Adler 745-34-2 Programming Manual

Manual, complete

745 - 34 - 2

Sewing unit for runstitching of piped flap

and welt pocket openings and pocket corners

Working methods: A, B, D, F

Operating Instructions

Installation Instructions

Service Instructions

Instructions for Programming DAC

Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld Telefon + 49 (0) 5 21 / 9 25-00 • Telefax + 49 (0) 5 21 / 9 25 24 35 • www.duerkopp-adler.com

Ausgabe / Edition: 02/2005 Printed in Federal Republic of Germany Teile-Nr./Part.-No.: 0791 745181

745 - 34 - 2

Manual, complete

Contents

Operating Instructions

Installation Instructions

Service Instructions

Instructions for Programming DAC

Interconnection-diagram

9870 745154 B

9890 745002 B

Pneumatic circuit plan

9770 745005

Contents page:

Part 4: Instructions for Programming DACIII, class 745-34-2

Program version A 01

1. General ................................................... 3

2. Operating terminal ............................................ 4

3. Selecting the language ......................................... 5

4. Memory dongle

4.1 Transferring data from the memory dongle to the control...................... 6

4.2 Transferring data from the control to the memory dongle...................... 6

5. Main operating screen

5.1 Sewingandtestprograms:menustructure.............................. 8

5.2 Changing parameter values ....................................... 9

6. Sewing programs

6.1 Calling sewing-program parameter screens ............................. 10

6.2 Running a machine program....................................... 11

6.3 Mainscreen................................................. 12

6.4 Pocketprograms.............................................. 14

6.5 Blowermode................................................ 34

6.6 Pocket sequence ............................................. 36

7. Setting and test programs

7.1 Callingsettingandtestprograms.................................... 38

7.2 Machineparameters ........................................... 40

7.3 Machine-specificsettingandtestprograms ............................. 46

7.3.1 Adjusting the looper-thread monitor .................................. 47

7.3.2 Initializingmemory............................................. 48

7.3.3 Checkingthesmootherfunction .................................... 49

7.3.4 Aligningthelightbarriers......................................... 50

7.3.4.1 Preparingthesewingunitandfeedclamps.............................. 51

7.3.4.2 Sewing unit with two light barriers for automatic angle recognition ............... 53

7.3.4.3 Sewingunitwithtwolightbarriers,leftorrightflappositioning.................. 55

7.3.4.4 Sewingunitwithonelightbarrier.................................... 57

7.3.4.5 ErrorDisplay................................................ 58

7.3.5 Checkingthecorner-bladesettings .................................. 59

7.3.5.1 Checkingthecorner-bladestation................................... 60

7.3.5.2 Checkingthefrontleftcornerblade .................................. 60

7.3.5.3 Checkingtherearleftcornerblade................................... 60

7.3.5.4 Checkingcorner-blademotion ..................................... 61

7.3.5.5 Corner-blademachineparameters................................... 62

Contents page:

7.3.6 Testing needle and centre-blade activation .............................. 64

7.3.7 Checkingthetapefeed.......................................... 65

7.3.8 Checking the gripper folder without feed clamp ( versions B and F only)............. 66

7.3.9 Checkingtheinsertionprocesswithfeedclamp........................... 67

7.3.10 Checkingandadjustingthepipingknives............................... 68

7.3.10.1 Checkingthepipingknifemotion.................................... 68

7.3.10.2 Settingthepipingknifereferenceposition .............................. 69

7.3.11 Step-by-stepmode ............................................ 70

7.3.12 Determiningthecycletime........................................ 71

7.3.13 Dongle Menu ................................................ 71

7.4 Multitestsystem.............................................. 72

7.4.1 Displaying the program version and checksum............................ 73

7.4.2 TestingRAM ................................................ 74

7.4.3 Selecting input elements ......................................... 75

7.4.4 Checking input elements ......................................... 77

7.4.5 Selectingoutputelements........................................ 78

7.4.6 CANtest................................................... 81

7.4.7 Checkingthesewingdrive........................................ 82

7.4.8 Errorlist................................................... 83

7.5 Terminalself-test ............................................. 84

7.6 Displaycontrastvalue .......................................... 85

7.7 Editing menus ............................................... 86

7.8 Adjustingtheserialinterface ...................................... 87

8. Error messages

8.1 Sewing motor controller error messages ............................... 88

8.2 Stepping motor error messages ..................................... 89

8.3 Operating indicator error messages .................................. 89

1. General

This manual contains important information on the safe and correct use of the “DACIII” (Dürkopp Adler Control) new-generation controller.

Screen images in this brief description

The symbol display on the various screens depends on the s ewing machine’s equipment and settings. The screen images illustrated in this brief description may therefore not always correspond exactly with the screens appearing in the controller display.

Operating terminal with graphic user guide

The operating terminal is fitted with an LCD display and a keyboard. The user guide employs only internationally intelligible symbols, supplemented with textual information in the selected language. The various symbols are arranged in groups in the menu structure of the sewing and test programs. Simplicity of operation ensures rapid familiarisation.

Ease of programming

99 freely programmable pocket programs are available to the user, which can be combined with any number of seam patterns. 20 pocket sequences. Each pocket s equence can be composed of a maximum of 8 pocket programs in any order. On the “slanting-pocket version” of the class 745-34-2 all practical angles can be programmed by the operator, who can thus dispense with the need to spend time and effort readjusting the corner blades and programming seam displacements.

Setting and test programs

The MULTITEST comprehensive testing and monitoring system is integral to the DACIII control. A microcomputer carries out the control functions, monitors the sewing process and displays incorrect operations and faults.

Errors and test results are shown in the LCD display. If the machine is operating normally the display shows information relating to operation and sewing. In the event of an operating error or fault the function sequence is interrupted. The display indicates the cause by means of the appropriate error symbol. In most cases the error symbol disappears once the error has been rectified. In some cases the main switch must be switched off for safety reasons when the error is rectified.

Special programs facilitate mechanical settings and enable receiver and transmitter elements to be rapidly tested without additional measuring devices.

Memory dongle

The dongle is used to memorize sewing programs and machine parameters and to transfer these data to other sewing units.

2. Operating terminal

Colour display

Data input and output is done via an operating terminal with a colour LCD display and a multipurpose keyboard.

RST (reset) key

Decimal keypad

Cursor keys

ESC key Function keys

Key/key group Function

Function keys Call sewing-program parameter screens

(from the main screen). Call test programs (after pressing the RST key) Switch functions on and off. Leave test programs and parameter screens.

Cursor keys Change parameter values.

Change parameter values.

ï, ð : select the symbol of the required parameter ñ, ò : switch the parameter function on and off,

select the previous/next parameter-value stage, activate the test program

Decimal keypad Enter parameter values.

: change the parameter-value sign

OK key

Escape key Display the old parameter value again.

OK key Open window to set the selected parameter.

Accept the set parameter value.

RST key Leave machine program.

Halt current program.

3. Selecting the language

– –

–

Switch on the main switch and keep pressing the “ñ” key or Press the keys “RST” and “ñ” in order to activate the language

selection The different languages are memorized in the control. By pressing the cursor keys “ñ“or”ò” the desired language can be

selected (it w ill appear white on black). With the “F5” key the language that will be activated when

switching on the automat the next time is marked with an asterisk.

4. Memory dongle

The dongle is used to memorize sewing programs and machine parameters and to transfer these data to other sewing units.

The transfer direction is selected with the keys ”F2” and “F4”. The data transfer is started with the “F5”key.

4.1 Transferring data from the memory dongle to the control

–

Use the “ð ”or“ï” cursor keys, to select the required parameter (machine parameter, sequences or seam program).

–

The pictogram representing the required parameter will then appear white on black.

–

Start the data transfer by pressing the “F5”key.

F1 F2 F3 F4 F5

4.2 Transferring data from the control to the memory dongle

–

When saving data on the dongle, all parameters, machine parameters, sequences and seam programs are memorized.

–

After pressing the “F5” key, appears the question whether the dongle is to be overwritten.

F1 F2 F3 F4 F5

–

The current type of the dongle being plugged in is determined and indicated on the display.

–

Data transfer can be started by pressing the “F5” key and stopped with the “ESC”key.

–

If no data dongle 745-34-2 is indicated but e. g. Boot 745-34-2, the dongle will first be formatted after pressing the “F5” key before the data are saved on the dongle.

–

The dongle is formatted

–

The data is saved onto the dongle

5. Main operating screen

5.1 Sewing and test programs: menu structure

The user interface exclusively employs internationally intelligible symbols.

In addition each function is briefly explained in an information line. The individual parameters and setting and test programs are arranged

in various groups.

Turn on

main switch

Main screen

Sewing programs Setting and test programs

Calling sew ing programs

–

Turn on the main switch. The controller is initialised. The DÜRKOPP-ADLER logo briefly appears in the display.

–

The display switches to the main screen. Sewing-program parameter menus are called by pressing one of the function keys F1 and F2.

Calling setting and test programs

–

Turn on the main switch. The controller is initialised. The DÜRKOPP-ADLER logo briefly appears in the display.

–

While the logo is displayed press one of the function keys F1 to

F5 or cursor up, cursor down.

or with the machine switched on: –

press the RST key, then hold down one of the function keys F1 to F5 or cursor up, cursor down. The display switches to the corresponding group of setting or test programs.

5.2 Changing parameter values

Parameter values are changed in the individual parameter screens.

–

– –

Select the required parameter with the “ï”or“ð”cursorkeys. A black background appears behind the symbol of the selected paramet er.

Press the OK key. The settings window appears with the current values or to enable values to be entered.

Change the parameters as described under 1 to 4 below. Press the OK key.

The new parameter settings are saved.

(on) (off)

Entry:

10, 12, 14, 16, 18, 20, 22, 24, 26, 30

[-20 ...+20]

When changing parameter values we must distinguish among four groups of parameters:

1. Functions that are switched on and off

–

Switch the parameter function on and off with the “ð”or“ï”cursor keys.

2. Parameters with various functions

–

Set the required parameter function with the “ð”or“ï”cursor keys.

3. Parameters whose values are changed in stages

–

Select the previous or next parameter-value stage with the “ñ”or “ò”cursorkeys.

4. Parameters whose values are entered with the decimal keypad

–

Enter the required parameter value on the decimal keypad.

CAUTION:

The value must be within the set limits. If the value entered is too large or too small, the upper or lower limit is displayed when the Enter key is pressed.

–

If a plus or minus sign appears in front of the parameter value, it can be changed with the “ ” key.

6. Sewing programs

With Class 745-34-2 you can program up to 99 different sewing programs. The individual sewing programs (pocket programs) are freely programmable.

20 independent pocket sequences are available. Each pocket sequence can be composed of a maximum of 8 pocket programs in any order.

6.1 Calling sewing-program parameter screens

You can switch from the main screen to the various sewing-program parameter screens with function keys F1 and F2. Function key F5 resets the piece counter to “0". Press F4 for the tape feed (if present).

Pocket Program Sequence

PP Seq

Parameters and sewing-program parameter screens

Pocket Program (PP) : parameters for programming the

Sequence (Seq) : programming pocket sequences Piece counter : daily piece counter

Piece counter

seam and the associated additional functions.

6.2 Running a machine program

–

Turn on the main switch. The controller is initialised.

–

The Dürkopp Adler Logo briefly appears in the display.

–

The controller checks the position of the transport carriage. The following display appears:

Info line:

Reference run

–

Start the reference run by pushing the left pedal back.

–

The display switches to the main screen of the sewing unit. You can switch from the main screen to the various parameter screens with function keys F1 or F2.

–

Press the RST key to leave the machine program. The controller is re-initialised.

6.3 Main screen

The main screen displays the seam pattern, sewing program, selected pocket sequence and important parameters.

Parameters can be individually selected by the user.

Info line

Seam pattern

The left half of the display shows the seam pattern of the selected pocket program.

Sequence

A box indicating the sequence appears in the top right-hand corner.

Selecting program number and pocket sequence

The selected pocket sequence is displayed in the top right-hand corner. If automatic pocket-program switching is on, arrows are displayed between the individual pocket programs of the sequence.

–

Select a pocket sequence with cursor keys “ñ”or“ò”.

“ò” : select next pocket sequence “ñ” : select previous pocket sequence.

Selecting a pocket program in the current pocket sequence

In the pocket sequence the selected pocket program is shown in reverse video.

–

Select a pocket program with cursor keys “ð”or“ï”. “ð” : select next pocket program “ï” : select previous pocket program.

Parameters

The symbols in the centre of the right half of the display give rapid access to important parameters. Up to ten parameters can be selected by the operator for display on the main screen (see also section 6.7).

Parameters can be changed directly on the decimal keypad. The number of the key to be pressed is displayed to the right of the parameter symbol.

Example:

0: carriage-return to stand-by position

1: slide-in velocity

2: flap sequence

3: holder

4: vacuum

5: breast welt

6: pocket-program name

7: save pocket program

8: smoother

9: smoother time

The functions and settings of individual parameters are described in more detail in section 5.4: Pocket programs.

The selection of the parameter symbols is described in section 6.7.

Info line

Text explaining the selected function is displayed in the information line.

Piece counter

The current piece count is displayed at bottom right (e.g. ).

The piece counter shows the number of pieces completed since the counter was last reset. The piece counter can be reset to “0" by pressing function key F5.

6.4 Pocket programs ( )

This menu item contains the parameters for programming the various pocket programs.

They are used to program the seam and its associated additional functions.

Info line:

Select pocket program

Pocket-program number

–

While the main screen is displayed press function key F1.

The display switches to the pocket-program screen. –

The pocket program currently selected is shown in the upper part

of the display (e.g. “PP : 01”).

The program name, if any, appears behind it (e.g. “<SAKKO>”). –

Select the required parameter with cursor keys “ï”or“ð”.

A black box appears under the symbol of the selected parameter. –

Change the selected parameter as described in section 4.2. –

Press function key F1 to switch back to the main screen.

This parameter selects the pocket program that is to be changed. On completion of the entry the new pocket program and its program

name appear in the top left-hand corner of the display. Entry: 1 .. 99

Programming the seam pattern

The actual pocket form is programmed under this menu item. The programmed pocket is shown with the corresponding information in the left half of the display.

The corresponding parameter symbols appear in the right half.

–

Select the required parameter with cursor keys “ï”, “ð”, “ñ”or “ò”. The symbol of the parameter selected appears in reverse video.

–

Press the OK key. The corresponding submenu is called.

Seam-start flap shape

This parameter is used to select the shape of the flap at the seam start. Three variants are available:

Straight flap

Slanting flap (left)

Slanting flap (right)

–

Select the required flap s hape with cursor keys “ï”or “ð”.

–

Press the “OK”key. The flap-angle entry window appears.

Flap angle

Entry: 01 … 13 [mm]

Seam-start pattern

This parameter selects the form of the seam pattern at the seam start.

Straight seam pattern

Slanting seam pattern (left)

Slanting seam pattern (right)

–

Select the required seam form with cursor keys “ï”or “ð”. –

Press the “OK”key.

The seam-angle entry window appears:

Seam angle

Entry: 01 … 13 [mm]

Seam-end flap shape

This parameter selects the form of the flap at the seam end. Three variants are available:

Straight flap

Slanting flap (left)

Slanting flap (right)

–

Select the required flap s hape with cursor keys “ï”or “ð”. –

Press the “OK”key.

The flap-angle entry window appears:

Flap angle

Entry: 01 … 13 [mm]

Seam-end pattern

This parameter selects the form of the seam pattern at the seam end.

Straight seam pattern

Slanting seam pattern (left)

Slanting seam pattern (right)

–

Select the required seam form with cursor keys “ï”or “ð”.

–

Press the “OK”key. The seam-angle entry window appears:

Seam angle

Entry: 01 … 13 [mm]

NB:

The seam-angle entry is checked. If the fixed sewing length and the values entered cannot be sewn on the machine, an automatic adjustment of the seam angle is carried out for the seam end.

Sewing-length measurement

Three different possibilities can be selected. Distance measurement, automatic recognition by light barrier and automatic recognition of the flap angle. An interlock system prevents more than one possibility from being selected. The other are blocked.

Distance measurement

In distance measurement the sewing length is displayed on the main screen.

Automatic recognition of flap beginning and flap end

In this setting the reflecting light barrier for the recognition of the flap beginning and flap end is switched on for sewing with flaps.

Maximum flap length Entry: 020 … 180 [mm] optional 220 mm

Automatic flap-angle recognition

Sewing with two light barriers for automatic flap-angle recognition.

Maximum flap length Entry: 020 … 180 [mm] optional 220 mm

Stitch length

Entry: 2.0 … 3.0 [mm]

Select flap side

The sewing length is equipped with a reflecting light barrier for the recognition of the seam start and end when sewing with flaps. The parameter indicates which side the flap is attached. When the parameter is changed the flap side of the seam pattern automatically switches in the display.

Flap left

Flap right

Seam-start mode left/right needle

Four different seam locks are available for the seam start. They can be set separately for the right and left needles.

Single bartack

Stitch compaction

Number of bartack stitches

Entry: 01 … 05 [stitches]

Number of stitch-compaction stitches

Entry: 01 … 10 [stitches]

Stitch-compaction stitch length / or bartack

Entry: 0.5 … 3.0 [mm]

Seam-end mode left/ right needle

Four different seam locks are available for the seam end. They can be set separately for the right and left needles.

Single bartack

Stitch compaction

Number of bartack stitches

Entry: 01 … 05 [stitches]

NB:

In zip-fastener mode the bartack length at the seam end is limited to a maximum of 3 mm.

Number of stitch-compaction stitches

Entry: 01 … 10 [stitches]

Stitch-compaction stitch length/ bartack

Entry: 0.5 … 3.0 [mm]

NB:

In a straight seam pattern only the left seam lock needs to be changed.

Selecting the positioning point

Depending on the type of piece being sewn, positioning takes place at the rear, centre or front positioning point.

Rear positioning point (with respect to the operator)

Centre positioning point

Front positioning point (w ith respect to the machine)

head)

Distance from the centre positioning point to the rear positioning point

Entry: 10 … 170 [mm]

NB:

The entry is checked. If the fixed sewing length and the value entered cannot be sewn on the machine, suitable values are automatically used.

Initialising program memory

The program function is to load standardised factory setting for the seam-pattern parameters.

–

Press function key F3.

“Initialise sewing program?” appears in the display. –

Press function key F5.

The parameters are reset to the factory-set values.

Light-barrier adjustment

This parameter is used to adjust the light barrier for the seam start and seam end.

Seam-start adjustment

Seam-end adjustment

Entry: -20.0 … + 20.0 mm

Selecting laser markings

A maximum of 16 lasers can be assigned to each pocket program.

With the number keys 1 to 8 on the numerical display the respective laser (1-8) can be switched on (with asterisk) or off (no asterisk).

With the “+” key and the number keys 1 to 8 on the number keypad the respective laser (+1-+8) can be switched on (with asterisk) or off (no asterisk).

1= * +1=*

2= * +2=* 3= +3= 4= +4= 5= +5= 6= * +6= 7= +7= 8= +8=

Sewing head

This parameter is used to change values affecting the sewing head.

Sewing speed

Entry: 2000 … 3000 [rpm]

Soft start

Entry: on/off

Soft-start speed

Entry: 0500 … 900 [rpm]

Number of soft-start stitches

Entry: 01 … 20 [stitches]

Reselect icon

Thread-clamp release stitches

Entry: 01 - 99

Sewing mode

Intermittent sewing

Continuous sewing

Centre blade

Entry: on/off

CAUTION:

Switching off the centre blade automatically switches off the corner blades too. However, switching the centre blade back on does not automatically switch the corner blades back on again. They must be switched on separately.

Centre-blade rpm

Entry: 1700...3000 [rpm] Select with the “ñ”or“ò”keys.

+ Adjusting the centre-blade incision at the seam start

- Changing this value carries out the fine adjustment of the centre-blade incision at the seam start.

Entry: - 9.9 … + 9.9 0 = no adjustment

+ = switch on centre blade

sooner

- = switch on centre blade later

+ Adjusting the centre-blade incision at the seam end

Entry: - 9.9 … + 9.9 0 = no adjustment

+ = switch off centre blade

sooner

- = switch off centre blade later

Corner blades

Manual corner-blade station

Switching c orner blades on/off

Entry: on/off

Info line:

Corner blades on/off

All four corner blades on/off

Left corner-blade incision at seam start on/off

Right corner-blade incision at seam start on/off

Left corner-blade incision at seam end on/off

Right corner-blade incision at seam start on/off

Adjusting the corner-blade incision at the seam start

Changing this value carries out the fine adjustment of the corner-blade incision at the s eam start.

Entry: -20,0 … +20,0 0 = no adjustment

+ = corner-blade position

sooner

- = corner-blade position later

Adjusting the corner-blade incision at the seam end

Changing this value carries out the fine adjustment of the corner-blade incision at the s eam end.

Entry: -20,0 … +20,0 0 = no adjustment

+ = corner-blade position

sooner

- = corner-blade position later

Automatic corner-blade station

Switching c orner blades on/off

Entry: on/off

Info line:

Corner blades on/off

All four corner-blades on/off

Left corner-blade incision at seam start on/off

Right corner-blade incision at seam start on/off

Left corner-blade incision at seam end on/off

Right corner-blade incision at seam end on/off

+ Adjusting the left-corner-blade incision at the seam

start

Changing this value carries out the fine adjustment of the left-corner-blade incision at the seam start.

Entry: - 20.0 … + 20.0 0 = no adjustment

+ = corner-blade position

sooner

- = corner-blade position later

+ Adjusting the right-corner-blade incision at the seam

start

Changing this value carries out the fine adjustment of the right-corner-blade incision at the seam start.

Entry: - 20.0 … + 20.0 0 = no adjustment

+ = corner-blade position

sooner

- = corner-blade position later

+ Adjusting the left-corner-blade incision at the seam

end

Changing this value carries out the fine adjustment of the left-corner-blade incision at the seam end.

Entry: - 20.0 … + 20.0 0 = no adjustment

+ = corner-blade position

sooner

- = corner-blade position later

+ Adjusting the right-corner-blade incision at the seam

end

Changing this value carries out the fine adjustment of the r ight-corner-blade incision at the seam end.

Entry: - 20.0 … + 20.0 0 = no adjustment

+ = corner-blade position

sooner

- = corner-blade position later

Tape feed

Switching t he tape feed on/off

Entry: on/off

Seam-start tape-length

Entry: 00.0 … 99.9 mm

Seam-end tape-length

Entry: 00.0 … 99.9 mm

Flap sequence

No flap clamps

Close left flap clamp first, then right

Close right flap clamp first, then left

Close both flap clamps simultaneously

Only right flap clamp present

Only left flap clamp present

Switching t he holder on/off

Entry: on/off

Switching t he vacuum on/off

Entry: on/off

Smoother

Switching t he smoother on/off

Entry: on/off

Smoother time

Entry: 010 … 1000 [strokes]

1 stroke = 0.001 s

Smoother velocity

Entry: 1 … 15 1 = minimum 15 = maximum

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