FALAN F525 N User manual

Footwear Machine Manufacturers

FALAN

Instruction Manual ( ENGLISH - Translation from Italian Original Language )

for Electronic Two-Thread Lockstitch Sewing Machine for Soles model F525 N

MODEL : F525 N

SERIAL N. : ...............

YEAR OF CONSTRUCTION : ...............

Manual Revision Number : 3

Builder Company and authorized to supply the Technical Documentation :

FALAN s.r.l.

Via Buscaglia, 14 - 27029 VIGEVANO (ITALIA)

Tel. +39 0381 346373

Fax +39 0381 346375

Codice fiscale/Partita I.V.A. 00293540183

INTERNET: http://www.falan.it

E-mail: info@falan.it

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Footwear Machine Manufacturers

FALAN

Instruction Manual

( ENGLISH - Translation from Italian Original Language )

for Electronic Two-Thread Lockstitch Sewing Machine for Soles model F525 N

MODEL : F525 N

SERIAL N. : ...............

YEAR OF CONSTRUCTION : ...............

Manual Revision Number :

3

Builder Company and authorized to supply the Technical Documentation :

FALAN s.r.l.

Via Buscaglia, 14 - 27029 VIGEVANO (ITALIA)

Tel. +39 0381 346373

Fax +39 0381 346375

Codice fiscale/Partita I.V.A. 00293540183

INTERNET: http://www.falan.it

E-mail: info@falan.it

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INDEX LIST

Important details for manual consultation

1 MACHINE DESCRIPTION

1.1 Protection and precautions to be taken for safety reasons

1.2 Residual Risks

1.3 Emergency signage on the machine

1.4 Position of the emergency signage on the machine

2 TECHNICAL FEATURES OF THE

3 PROPER USE AND REASONABLY FORESEEABLE

3.1 Danger and warnings against incorrect use of machine

4 TRANSPORT AND HANDLING OF THE MACHINE

5 MACHINE INSTALLATION

5.1 Machine measurements

5.2 Base support plan

5.3 Bird’s eye view

5.4 Distances to be observed around the machine

6 SETTING UP AND PREPARATION OF THE MACHINE READY FOR USE

6.1 Accessories

6.2 Preliminary control checks

6.2.1 Check on any damage the machine may have suffered during transport

6.2.2 Machine cleaning procedure

6.3 Connection to external energy supply

6.3.1 Connection to electrical energy supply

6.3.2 Connection to compressed air supply

6.4 Control, setting, and regulating operations

6.4.1 Correct motor rotation direction check

6.4.2 Compressed air adjustment

6.4.3 Stitch length adjustment

6.4.4 Adjustment of cogged pinion for whirl control

6.4.5. Presser foot height adjustment

6.4.6 Presser foot advance adjustment

6.4.7 Needle support adjustment

6.4.8 Presser foot adjustment

6.4.10 Horn thread tension adjustment.

6.4.11 Setting operation for hidden stitch sewing

6.4.12 Check on correct spring function (art. n.5468.04)

7 SEWING MACHINE SETTING OPERATIONS

7.2 Shuttle position setting

7.3 Thread puller position setting

7.4 Whirl position setting

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8 MACHINE RUNNING OPERATIONS

8.2 Threading preparation

8.2.1 Horn threading for Blake stitching

8.2.2 Horn thread stripper plug adjustment

8.2.3 Shuttle spool threading order

8.3 Position of article for stitching

9 MACHINE USE

9.1 Work cycle description

9.2 Machine electrical layout plan

9.3 Machine compressed air pneumatic layout.

10 REPLACEMENT OPERATIONS

10.1 Heater resistor replacement

10.2 Shuttle heater resistor replacement.

10.3 Needle replacement.

10.3.1 Needle size to be used according to thread size.

10.4 Loop opener replacement

10.5 Loop opener support replacement

10.6 Whirl replacement.

10.8 Needle support replacement

10.9 Flexible cord (for the horn) replacement

10.10 Flexible sheating (for the horn) replacement

11 ACCESSORIES

11.1 Heating equipment

11.1.1 Spool stripper plug adjustment

11.2 Shuttle spool preparation using the spool winder

12 MOUNTING OPANKA AND BLAKE HORNS FOR MACHINE

12.1 Replacement of Blake stitching horn with Opanka horn.

12.2 Mounting of BLAKE horn.

13 REPAIRS AND MAINTENANCE

13.1 Maintenance.

13.2 Normal periodic maintenance operations

13.3 Information concerning lubrification operations

13.4 Operations which must be carried out only by manufacturer’s qualified personnel

13.5 Possible problems that can arise

13.6 Spare parts and parts subject to wear and tear

13.7 Equipment supplied

14 DEMOLITION INSTRUCTIONS

15-1 SEWING MACHINE NOISE LEVEL

15-2 SEWING MACHINE VIBRATION LEVEL

16 PRINCIPAL WARNINGS

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Important information necessary for manual consultation:

1) In all the technical descriptions , the location of all accessories and various machine parts is always

given in relation to the control and work position.

This machine has been designed for use by a single operator for safety reasons.

2) In the technical descriptions, to be able to understand the text more clearly,all mechanical details are

described with their part number expressed in brackets alongside. These details can be easily seen in

the blow-up drawings contained in the appropriate catalogue supplied with the machine.

3) All operations described in this instruction manual must be carried out ONLY AFTER having:

- turned off the machine (MAIN SWITCH IN O POSITION)

- disconnected the machine cable from the main electrical supply.

- closed the compressed air draft tap located near the filter-reducer block mounted on the

machine, and emptied all the compressed air from the pneumatic installation.

4) All adjustment and maintenance operations described as follows must be carried out by expert qualified

personnel in order to avoid any injuries, or damage to the machine.

5) If You will verify some differences between article codes inside the manual and inside the exploded

views, You have to refer to the codes inside the exploded views (also to order the spare parts).

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1. MACHINE DESCRIPTION.

The Mod. 525N machine manufactured by the FALAN s.r.l. company, is a lock stitch sewing machine with

interchnageable horns both for traditional stitching (Blake), and for side stitching (Opanka) of shoe soles.

The sewing operation is carried out by a needle and shuttle system, mechanically run by a transmission

shaft, cam and gears, controlled by an electronic motor and V-belt.

The machine is equipped with a working position and a control panel; this machine is designed for manual

work.

Drawing 1

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1.1 Protections and precautions to be taken for safety reasons.

The manufacturer has provided for the following safety precautions:

- Closeable front door on the sewing head that can be opened with the key supplied with the

machine.

- Protection plate placed above the shuttle control shaft. This protection is to prevent the operator

being injured by coming into contact with any moving parts (shuttle control shaft).

- Front door on the machine base, opened using the key supplied with the machine, which can be

pulled out and upwards after opening.

- Rear carter , fixed with 6 screws.

- Rear carter pneumatic installation, fixed with 4 screws,

- Rear transmission protection carter, fixed with 6 screws.

- Carter on the right side, fixed with 8 screws.

- Carter on the left side, fixed with 8 screws.

- Protection carter for electrical installation.

- All the safety microswitches are at bayonet, at positive action and at tied up contacts.

The last two protective systems protect the following parts:

- electronic control motor and transmission V-belt

- thread-puller device

- heater

Warning.

1) These protection systems have been installed by the manufacturer to save the operator from injury during

work operations.

These protections must not be removed while the machine is running.

2) IT IS EXTREMELY IMPORTANT that the operator pays close attention when using the machine

during all stitching operations. Since it is impossible to protect the sewing area (needle-shuttle

area) operators are strongly advised to take great care, and to rest when tired.

For the same reason, protective glasses must be worn ;

indeed, the needle might break when stitching (projection of debris).

Be very careful not to press the pedal that controls the sewing speed by mistake while the machine

is switched on.

WARNING!

Pushing the mushroom-head emergency stop button or turning off the machine (main switch

on 0 position) or cutting out the air supply (with the sectioning tap), the

foot holder bar

positions itself to its bottom dead center (PMI) after about 1 seconds.

So it's necessary to pay close attention, when the operator makes the above-mentioned

operations, that nobody put any parts of his body (like hands or fingers) between the foot

holder bar and the horn of the machine, to avoid squashings or lacerations (since it's impossible

to protect this sewing area).

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1.2 Residual Risks.

In the previous paragraphes some situations, potentially classificable as “Residual Risk”, have been identified.

The “Residual Risk” is a more or less dangerous situation (for the Operator or for anybody who approaches to

the machine) that is not eliminable becouse of the kind of manifacture the machine is used as or becouse of

other reasons.

In the follow, a Residual Risks list is reported.

Residual Risks List (not in order of risk gravity-probability):

1) Sewing area (Niddle/Shuttle area) : safety instructions into the par. 16.

2) Motor tradle : safety instructions into the par. 16.

3) Foot-holder bar movement : safety instructions into the par. 16.

4) Heated Shuttle : safety instructions into the par. 16.

5) Outer and inner area of the heated kier (It contains wax or paraffin at high temperature)

making this operation, thermal gloves and tweezers are advice.

6) Shuttle heater Resistor replacement : safety instructions into the par. 10.2.

7) Heating element for kier-warmer: safety instructions into the par.10.1.

8) Sound Level: informations into the par. 15.

9) Electrical installation transformer : safety instructions into the par. 16.

10) Some operations described in this instruction manual must be carried out with the motor

switched off and the electric system disconnected. Even if it is not possible (for pneumatic or

electronic reasons), the machine is supplied with an effective "emergency position", which

enables the operator to work in safety conditions :

informations into specific paragraphes.

CAUTION!

As already pointed, out some parts of the machine are warmed up through the use of suitable heating

elements .

Considering that the operator can change the temperature of all mentioned parts within a very wide interval of

values, it is not possible to fix the cooling rates (once that the machine has been turned off through the main

switch).

For this reason we recommend to put on always the thermal gloves before making any operation,

who may cause a direct contact with the heated zones.

On our Mod. 525N the parts with a thermic risk are the following ones:

Shuttle area / Outer and inner area (It contains wax or paraffin) / Heating element for shuttle warming

apparatus / Heating element for kier-warmer.

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1.3 Emergency signage on the machine

- WRITABLE STIFF DATA PLATE: it contains informations concerning

the machine.

Hereunder pls. find the prospectus of the emergency signage on the machine

- OBLIGATORY TO READ THE INSTRUCTIONS MANUAL.

(BEFORE USING THE MACHINE)

- CAUTION, DON'T REMOVE THE SAFETY DEVICES.

- CAUTION, SURFACE AT THERMIC RISK.

- CAUTION, RISK OF PERFORATION.

- OBLIGATORY THE USE OF PROTECTIVE GLASSES.

- WARNING! VOLTAGE COMPONENTS.

- ELECTRICAL INSTALLATION

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1.4 Position of the emergency signage on the machine

Fastened by a mechanical connection

with 2 rivets of 3 mm

Fastened by a mechanical connection

with 4 rivets of 3 mm

Fastened by a mechanical connection

with 2 rivets of 3 mm

Fastened by a mechanical

connection

with 4 rivets of 3 mm

front view

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2 TECHNICAL DESCRIPTION OF THE MOD. 525N MACHINE.

FEATURES TECHNICAL INFORMATION

Machine measurements

width 550 mm

depth 689 mm

height 1705 mm

Measurements including packing

width 820 mm

depth 820 mm

height 1850 mm

Net weight 245 Kg

Gross weight in open crate 325 Kg

Gross weight in closed case 335 Kg

Stitches per minute from 130 to 320

Machine control system continuous current electronic motor with

needle stop in position.

Automatic pneumatic presser foot

lift control

Independent spool winder

Stitch length variable from 3 to 15 mm

Maximum thickness sewn 30 mm

TECHNICAL DESCRIPTION OF MAIN MOTOR (STITCHING CONTROL)

Monophase electronic motor

Power 1 Hp = 0,75 kW.

N.B. For technical details of the elctrical motors on the machine, refer to the plate attatched to each motor ,

and the relative service instructions.

On the sewing machine column is a metal plate with the main technical features of the machine.

= POTENZA DI ESERCIZIO

= TENSIONE DI ALIMENTAZIONE

= FREQUENZA DI ALIMENTAZIONE

= PESO NETTO

= PRESSIONE

= FASI

= MODELLO

= NUMERO DI MATRICOLA

= ANNO DI COSTRUZIONE

RUNNING POWER:.......................................

POWER SUPPLY:.........................................

SUPPLY FREQUENCY:..................................

NET WEIGHT:................................................

PRESSURE:..................................................

PHASE:.........................................................

MODEL:.........................................................

SERIAL NUMBER:..........................................

YEAR OF CONSTRUCTION:............................

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3 PROPER USE AND REASONABLY FORESEEABLE

The Mod. 525N manufactured by the FALAN S.r.l. company, is an electronic lock stitch with

interchangeable horns for Blake or Opanka sole stitching.

Any operations other than those for which the machine was designed are considered incorrect use, and can

damage the machine, as well as creating a danger hazard for the operator.

3.1. Danger warnings and advice against correct use.

- The cam and kinetics are set at the manufacturing plant.

- The work cycle is tested several times on each machine before delivery to the customer.

Under no condition must the cam and kinetic positions be changed in order to modify the machine’s running

sequence.

- There a chance to change the speed through the sewing machine motor parameters.

- The machine must never be used in explosive risk environments, and its use in these environments

is strictly forbidden.

- The machine was designed and built for stitching shoe soles.

- For carrying out any operations not established for use with this machine, or in any case, for any

interventions which need to be made to the machine, the user is requested to ask advice from

the manufacturer concerning any danger or risk resulting from incorrect use of the machine.

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4 TRANSPORT AND HANDLING OF THE MACHINE.

Passing through the machine head is a cylindrical hole for inserting a raising beam. Use a beam with two

end bolts, that can be dismantled for beam insertion into the hole, then bolt very tightly to ensure that the

machine does not fall causing danger during transport.

For correct machine handling, proceed as follows:

- Bolt the 4 pallet fixing brackets to the machine using M6 bolts. Make sure the brackets are

securely fixed to avoid dangerous falling when hoisted.

- connected to the eyebolt on the head of the machine (see drawing. 2) the hook with the lifting

cables.

Raising and handling of the machine should be carried out by a small crane driven by an expert.

One of the handling crew must be on the ground to control the machine during movement,

because the size and shape of the machine make it difficult for the crane operator to see any

eventual obstacles during machine handling.

- Position the machine on a support pallet and fix it to the pallet with 4 M8 screws, which must

pass through the holes in the brackets fixed to the pallet.

- All desired handling should be carried out according to the advice given in point 3.

Drawing 2

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Warning:

- Whether the machine is shipped in an open or closed wooden crate, all handling must be carried out

appropriately according to the type of packing.

. Before lifting the machine, make sure that the hook into the eyebolts is strictly fixed using the special

bolts to prevent dangerous falls.

- Before raising the machine with the crane, make sure that the 4 brackets are tightly screwed to the pallet

and to the machine with the M8 and M6 bolts to avoid any danger of machine falling.

Drawing 3

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di legno o gabbia

Trasporto macchina in cassa

Drawing 4

- Take great care to ensure that nobody is present in the hoisting area in order to avoid injuries to personnel

during handling of the lifted load.

- Coat all exposed and non-painted parts with grease, taking particular care with the needle-shuttle block,

and the horn and traction parts.

Especially when being shipped by sea, whether in an open or closed wodden crate, it is adviseable to

pack the crate with bags of hygroscopic salt, and to protect the various machine parts by spraying with

anti-rust paint.

- During transport the horn must be mounted on the machine.

Never move the machine by pushing it on a trolley. If there is no other solution, remember that one of the

heaviest parts of the machine is in the sewing head, so during handling , care must be taken not to incline

or move the machine back and forward.

Always be careful not to touch the needle-shuttle area.

- During handling operations remove the needle from its clamp and replace it only when the machine is

ready for use.

Open or closed wooden crate transport

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5 MACHINE INSTALLATION.

5.1 Machine measurements.

The maximum measurements of the Mod. 525N machine are shown in the drawing below.

Drawing N° 5.

During machine installation, the pallet fixing brackets are removed, so the width of the machine is reduced

from 689 mm to 550 mm.

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5.2 Mod. 525N Base.

For correct functioning, the machine does not need to be bolted to the flooring.

Drawing N° 6.

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5.3 Front view with the main Mod. 525N machine reference points.

Drawing 7.

safety switch

safety switch heater

main engine

light spot

front head

shuttle,needle, foot

control panel

Horn

spool winder block

technical information plate

Pedal

electrical equipment

shuttle horn

solenoid spool shuttle

plaque accident prevention

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1 mt

5.4 Distances to be observed around the machine.

For correct use of the machine, and to permit safe and easy repairs and maintenance, it is adviseable to

respect the minimum distances shown in the drawing.

Drawing 8.

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6. SETTING UP AND PREPARATION OF THE MACHINE READY FOR USE.

6.1 Accessory assembly.

The machine is completely assembled in the manufacturing plant.

6.2 Preliminary control checks.

On reception of the machine, it is adviseable to:

- check that all the machine components have arrived at destination. (user’s plant).

- Run a series of preliminary control checks as described in the paragraph below.

6.2.1. Check on any damage the machine may have suffered during transport.

In order to establish any damage the machine may have suffered during transport, control the condition of

the following parts:

- flexible tubing and piping of the compressed air equipment,

- protection systems mounted on the machine,

- electrical wiring, electrical and pneumatic components.

- electric motors

- transmission V-belt

- horn

-all jutting out parts of the machine.

6.2.2. Machine cleaning procedure.

Clean the machine carefully removing all dust , dirt and foreign matter that may have deposited during

transport.

Eliminate all traces of anti-rust protection that has been sprayed on the machine against humidity.

Remove any grease that has been used to protect non-painted parts.

Warning:

For machine cleaning, wear protective gloves, and disconnect the electrical installation by removing the

machine cable from the electricity suuply.

To clean the machine, use products which are biodegradable and easy to buy.

After having removed all the grease protection on the mechanical parts, lubrify all parts generously with

the oil supplied with the machine (see paragraph 13. repairs and maintenance).

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FALAN F525 N User manual

FALAN F525 N User manual

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