Key PlateText Box: (36) Arm LeverText Box: (37) Arm Lever ShaftText Box: (27-2) Tie-RodText Box: (27-3) Tie-Rod
 
 
Rotation Driving Area (1)
 
 
 
 
Fig. I-9
 

Text Box: (49-1) Oil SealText Box: (52) Rotation Main ShaftText Box: (53) Switching Valve WasherText Box: (9) Rotation CylinderText Box: (27-1) Rod-EndText Box: (48) Air Bag Air Switching ValveText Box: To setting side air bagText Box: To pressing side
air bag
Text Box: (50) Rotation Ring BossText Box: (49-3) Oil SealText Box: (51) Vacuum CouplingText Box: VacuumText Box: From
Dummy
Text Box: (49-2) Oil SealText Box: (47) Ball Bearing
Rotation Driving Area (2)
 
 
Fig. I-10
 

Text Box: (19-13) Pressure GaugeText Box: (21-4) Seamless TubeText Box: (9) Rotation CylinderText Box: (22-1) Sensor SwitchText Box: (22-1) Sensor SwitchText Box: (26-4) Oil-less BushText Box: (19-17) Speed ControllerText Box: (22-3) Limit SwitchText Box: (12) 2-Port Solenoid ValveText Box: (for Air Bag)Text Box: (19-8) Reducing Valve
 
Pressing Cylinder (Inside)
 
 
 
Fig. I-11
 
 
Text Box: (8-5) Pressing Cylinder GasketText Box: (8-1) Pressing Cylinder Piston PackingText Box: (8-4) Pressing Cylinder Dust WiperText Box: (8-9) Pressing Cylinder WearingText Box: (8-2) Pressing Cylinder
Cushion Packing
Text Box: (8-6) Pressing Cylinder
Piston Gasket
Text Box: (8-3) Pressing Cylinder Rod PackingText Box: (8-7) Pressing Cylinder Needle Gasket
 
Vacuum Switching Unit
 
 
 
 
Fig. I-12
 

Text Box: (44-2) Dumper Lid PackingText Box: (45-2) Dumper Shaft CollarText Box: (46) Miniature Flange Unit Text Box: (64) Dumper ArmText Box: (10) Dumper CylinderText Box: (45-1) Rotation Ring Dumper
Collar Lock
 
 
 
Sleeve Lifter
 
 

Text Box: (6-11) Collar Lock Cyl. Head ShaftText Box: (26-3) Oil-less BushText Box: (6-5) Collar Lock CylinderText Box: Fulcrum PinText Box: (6-3) Collar Lock Text Box: (6-1) Collar Lock Text Box: (6-1) Collar Lock LeverText Box: (26-2) Oil-less BushText Box: (6-12) Collar LockText Box: (6-9) Cylinder SwitchText Box: Cylinder BracketText Box: (6-10) Cylinder CasingText Box: (6-8) Cylinder HeadText Box: (6-4) Collar Lock CylinderText Box: (6-6) Collar Lock
Collar Holding Rubber
Text Box: (6-7) Collar Holding Rubber
Fixture Screw
Text Box: (20-2) TAC Elbow FittingText Box: (7-2) Sleeve Lifter Cyl BracketText Box: (5-11) Glass Fiber Cable with 2-pin ConnectorText Box: (20-2) TAC Straight FittingText Box: (7-1) Sleeve Lifter CylinderText Box: (7-3) Sleeve Lifter HeadText Box: (7-4) Sleeve Lifter Text Box: Cylinder SpacerText Box: Fig. I-13Text Box: Fig. I-14
Solenoid Valve for Pressing
 
Fig. I-15
Pressing Cylinder (Inside)
 
Fig. I-16
 

Text Box: (55) NutText Box: (54) NeedleText Box: (11) 4-Port Solenoid Valve (for Pressing)Text Box: (19-18) SilencerText Box: (26-8) Phenol Bush Text Box: (22-2) Sensor SwitchText Box: (22-2) Sensor Switch
 
Steam Inlet Piping
 
Fig. I-17
 
Steam Outlet Piping
 
Fig. I-18
 

Text Box: (21-5) Stem Pressure GaugeText Box: (21-6) Ball ValveText Box: (56) StopperText Box: (21-2) Check ValveText Box: (21-1) Steam Strap
 
 
 
 
 

Text Box: (18) 2-Port Solenoid Valve
(Optional)
Text Box: (60) Spray Nozzle
(Optional)

 
 
 
 

Text Box: Steam Inlet 1/2BText Box: Air Inlet 3/8BText Box: Steam Outlet 1/2BText Box: Steam Inlet 1/2BText Box: Steam Outlet 1/2BText Box: Exhaust dia. 76

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