Duerkopp Adler 511 Operating Instruction

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511

CNC-Automat für Riegel- und Kurznähte

CNC automat for bartacking seams

and short seams

Bedienanleitung / Operating Instructions

Aufstellanleitung / Installation Instructions

Serviceanleitung / Service Instructions

Postfach 17 03 51, D-33703 Bielefeld  Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 5 21/ 9 25-00  Telefax+49(0)521/9252435 www.duerkopp-adler.com

Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:

08/2009 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 511001

Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG verboten.

Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner, even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.

Dürkopp Adler AG - 2009

Foreword

This instruction manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations.

The instruction manual contains important information on how to operate the machine securely, properly and economically. Observation of the instructions eliminates danger, reduces costs for repair and down-times, and increases the reliability and life of the machine.

The instruction manual is intended to complement existing national accident prevention and environment protection regulations.

The instruction manual must always be available at the machine/sewing unit.

The instruction manual must be read and applied by any person that is authorized to work on the machine/sewing unit. This means:

– Operation, including equipping, troubleshooting during the work

cycle, removing of fabric waste,

– Service (maintenance, inspection, repair) and/or

– Transport.

The user also has to assure that only authorized personnel work on the machine.

The user is obliged to check the machine at least once per shift for apparent damages and to immediatly report any changes (including the performance in service), which impair the safety.

The user company must ensure that the machine is only operated in perfect working order.

Never remove or disable any safety devices.

If safety devices need to be removed for equipping, repairing or maintaining, the safety devices must be remounted directly after completion of the maintenance and repair work.

Unauthorized modification of the machine rules out liability of the manufacturer for damage resulting from this.

Observe all safety and danger recommendations on the machine/unit! The yellow-and-black striped surfaces designate permanend danger areas, eg danger of squashing, cutting, shearing or collision.

Besides the recommendations in this instruction manual also observe the general safety and accident prevention regulations!

General safety instructions

The non-observance of the following safety instructions can cause bodily injuries or damages to the machine.

1. The machine must only be commissioned in full knowledge of the

2. Before putting into service also read the safety rules and

3. The machine must be used only for the purpose intended. Use of

4. When gauge parts are exchanged (e.g. needle, presser foot, needle

5. Daily servicing work must be carried out only by appropriately

instruction book and operated by persons with appropriate training.

instructions of the motor supplier.

the machine without the safety devices is not permitted. Observe all the relevant safety regulations.

plate, feed dog and bobbin) when threading, when the workplace is left, and during service work, the machine must be disconnected from the mains by switching off the master switch or disconnecting the mains plug.

trained persons.

6. Repairs, conversion and special maintenance work must only be carried out by technicians or persons with appropriate training.

7. For service or repair work on pneumatic systems, disconnect the machine from the compressed air supply system (max. 7-10 bar). Before disconnecting, reduce the pressure of the maintenance unit. Exceptions to this are only adjustments and functions checks made by appropriately trained technicians.

8. Work on the electrical equipment must be carried out only by electricians or appropriately trained persons.

9. Work on parts and systems under electric current is not permitted, except as specified in regulations DIN VDE 0105.

10. Conversion or changes to the machine must be authorized by us

and made only in adherence to all safety regulations.

11. For repairs, only replacement parts approved by us must be used.

12. Commissioning of the sewing head is prohibited until such time as

the entire sewing unit is found to comply with EC directives.

13. The line cord should be equipped with a country-specific mains

plug. This work must be carried out by appropriately trained technicians (see paragraph 8).

It is absolutely necessary to respect the safety

instructions marked by these signs.

Danger of bodily injuries !

Please note also the general safety instructions.

Contents Page:

Preface and General Safety Instructions

Part 1: Operating Instructions for Class 511

(Edition 08/2009)

1. Product Description ........................................... 3

2. Proper and Intended U se ........................................ 4

3. Sub-classes ................................................. 5

4. Additional Equipment .......................................... 5

5. Frame ..................................................... 6

6. Technical Specifications......................................... 6

6.1 Sub-class-specifictechnicalparameters................................ 7

7. Operations

7.1 Threading the needle thread ....................................... 8

7.2 Adjusting the needle thread tension ................................... 9

7.3 Opening the needle thread tension ................................... 9

7.4 Adjusting the thread regulator ...................................... 10

7.5 Winding the bobbin thread ........................................ 11

7.6 Replacing the shuttle bobbin ....................................... 12

7.7 Adjusting the bobbin thread tension ................................... 13

7.8 Replacing the needle ............................................ 14

8. Operating the 511 Controller

8.1 The control panel .............................................. 15

8.1.1 Thekeys ................................................... 15

8.2 Userinterface................................................ 17

8.2.1 Structureofmenu.............................................. 17

8.3 Alternumericalvalues,parametervalues,selectionofalternatives................ 18

8.3.1 Alternumericalvalues........................................... 18

8.3.2 Selectionofaparameter.......................................... 19

8.3.3 Selectionofalternatives.......................................... 19

8.4 Seampattern ................................................ 20

8.5 Powersavingmode............................................. 20

Contents Page:

8.6 Mainmenu.................................................. 21

8.6.1 Seam pattern operation .......................................... 21

8.6.2 Programmingmode............................................. 26

8.6.3 Seam pattern sequences ......................................... 30

8.6.3.1 Switching the sequence programming mode on or off ........................ 30

8.6.3.2 Programming a sequence ......................................... 33

8.6.4 Technicianmode .............................................. 34

8.7 DistributorPCB............................................... 78

8.8 Error messages ............................................... 80

8.8.1 Error categories ............................................... 80

8.8.2 Application messages ........................................... 81

8.8.3 Machine faults (DACIII) .......................................... 83

9. Sewing .................................................... 87

10. Maintenance

10.1 Cleaning and checking ........................................... 88

10.2 Oillubrication................................................ 89

11. Standard Seam Patterns ......................................... 90

12. Clamping Feet ............................................... 97

1. Product Description

The Dürkopp Adler 511 is a CNC machine for bartacking seams and short seams. The available standard bartacks are size-adjustable and can additionally be saved in this modified shape.

Free seam contours can be programmed directly at the control panel without any further devices.

Technical features

–

DAC control unit with control panel. The following functions are available:

–

50 standard bartacks. These bartacks can temporarily be modified in respect to length, width and speed. When switching off the machine, the modified values of the bartack last sewn are maintained.

–

40 modified bartacks can also be saved.

–

9 free seam contours with a total of 5000 available stitches canalsobesaved. So it is possible to attach small appliqués. The coordinates are entered at the control panel. No further devices are required.

–

25 seam pattern sequence programs with up to 20 seam patterns per seam pattern sequence program can be created and saved.

–

The coordinates are entered with a precision of 0.1 mm.

–

If there is a rectangular contour of the fabric clamping feet, the modification of bartacks is automatically checked in order to avoid a collision of needle and fabric clamping feet.

–

Counters are available for capacity and daily number of pieces.

–

Bartacks and seam pattern sequence programs and the modification of special bartacks can be blocked.

–

The speed can be changed from 0 rpm (manual operation with full operability of the x-y drive) up to 2700 rpm in steps of 100 rpm.

–

Fabric drive via two step motors.

–

Drive of the automatic bartacker directly at the arm shaft via brushless direct current motor.

–

Maximum sewing field size 40 x 20 mm.

–

Oil wick lubrication of arm shaft and driving shaft with two oil reservoirs.

–

Service and maintenance work is supported by a comprehensive test programs.

2. Proper and Intended Use

The class 511 machine is a bartacking machine designed for s ewing light to medium-heavy material. Such material is generally made of textile fibres, but it may also be leather. Such fabrics are used in the clothing industry and for domestic and motor-vehicle upholstery.

Furthermore, this automatic bartacker can also sew “technical” seams. In such a case, the operator must assess the possible dangers which may arise (preferably in conjunction with DÜRKOPP ADLER AG). Such applications are relatively unusual and also so varied that no single set of criteria can cover them all. You may need to take appropriate safety measures based on the outcome of this assessment.

Generally, only dry fabrics can be processed on this automatic bartacker. The material may be no thicker than 10 mm when compressed by the lowered sewing feet. The material should not contain any hard objects. If hard objects are present, the machine must be operated with protective eye wear. We currently do not provide such eye protection.

In general the seam is produced with sewing threads made of textile fibres (cotton threads, synthetic threads or core threads) with the following dimensions: Class 511-211/212 threads of the dimension 50/3 - 120/3 Class 511-213/214 threads of the dimension 30/3 - 120/3 If other threads are to be used, it is important to consider the possible risks and to take corresponding safety measures.

This automatic bartacker must only be installed and operated in dry and well-kept rooms. If it is operated in other spaces which are not dry and well-kept, further measures may need to be agreed upon (see EN 60204-31: 1999).

As manufacturers of industrial sewing machines, we proceed on the assumption that personnel who work on our products will have received training at least sufficient to acquaint them with all normal operations and with any hazards which these may involve.

3. Sub-classes

Class 511-211 Automatic single-needle lockstitch bartacker with thread trimmer and

thread wiper. Equipped with special sewing equipment for general bartacking operations in outer garments.

With electro-magnetic sewing foot lift.

Class 511-212 Automatic single-needle lockstitch bartacker with thread trimmer and

thread wiper. Equipped with a contraction clamp specially for bartacking double-chainstitch buttonholes. With electro-magnetic sewing foot lift.

Class 511-213 Automatic single-needle lockstitch bartacker with thread trimmer and

thread wiper. Equipped with special sewing equipment for particularly thick fabrics. Field of application: General bartacking operations, e.g. bartacking of loops, pockets or fly pieces in jeans or working clothes. With electro-magnetic sewing foot lift.

Class 511-213 Automatic single-needle lockstitch bartacker with thread trimmer and

thread wiper. Equipped with a special sewing equipment for particularly thick fabrics. Field of application: General bartacking operations, e.g. bartacking of loops, pockets or fly pieces in jeans or working clothes. With electro-magnetic sewing foot lift.

4. Additional Equipment

The following optional equipment is available for the automatic bartacker 510:

Order no. Optional equipment

Refer to Parts List Special clamping foot set (optional/special manufacture, APC)

0510 59 015 4 Electric thread wiper (511-211, -213, -214) 0510 59 006 4 Pneumatic sewing foot lifting (511-211, -213, -214) 0510 59 012 4 Separate pneumatic sewing foot lift (pneum. control unit)

and sewing foot lift arm are on right and left (511-211, -212, -213, -214).

9780 00 010 8 Maintenance unit 0510 59 009 4 Conversion set for -211 to -213 0510 15 001 4 Large capacity hook; conversion kit for classes (511-211, -212, -213) 0510 59 004 4 Laser marking light (3 lights) 0510 59 003 4 Additional laser light 0510 59 005 4 Hand switch 9822 51 002 6 Sewing light 9822 51 002 7 Table clamp 9870 00 102 1 Cable assembly K (add-on kit socket for sewing light)

5. Frame

The following stand is available for the automatic bartacker 511:

MG55 40 029 4 Stand package

Table top size 600 x 1060 mm

Stand height 1160 to 1305 mm

MG53 40 148 4 Stand package (China)

Table top size 600 x 1060 mm

Stand height 1160 to 1305 mm

6. Technical Specifications

Noise level: Lc = 78dB (A)

Workplace-related emission value according to DIN 45635-48-A-1-KL-2:

Bartack length: 15 mm Stitch/bartack: 28

Throw width: 2.5 mm Speed: 2700 min

Fabric: G1 DIN 23328 two-ply Sewing cycle: 1.3 sec on and 1.0 sec off

-1

6.1 Sub-class-specific technical parameters

Sub-class: -211 -212 -213 -214

Stitch type: 301 301 301 301

Hook type: oscillating hook

Needle system: DPx5 (134) DPx17 (135x17)

Needle size: [Nm] 90 90 120 120

Needle size [Nm] standard production:

Thread size: 50/3 - 120/3 50/3 - 120/3 30/3 - 120/3

Stitch length: [mm] dependent on seam pattern

Max. speed [min-1] 2700

Clamp stroke [mm] Delivery 13

maximum 17

Sewing field size [mm] Max. in X-direction: 40

Max. in Y-direction: 20

Number of standard bartacks 50

Number of storable modifiable bartacks 40

Number of seam-pattern sequence programs 25

Number of seam patterns per seam-pattern sequence program 20

Soft start: connectable / dis-connectable

Operating pressure: [bar] 6

Air consumption: [NL] 3

Sewing drive: DC motor

Rated voltage: [V] 1 ~ 230V/ 50/60 Hz

Rated load: [kW] 0.45

Length, width, height [mm] 730 / 1060/ 1160 - 1305

Weight [kg] 125

7. Operations

7.1 Threading the needle thread

Caution – Risk of Injury !

Turnthemainswitchoff! Insert the needle thread only when the automatic bartacker

is switched off.

–

Put thread reels on the thread reel holder and insert needle thread and bobbin thread through the unwinding arm. The unwind holder must be perpendicular to the reel.

Thread the needle thread as shown on the following illustration.

7.2 Adjusting the needle thread tension

321

Pretension 3

With the main tension 2 open, a minor residual stress of the needle thread is required. This residual tension is created by the pre-tensioner 3.

The pre-tensioner 3 influences both the length of the cut needle thread and the starter thread for the next seam.

–

Shorter starter thread: Turn knurled nut 1 in clockwise direction.

–

Longer starter thread: Turn knurled nut 1 counter-clockwise.

Main tension 2

The control unit is used to adjust the main tension 2. A maximum of five thread tension ranges can exist for one seam pattern. (Refer to the chapter on “Controller Operations”.)

7.3 Opening the needle thread tension

Automatic

The needle thread tension is automatically opened when trimming the thread and when lifting the fabric clamping feet.

7.4 Adjusting the thread regulator

32 1

Caution – Risk of Injury !

Turnthemainswitchoff. Adjust thread regulator only when the automatic bartacker is switched

off.

The thread regulator 3 is used to control the quantity of needle thread required by the stitch formation. The best s ewing results can only be ensured when using a precisely adjusted thread regulator.

At the properly adjusted setting, the needle thread loop must be able to slide over the thickest section of the hook.

–

Loosen screw 1.

–

Change the position of the thread regulator 3. Thread regulator to the left = more thread. Thread regulator to the right = less thread.

–

Tighten screw 1.

Settings note:

If the largest thread quantity is required, the thread controller spring 2 must be pulled down by approx. 0.5 mm from its upper end position. This occurs when the needle thread loop passes the section of the hook with the widest diameter.

7.5 Winding the bobbin thread

: Off

:On : ...

–

Put bobbin on bobbin winder 4.

–

Pull thread through guide 2 and around tension 1.

–

Wind thread counter-clockwise around the core of the bobbin (approx. 5 times).

–

Press the bobbin-winder lever 3 in the bobbin.

–

Sew. The winder lever stops as soon as the bobbin is full.

–

Tear off thread at thread clamp 5 after winding up is finished.

Note!

If the thread is to be wound on without sewing, the thread winding mode can be altered in sub-menu “Special functions”.

If the thread winding mode is active, the sewing motor can be started via pedal or push button independent of the sewing field drive (unthread at the thread lever).

For adjustment, see chapter 8.5.1 “Thread winding mode”.

7.6 Replacing the shuttle bobbin

Caution – Risk of Injury !

Turnthemainswitchoff. Change hook thread bobbin only when automatic bartacker

is switched off.

Taking off the empty bobbin

–

Pull down hook cover 3.

–

Raise up the bobbin enclosure hood 1.

–

Take out the upper part of the bobbin enclosure 2 with the bobbin 6.

–

Remove the empty bobbin from the upper part of the bobbin enclosure 2.

Inserting a full bobbin

–

Place full bobbin in the top of bobbin case 2.

–

Thread bobbin thread through slot 5 below tension spring 7 in the drill-hole 4.

–

Pull out the tension spring from the bobbin enclosure 2 about

2.5 cm. When the thread is being pulled out, the bobbin must rotate in the direction shown by the arrow.

–

Replace bobbin housing 2.

–

Close bobbin enclosure hood 3.

7.7 Adjusting the bobbin thread tension

Caution – Risk of Injury !

Turnthemainswitchoff. Adjust the bobbin thread tension only when the automatic bartacker is

switched off.

The required bobbin thread tension should be generated by tension spring 1. The top of bobbin case 3 should drop slowly due to its own weight when being held at the threaded-in bobbin thread.

Setting the tension spring

–

Take off top of bobbin case 3 with the bobbin.

–

Adjust tension spring 1 at the regulating screw 2 until the required tension value is reached.

–

Reinsert top of the bobbin case.

7.8 Replacing the needle

Caution – Risk of Injury !

Turnthemainswitchoff. Change the needle only when the automatic bartacker is switched off.

–

Loosen screw 1.

–

Push in the new needle until it reaches the limit stop in the hole for the needle bar 2.

CAUTION !

The hollow groove 3 of the needle must point to the hook.

–

Tighten screw 1.

CAUTION !

After the changeover to another needle size, the distance between hook and needle has to be corrected (see service instructions).

8. Operating the 511 Controller

8.1 The control panel

A control panel with an LCD display and function keys is used for input and output of data.

8.1.1 The keys

Function key Function

Cursor keys

If no text field is activated:

Press the “ï” key to return from a sub-menu to the parent menu.

If a text field is activated:

Change between the points (this does not refer to the selection of seam patterns or sequences).

In the sewing mode during sequence operation: Change to the next or to the preceding seam pattern.

Function key Function

If no text field is activated:

Change between the lines of the menus. The selected line is displayed white on black.

If a text field is activated:

Increase or reduce the value of the respective point by one, or change between the parameters in the event that there are functions with several choices.

OK key If no text field is activated:

Activate the text field. The value can be altered with the “ñ” and “ò”keys.

If a text field is activated:

The set value is applied.

If the clamping foot has been lowered using the keys OK + F:

The test procedure will be started.

ESC key If test functions are activated (Multitest / 180° disc):

You return to the selection menu.

If a text field is activated:

An input will be aborted. The preceding value is maintained.

In the technician and programming level

The control changes over to the sewing mode.

In the sewing mode:

Lift clamping foot and stop sewing operation.

P key The control unit changes over from the sewing mode to the

programming mode. In this mode, altered stitch patterns can be saved under a new program number.

S key The control unit changes over from the sewing mode or seam pattern

programming mode to the sequence programming mode. In this mode it is possible to create new sequences or to alter existing ones.

F key The control changes over from the sewing mode to the technician

mode. This mode can only be activated after a code has been entered. In this operating status it is possible to set basic machine parameters and to retrieve diagnostic and adjustment programs.

8.2 User interface

8.2.1 Structure of menu

ESC key ESC key

Turn on main switch

Fkey

Code 1

Sewing mode

Fkey

P key Code 1

Service

Key

Programming mode ESC Technician mode

Skey

Pkey

Sequence programming mode

Call up the service mode

–

Press the function key “F” and keep it pressed.

–

Turn on the main switch. The control unit is initialized. After a short while, the window for entering the code number will appear.

–

Enter the code number (code 1, refer to chapter 8.5.4). The display changes to the service menu.

Call up the technician mode

–

Turn on the main switch. The control unit is initialized. The sewing mode menu appears on the display.

–

Press the “F” key.

–

Enter Code 1 (see Chapter 8.5.4).

–

Press the “OK” key.

–

The display changes over to the technician mode.

8.3 Altering numerical values, parameter values and selection of alternatives

8.3.1 Alter numerical values

–

Select the desired line with the “ñ” and “ò”keys.

–

Press the “OK” key. The chosen numerical value is marked by a blinking cursor.

–

Change between the points with the “ï”or“ð”keys. Increase or reduce the value of the selected point by one with the

“ñ” and “ò”keys.

–

Press the “OK” key. The currently set value is applied.

or –

Press the “ESC” key. The original value is maintained.

Note

All values can only be altered within the range of minimum and maximum values.

8.3.2 Selection of a parameter

Some parameters offer a selection of non-modifiable adjustments.

–

Select the desired line with the parameter to be altered with the “ñ ” and “ò”keys.

–

Press the “OK” key.

–

Change between the given possibilities with the “ñ” and “ò”keys. For example:

Seam pattern number

–

Press the “OK” key.

The currently set parameter is applied. Or –

Press the “ESC” key.

The original parameter is maintained.

8.3.3 Selection of alternatives

Some menu items can be selected alternatively. The current selection is marked with a checkmark (...ü).

If another alternative is selected, the marking of the current choice is removed and the new menu item is marked.

Alternatively selectable items are set off against other menu items by a separating line.

8.4 Seam pattern

Three different seam pattern types are available for the automatic bartacker 511:

Specified standard seam patterns (Type 1) (see chapter 11):

The sewing parameters length, width and sewing speed can be altered in the sewing mode; the laser marking lamps can be switched on and off. The alterations are saved. However, after selection of another seam pattern, the alterations will be lost. For these seam patterns the seam pattern numbers 1 to 50 are available and cannot be deleted or overwritten.

Programmable seam patterns (Type 2)

Specified standard seam patterns can be altered in the programming level (length, width, sewing speed, laser light 1 to 8) and saved under a new program number. For these seam patterns, the seam pattern numbers 51 to 90 are available and can be deleted or overwritten.

Free seam contours (Type 3):

For these seam contours, the seam patterns numbers 91 to 99 are available. The creation of free seam contours is described in chapter 8.5.4.4. The sewing parameters length, width and sewing speed can be altered in the sewing mode; the laser marking lamps can be switched on and off. The alterations are saved. However, after selection of another seam pattern, the alterations will be lost.

8.5 Power saving mode

Power saving mode is activated after an adjustable interval (1 – 60 min) by using t5 in the Machine Configuration/Times menu. Power saving mode can be deactivated by setting t5 to 0.

The clamping foot descends when it is activated in order to save power. This also reduces the generation of heat.

The defined time elapses when there is no user input is carried out on the control panel, pedal or hand switch.

Before the power saving mode activates, a message indicating that the clamping foot will descend flashes twice as an alert.

After that, the message stays on the screen. As soon as a user operates the control panel, pedal or hand switch, the

normal mode of operations is resumed. The clamping foot is then raised and the message is no longer displayed.

The machine is now ready for use.

8.6 Main menu

8.6.1 Seam pattern operations

The parameters for the individual seam patterns are found in the main menu.

The seam patterns can be altered using these parameters.

–

Turn on the main switch.

The control unit is initialized.

The main menu appears. –

Select the desired parameter with the “ñ” and “ò”keys.

The symbol of the selected parameter is displayed white on black. –

Alter selected parameter as described in chapter 8.3.

Menu option

The symbol in the top left corner of the display describes the currently selected menu item.

Bartack pattern

The symbol at the bottom left of the display shows the current bartack pattern.

Seam pattern

This parameter is used to select the seam pattern to be sewn.

Selection: 1 – 51 (52 to 99 if available)

Speed

The desired speed is set using this parameter. Input: 0 to 2700 rpm

Thread tension in range 1 (refer to table 1) Input: 0 – 100 0 = lowest thread tension

100 = highest thread tension

The thread tension magnet adjusts the thread tension according to the current value so that it can then be checked.

The thread tension values for all further ranges in the seam pattern are set as the difference to the previous value.

For the standard seam patterns (1 – 50), the thread tension cannot be individually set for the different ranges. If this is required, then a seam pattern program must be created.

Sub-menu for seam pattern size and offset

Select this sub-menu to set the seam pattern length and width.

Display: current length/width

Width

Setting the seam pattern width Input: 0.1 – 40 [mm]

Length

Setting the seam pattern length Input: 0.1 – 20 [mm]

X Offset

Setting the seam pattern offset in the X-direction.

Input: -20.0 – +20.0

Y Offset

Setting the seam pattern offset in the Y-direction.

Input: -10.0 – +10.0

When switching to this menu, the clamping foot will be lowered. If the value for the X- and Y-Offset is changed, the stepping motors will move the material accordingly. When exiting the sub-menu, the clamping foot will then be raised again.

Caution – Risk of Injury !

Do not reach into the working area of the machine while you are in this sub-menu and performing changes on the seam pattern offset.

Number of stitches

The number of stitches is indicated on this menu line (it cannot be modified).

When selecting the line with the “OK” key, the sub-menu “Special functions” is opened.

When selecting the line with the “OK” key, the sub-menu “Counter of daily number of pieces/Counter of capacity” is opened.

Reset counter for daily number of pieces

–

Select the menu item by using the “ñ” and “ò”keys. –

Press the “OK” key for 3 seconds until the displayed piece count is

reset to 0.

The daily piece count can be reset in this way. However when the capacity status is displayed, the value cannot be reset to 0 in this way.

Capacity counter

When selecting the line with the “OK” key, the sub-menu “Counter of daily number of pieces/Counter of capacity” is opened.

Sub-menu “Special function and soft start status”

Thread winding mode

The bobbin thread winder can be operated separately. At the setting “ON”, the sewing motor can be started independent of the step motors using the pedal or key.

Input: ON / OFF

Winding thread onto a bobbin:

With the pedal: –

Step pedal forwards (step 2). The sewing motor starts.

–

Step pedal backwards. The sewing motor stops.

With the control panel –

Press the “F” key. The sewing motor starts.

–

Press the “ESC” key. The sewing motor stops.

With push button (optional) –

Press button 2. The sewing motor starts.

–

Press button 1. The sewing motor stops.

Soft start

The soft start can be switched on or off using this parameter. Input: ON / OFF

Sub-menu laser marking light (optional)

This menu item is only available when the laser light

option in the Configuration menu is activated.

Laser light 1 – 3

Switching on/off for the laser marking light 1 to 3. Input: ON / OFF

Sub-menu for counter of daily number of pieces or counter of capacity

.......

(5000)

=?: 5000

SÖ

-: On

Alternative display of counter of daily number of pieces or counter of capacity.

Both counters work in parallel. You can select which c ounter is displayed in the main menu.

The counter of the daily number of pieces counts the number of the

sewn seam patterns

Display: 0 – 65000

The bobbin thread counter counts backwards.

When the value “0" is reached and a sewing operation is started, a

message is shown.

Display: 9999 – 0 –

Press the “ESC”key.

Back to the main menu.

If the daily piece counter is set, the following display appears:

Displaying the daily piece in sewing mode: Input: Select using the “OK” key

Displaying the counter of capacity in sewing mode: Input: Select using the “OK” key

Counter of capacity ON/OFF

Input: ON/OFF

Initial value counter of capacity

Input: 0 ... 9999

8.6.2 Programming mode

:51

:1 : 2700 :25 : 16.0/ 2.0 : 0.0/ 0.0 :42 :On

Under this menu item, the parameters for programming of seam patterns are arranged.

With the help of these parameters, the shape, length, width and speed of the seam pattern are specified.

–

Turn on the main switch. The control unit is initialized. The main menu appears.

–

Press function key “P” on the main menu. The display changes over to the menu of the programming mode.

–

Select the desired parameter with the “ñ” and “ò”keys.The symbol of the selected parameter is displayed white on black.

–

Alter the selected parameter as described in chapter 8.3.

Number of seam pattern

The number of the seam pattern to be created or altered is selected using this parameter.

When preparing a new program, an asterisk (*) is indicated before the number.

Input: 51 90 –

Select the desired seam pattern program with the “ñ” and “ò” keys.

–

Press the “OK” key. The program is activated.

Basic seam pattern

Using this parameter, a standard seam pattern can be selected on the basis of which the new seam pattern is to be created.

Input: 1 50 or

91 99 if available

Sewing speed

Using this parameter, the desired sewing speed can be adjusted. Input: 0 – 2700 [rpm]

Sub-menu for thread tension

The thread tension values for the ranges in the current seam pattern are specified here.

Sub-menu for thread tension: The thread tension sub-menu for the cross-tack seam pattern.

Thread tension in range 1 (linear thread tension) Thread tension in range 2 (zig-zag thread tension) Thread tension in range 5 (thread tension at seam end) Input: 0 100 ,

0 = lowest thread tension 100 = highest thread tension

All values can be set independently from each other.

The adjustable tension values for all additional standard seam patterns can be taken from the following table.

A maximum of five thread tension ranges can exist for one seam pattern. At the programming level, another tension value can be specified for each range. The ranges are defined internally for the standard seam pattern. They can be programmed as desired for the free seam contours. The first tension range (1) is available for all types of seam patterns and also for the free seam contours.

The thread tension can be distinctly adjusted in the individual ranges only when working with the seam pattern programs. For standard seam patters, only the thread tension in the first range can be set. The other ranges are then changed accordingly.

Seam pattern Thread tension Description Tack type No. Range

Cross tack 1 - 16 1 Linear thread tension

2 Zig-zag thread tension

5 Seam-end thread tension

Straight-lined cross tack 17 - 22 1 Linear thread tension

5 Seam-end thread tension

Longitudinal tack 23 - 26 1 Linear thread tension

2 Zig-zag thread tension

5 Seam-end thread tension

Straight-lined longitudinal tack 27 - 30 1 Linear thread tension

5 Seam-end thread tension

Circular tack, stitched eyelet 31 - 34 1 Thread tension right

2 Thread tension left

3 Zig-zag thread tension

(only stitched eyelet)

5 Seam-end thread tension

D tack 35 - 44 1 Linear thread tension

2 Half-circle thread tension

3 Zig-zag thread tension

5 Seam-end thread tension

Imitated button-hole tack 45 - 46 1 Seam-end thread tension

2 Zig-zag thread tension

5 Seam-end thread tension

Circular tack 47 - 48 1 Thread tension up/down

2 Thread tension left diagonal

3 Thread tension right diagonal

5 Seam-end thread tension

Tri-tack 49 - 50 1 Linear thread tension

2 Triangular thread tension

3 Zig-zag thread tension

5 Seam-end thread tension

In the thread tension menu found on the seam-pattern programming level, the ranges are displayed in the menu bar and also as an icon at the bottom left. The range numbers are only displayed when working with a free seam contour or a seam-pattern program with a free seam contour as a base seam pattern.

Sub-menu for seam pattern dimension

Select this sub-menu to set the seam pattern length and width. Display: current length/width

Sub-menu for seam pattern offset

Select this sub-menu to set the seam pattern offset in the X and Y directions.

Display: current X/Y offset values

Number of stitches

Only indicates the number of stitches.

Soft start

The soft start can be switched on or off using this parameter. Input: ON / OFF

First clamp (optional)

With this menu item you can set which part of the clamping foot (left or right) will be lowered first. The menu item will only be displayed if the “lower clamping foot separately” option is activated in the Configuration menu.

Input: ½ (left/right)

Sub-menu for laser marking light (optional)

This menu item will only be displayed if the option Laser light is activated in the Configuration menu.

Laser lights 1 – 3

Switching on/off for the laser marking lights 1 to 3. Input: ON / OFF

8.6.3 Seam pattern sequences

8.6.3.1 Switching the sequence programming mode on or off

Changeover from seam pattern operations to the seam pattern sequence operations

–

Press the function key “S” while the main menu is being displayed in order to go to the sequence programming mode.

–

Start the editing by pressing the “OK” key.

–

Select any sequence by using the “ñ” key (1-25)

–

Confirm the selection with the “OK” key. The seam pattern sequence operation is switched on.

–

Press the “ESC” key or the “ï”key. The main menu for the seam pattern sequence operation will be displayed

The sequence number and sequence items in the main menu will be described at the end of this section.

Switching from seam pattern sequence operation to seam pattern operation

–

Press the function key “S” while the main menu is being displayed

in order to go to the sequence programming mode.

–

Start the editing by pressing the “OK”key. –

Select the sequence number 0 by using the “ò “key. –

Confirm the selection with the “OK”key.

The seam pattern sequence operation is switched off. –

Press the “ESC” key or the “ï “key.

The main menu for the seam pattern operation will be displayed.

Menu items in the main menu for the seam pattern sequence

Sequence

Selection of the seam pattern sequence. Input: 1 (2 – 25, if available)

Sequence succession

Display of the sequence succession. The current seam pattern number is marked with a bar (underlined).

If there are more than five numbers, the display is scrolled.

Further seam patterns on the right:

Further seam patterns on the left:

Further seam patterns left and right:

Automatic operations

After the completion of a seam pattern, the control unit changes over to the next seam pattern shape automatically. After sewing of the last seam pattern, the control unit changes over to the first seam pattern within the sequence again. The current seam pattern is marked by a bar below the number. The shape of the selected seam pattern is indicated on the left half of the display.

Manual operations

The control unit does not change between the seam patterns automatically.

–

Select the next seam pattern with the “ï”or“ð”keys. The shape of the selected seam pattern is indicated on the left half of the display.

Changing between automatic and manual operations

–

Select the second menu line with the “ñ” and “ò”keys (sequences) .

–

Press the “OK” key.

–

Select the mode of operation with the “ñ” and “ò”keys. For automatic operation, arrows are indicated between the seam patterns.

Automatic operations

Manual operations

8.6.3.2 Programming a sequence

In this menu item, individual seam patterns are combined to form retrievable seam pattern sequences. A total of 25 independent seam pattern sequences are available. Every seam pattern sequence can be combined out of 20 seam patterns in any order.

The seam pattern sequence operations can also be turned on in this menu.

–

Turn on the main switch.

The control unit is initialized.

The main menu appears. –

Press function key “S” in the main menu.

The display changes over to the menu of the sequence

programming mode. –

Select desired menu item with the “ñ” and “ò”keys.

The menu line is displayed white on black. –

Press the “ESC ”or“ï”key.

Back to the main menu.

Sequence number/ seam pattern sequence operation

Selection of the sequence to be created or to be altered. When preparing a new program, an asterisk (*) is indicated before the number.

Input: 0 – 25 –

Select the desired sequence number with the “ñ” and “ò”keys.

If the seam pattern sequence operation should be switched off,

select the s equence number 0.

The menu line is displayed white on black. –

Press the “OK” key.

The program is activated.

Seam pattern number (1 – 20)

With this menu item, you can select the seam pattern number to be taken up in the current sequence.

Input: 1 51 (52 – 99 if available)

8.6.4 Technician mode

The following menus are included in the technician mode:

Machine configuration

In this menu, machine-specific adjustments are made.

User configuration

In this menu, operation-specific adjustments are made.

Service functions

These service functions allow a quick verification of all hardware components.

Free contours

With the automatic bartacker 510, up to nine freely-defined seam contours can be created and sewn. The coordinates are entered directly at the control panel.

Memory dongle

With the help of the memory dongle, data can be transferred from the machine to the dongle or vice versa.

Cycle time

This indicates the cycle time of the seam pattern last sewn (time from sewing start to sewing end).

Access technician mode

Machine

User settings Service Free contours Memory dongle

: ----

–

Turn on the main switch.

The control unit is initialized.

The main menu appears. –

Press function key “F” in the main menu.

The screen for the code entry appears.

–

Enter code number “25483“ (Code 1).

After entry of the correct code number, the display changes over to

the menu “Technician mode”. –

Confirm with the “OK”key.

The following menu appears:

–

Select the desired sub-menu with the “ñ” and “ò”keys. –

Switch into the selected sub-menu with the “OK” key.

8.6.4.1 Machine configuration

Parameter

Soft start Equipment Times

: 262S

Parameters

In this sub-menu, different machine parameters can be set.

Soft start

In this sub-menu, the driving speeds for the soft start slope can be set.

Equipment

In this sub-menu, settings for the sewing equipment and optional units can be made.

Times

In this sub-menu, different timing parameters can be set.

Machine cycles

The total sewn cycles are displayed here.

Sub-menu for machine parameters

Cut.rpm: 250

Max.rpm: 2700 Stop pos.: 0 Sew.st.pt.: A Ref.freq.: 1 Cl.thr.cl.:160 Op.thr.cl.:300 Op.thr.tn.:300

–

Select the desired parameter with the “ñ” and “ò”keys.

The symbol of the selected parameter / sub-menu is displayed

whiteonblack. –

Start selected parameter with the “OK” key or change into the

sub-menu.

Cutting speed

Input of the sewing motor speed in the last three stitches. Input: 100 – 600 [rpm]

Maximum sewing speed

Input of the maximum adjustable sewing speed Input: 2000 – 2700 [rpm]

Stop position

With the stop position, the positioning of the sewing motor / needle bar can be altered.

Input: 0 = thin fabrics

-15 = thicker fabrics

Note

The stop position is required for adjusting the corresponding material thickness.

Chapter 8.3 “Changing the stop position” of the Installation Instructions includes a more detailed description for positioning the sewing motor.

Loading position

Selection of the material feeding position. Input: A = Seam start point

B = Machine’s neutral position

Note

The following advantages or disadvantages can arise depending on the loading (feeding) position:

Feeding point A = shorter cycle time Feeding point B = easier feeding of large seam patterns

Seam patterns, longer cycle time

Referencing

The referencing mode of the step motor after the sewing process can be configured in this menu item.

Input: 0 = no referencing 1 = referencing each time

2 – 10 = referencing after each second to tenth

sewing step

Closed thread clamp angle

Setting the angle for closing the thread clamp. Input: 100 ° 240°

Opened thread clamp angle

Setting the angle for opening the thread clamp. Input: Closed thread clamp ... 355°

Opened thread tension angle

Setting the angle for opening the thread tension in the last stitch. Input: 200° 355°

The thread tension is opened before the thread-cut position is reached. Thus only the mechanical pre-tensioner is active during the cutting process.

All angles are specified in relation to the reference position of the sewing motor.

Sub-menu for soft start

In this sub-menu, speed adjustments for the soft start can be made.

Speed first stitch

Input of the speed in the first stitch. Input: 400 – 900 [rpm]

Speed second stitch

Input of the speed in the second stitch. Input: 400 – 2700 [rpm]

Speed third stitch

Input of the speed in the third stitch. Input: 400 – 2700 [rpm]

Speed fourth stitch

Input of the speed in the fourth stitch. Input: 400 – 2700 [rpm]

Speed fifth stitch

Input of the speed in the fifth stitch. Input: 400 – 2700 [rpm]

Sub-menu for sewing equipment

W.clamp f....

Open dimens.

Length: 4.5 Width: 20.0

Configuration

Number: 1

In this sub-menu, adjustments for the sewing equipment can be made.

Note

The entry of the clamping foot number (also refer to chapter 12) is used to automatically verify whether the seam pattern to be currently sewn is positioned within the inner frame of the clamping foot.

If the clamp numbers 9 to 13 and 16 are selected, only certain seam pattern numbers and sequence numbers are allowed.

If no clamping feet are specified, free (open) dimensions can also be defined.

Clamping foot

Selection of a specified clamping foot as equipment.

Input: Alternative

Open dimensions

Selection of a clamping foot with free (open) sewing field dimensions.

Input: Alternative

Number

Selection of a DA clamping foot number. Input: 1 ...16

Clamping foot Max. Size X x Y Inner frame Description

number Tack size [mm] Rectangular

(X,Y) [mm] Inner frame

1 19.0 x 3.5 20.0 x 4.5 yes Cross tack 2 20.0 x 4.1 21.0 x 5.1 yes Cross tack 3 26.0 x 4.0 27.0 x 5.0 yes Large cross tack 4 9.0 x 3.5 10.0 x 4.5 yes Small cross tack 5 4.6 x 20.0 5.6 x 23.0 yes Longitudinal tack 6 18.0 x 11.0 19.0 x 12.0 yes Small-field clamping foot 7 40.0 x 20.0 44.0 x 24.0 yes Large-field clamping foot 8 8.5 x 3.6 9.5 x 4.5 yes Contraction clamp

9 14.0 x 14.0 16.0 x 16.0 no Circle 10 11 .0 x 8.0 12.0 x 14.0 no D-clamping foot, simple 11 8.6 x 11.6 24.6 x 12.6 no Double-D clamping foot, lateral 12 11. 6 x 7.5 12.6 x 2 1.0 no Double-D clamping foot, longitudinal 13 12.9 x 11.2 34.8 x 12.2 no Double-tri clamping foot, lateral

14 16.0 x 2.6 17.0 x 3.6 yes “Belt looph 16 8.6 x 13.6 24.0 x 14.6 no Double-D clamping foot, lateral

Length

Input of a freely selectable sewing field. Input only possible when “free clamp dimension” has been selected. Otherwise the length / width of the selected clamp is indicated ( and cannot be modified).

Input: 0.5 – 20.0

Width

Input: 0.5 – 40.0

Configuration

The optional units can be activated in this sub-menu.

Caution – Fragile, danger of breakage!

When manufacturing the clamps for open dimensions, a safety margin must be taken into account.

Sub-menu Configuration

Hand sw.: Off

El.wiper.: Off Thr.clamp: On _/-clamp: Off Laserl.: Off

Input alloc. Output alloc.

Hand switches

Activating of optional hand switches. When the option is switched on, a menu item for selecting the operation mode will appear in the menu “User configuration”.

Input: ON / OFF

Electric thread wiper

The optional electrical thread wiper can be turned on or off here. It can only be turned on as an alternative to the thread clamp. If this option is activated while the thread clamp is turned on, the thread clamp will be deactivated.

Input: ON / OFF

Thread clamp

Turn the thread clamp on and off. It can only be turned on as an alternative to the electric thread wiper. If this thread wiper is activated when the thread clamp is turned on, the thread wiper will be deactivated.

Input: ON / OFF

Separate lowering of the clamping f oot

Activating the operating of the optional, separate clamping feet. Input: ON / OFF

Operating the separate lowering of the clamping foot

NOTE!

The function is only available with seam pattern programs (variants).

Sewing procedure with pedal

– – – – –

–

Push the pedal to the front to level 1: clamp 1 will be lowered Move the pedal into the resting position Push the pedal again to the front to level 1: clamp 2 will be lowered Push the pedal to level 2: the sewing process will be started Push the pedal back to level:

the clamp closed last will be lifted again Push the pedal back to level and keep it pushed (0.8 second):

clamp 1 and clamp 2 will be lifted one after the other

Sewing process with the hand switch (optional)

–

Press key 1: clamp 1 will be lowered

–

Press key 2: clamp 2 will be lowered

–

Press key 2 again: the sewing process will be started

–

Press key 1: the clamp closed last will be lifted again

–

Press key 1 and keep it pressed (1.5 sec.): clamp 1 and clamp 2 will be lifted

Laser lights

Activating the 3 optional laser lights. Input: ON / OFF

Assignment of the inputs

This menu item gives an overall view of the assignment of the inputs with (optional) units.

Assignment of the outputs

This menu item gives an overall view of the assignment of the outputs with optional units.

Sub-menu Times

Delay between pedal level 1 (low ering the clamping foot) and sewing start (t1)

This time is only relevant with quick start via pedal or hand switch (optional). The menu is item is only displayed when the monitoring switch for the clamping foot is not connected.

Input: 50 255 ms

Turn-on delay for the thread wiper magnet (t2)

This menu item will only be displayed if the “electric thread wiper” option is activated in the “Configuration” menu.

Input: 30 –100 ms

Delay thread w iper magnet off - c lamping foot magnet on (t3)

The delay between the switching off of the thread wiper magnet and the switching on of the clamping foot magnet.

This menu item will only be displayed if the option “electric thread wiper” is activated in the “Configuration” menu.

Input: 0 –255 ms

Delay between clamping foot magnet on — reference run (t4)

The delay between the switching on of the clamping foot magnet and the referencing of the step motors. The menu is item is only displayed when the monitoring switch for the clamping foot is not connected.

Input: 0 255 ms

Activation time for the power saving mode (t5)

Delay time after activation of any control element (control panel, pedal, hand switch) until the power saving mode is activated.

Input: 0 60 min 0 =Power saving mode deactivated

8.6.4.2 User configuration

Language

Hand switch: B Par.lock.: Off Pattern lock. Sequence lock.

In this menu, user-specific settings are made.

–

Select the desired parameter or sub-menu with the “ñ” and “ò” keys. The selected parameter or sub-menu is displayed white on black.

–

Start the selected parameter with the “OK” key or change into the sub-menu.

Language

In this sub-menu, the language can be chosen.

German

Selection of the German language for the technician level.

English

Selection of the English language for the technician level.

Parameter

Selection of the numbering of menu items for the

technician level (see chapter 13).

–

Select the desired line with the “ñ” and “ò”keys.

–

Confirm by pressing the “OK” key. The menu item in the technician level is then displayed in the selected language.

Push button operating mode (optional)

Selection of the push button mode. This menu item is only available if the “hand switch” option in the “Configuration” menu is switched on.

Input: A = Quick-start

B=Normal

In the push button mode “NORMAL”, the keys have the following functions:

Key 1: Lifting and lowering of the clamping foot.

Interruption of the sewing operation. Sewing operations stopped after interruption.

Key 2: Sewing start when clamping foot is lowered.

Interruption of the sewing operation. Sewing operation continued after interruption.

In the push button mode “QUICK START”, the keys have the following functions:

Key 1: Lifting and lowering of the clamping foot.

Interruption of the sewing operation. Sewing operations stopped after interruption.

Key 2: Sewing start.

If clamping foot is not already lowered, it will be lowered. Interruption of the sewing operation. Sewing operation continued after interruption.

Parameter locking

Switching on/off for permission to alter parameters in the sewing and programming mode.

Input: ON / OFF

Note

If the parameter locking is switched on, changes to parameters in the sewing and programming mode can no longer be made.

Lock seam pattern

Lock all

Unlock all

2: On 3: On 4: On 5: On 6: On 7: On

In this sub-menu, individual seam patterns can be released or locked, for selection in the sewing mode.

The following restrictions apply:

1. Seam pattern operations

The seam pattern currently selected in the sewing mode cannot be

locked.

In the sewing mode, locked seam patterns cannot be chosen from

the selection list. Locked seam patterns are marked with “#”.

2. Seam pattern sequence operations

A locked seam pattern can be selected in a sequence. However,

when starting the sewing process (lowering of the clamping foot) an error message will appear. The sewing process cannot be started.

The last s eam pattern selected in the seam pattern operation

cannot be locked.

Lock all

All seam patterns with the restrictions specified above will be locked. The status of the displayed seam pattern number switches to “OFF”.

Unlock all

All seam patterns will be unlocked. The status of the displayed seam pattern number switches to “ON”.

Lock/unlock individual seam pattern

Input: ON / OFF

Lock sequences

Lock all

Unlock all

2: On 3: On

In this sub-menu, individual sequences can be released or locked for selection in the sewing mode.

The menu item is only displayed when more than one seam pattern sequence is programmed (refer to chapter 8.5.3, seam pattern sequence)

The following restrictions apply:

1. Seam pattern operations

The last s equence selected in the sequence operation cannot be

locked.

2. Seam pattern sequence operations

The sequence currently selected in the sewing mode cannot be

locked.

In the sewing mode, locked sequences cannot be chosen from the

selection list. Locked sequences are marked with “#”.

Lock all

All sewing sequences with the r estrictions specified above will be locked. The status of the displayed sewing sequence number switches to “OFF”.

Unlock all

All sewing sequences will be unlocked. The status of the displayed sewing sequence number switches to “ON”.

Lock/unlock individual sew ing sequences

Input: ON / OFF

8.6.4.3 Service functions

Multitest

180°-disc Events Init

The service functions allow for quick inspection of all hardware components.

Note

The service menu can also be reached directly when switching on the machine (see chapter 8.2.1).

Multitest

In the “Multitest” menu, all hardware components can be checked.

180° disc

This menu item offers a function to correctly adjust the reference position of the sewing motor (180° disc) (refer to the Service Instructions).

Events

In case of trouble, this menu item can contain important indication about the source of the trouble.

Initialization

Output test

PWM output tst Input test Auto input tst Motor test Step.motor tst RAM test EEPROM test

The event memory buffer and the permanent data can be reset to the factory default s ettings in this menu.

Multitest

Selection of the Multitest sub-menu

–

Select the desired test function with the “ñ” and “ò”keys.The selected test function is indicated white on black.

–

Choose the selected test function using the “OK” key.

Output test

==== Output test ====

Output Y1: +

With this testing function, the function of the output elements is checked.

–

Start testing function with the “OK” key.

–

Select the desired output element by pressing the “ñ ”or“ò”keys.

–

Switch the selected output element on and off by pressing the “OK” key.

–

Press the function key “ESC” in order to leave the testing function.

Caution – Risk of Injury !

Do not reach into the running machine during the function test of the output elements.

Output-

element Function

Y1 Thread clamp/thread wiper (option)

Y2 Magnetic valve for the pneumatic sewing foot lift

Y4 Thread tension

Y13 Thread trimmer magnet

Y18 Separated clamping foot 1, if the option is activated

Y19 Separated clamping foot 2, if the option is activated

Y21 Laser marking light 1, if the option is activated

Y22 Laser marking light 2, if the option is activated

Y23 Laser marking light 3, if the option is activated

Also refer to the “Distributor PCB” section

The current configuration of the outputs is indicated in the sub-menu “Output assignments” in the “Configuration” menu.

PWM output test

== PWM output test ==

Output Y31: 0

This testing function checks the function of the magnets.

–

Start test function with the “OK” key.

–

Select the desired output element by pressing the “ñ ”or“ò”keys.

–

Switch the selected output element on and off by pressing the “OK” key.

–

The present electricity, flowing through the clamping foot solenoid will be displayed.

–

If the machine is equipped with a monitoring switch for the clamping foot, the Output PWM-1 will have the value + or -, according to the switching status of the output element.

–

Press the function key “ESC” in order to leave the testing function.

Caution – Risk of Injury !

Do not reach into the running machine during the functional test of the output elements.

Output element Function

Y31 Clamping foot magnet

Also refer to the “Distributor PCB” section

Input test

==== Input test =====

Input S1: +

With this testing function, the input element to be tested is selected.

CAUTION !

The input elements have been carefully adjusted in the factory. Adjusting and correcting should only be carried out by trained service staff.

Caution – Risk of Injury !

Do not reach into the working area of the machine when starting and ending the input tests.

–

Start the test function with the “OK” key.

–

Select the desired input element with the “ñ” and “ò”keys. The switching status of the input element is indicated.

Input element Function

S 1 Hand switch 1, if the option is activated

S2 Hand switch 2, if the option is activated

S14 Pedal A

S15 Pedal B

S16 Pedal C

S17 Pedal D

Ref. N Referencing switch for the sewing motor

Ref. X X-reference switch

Ref. Y Y-reference switch

–

Press the function key “ESC” in order to leave the test function. The Multitest menu is displayed.

Also refer to the “Distributor PCB” section

The current configuration of the inputs is indicated in the sub-menu “Input configuration” in the Configuration menu.

Auto-Input test

== Auto input tst ===

With this testing function, the functioning of the input elements is checked.

CAUTION !

The input elements have been carefully adjusted in the factory. Adjusting and correcting should only be carried out by trained service staff.

Caution – Risk of Injury !

Do not reach into the working area of the machine when starting and ending the input tests.

–

Start testing function by pressing the “OK” key.

–

Press desired input element. The switch status and the number of the actuated input element are displayed.

–

The current configuration of the inputs is indicated in the table under “Input test”.

Press the function key “ESC” in order to leave the testing function. The Multitest menu is displayed.

Sewing motor test

==== Motor test =====

With this testing function, the sewing motor can be checked.

–

Start testing function with the “OK” key.

–

Start motor with the “ñ”key.

–

Adjust the speed with the “ñ ” and “ò”keys. The speed is displayed.

–

Press the function key “ESC”. The test is finished and the motor stops. The sewing motor control makes a reference run and the clamping foot is lifted. The menu Multitest appears on the display.

Step motor test

= Step. Motor test ==

With this test function the step motors and the related reference switches can be checked.

–

Start testing function with the “OK” key.

–

Check transverse motion of the step motor (X axis). Move step motor with the “ ï”or“ð”keys.

The number of steps made is indicated to the left of the arrow. The status of the reference switch changes in the vicinity of the reference position.

–

Check longitudinal motion of the step motor (Y axis). Adjust the speed with the “ñ ” and “ò”keys.

The number of steps made is indicated above the arrow. The status of the reference switch changes in the vicinity of the reference position.

–

Press the function key “ESC”. The test is finished. The menu Multitest appears on the display.

RAM test

===== RAM test ======

SRAM : NVSRAM:ÖÖ

With this testing function, the static memory (SRAM and program data memory) is checked.

–

Start testing function with the “OK” key. The display shows the testing result.

Display Explanation

SRAM OK Static Random Access Memory works perfectly SRAM ERROR Error in the static memory NV-RAM OK Program data memory is okay NV-RAM ERROR Error in the program data memory

–

Press the function key “ESC”. The test is finished. The menu Multitest appears on the display.

EEPROM test

==== EEPROM test ====

ROM size: 628k

Class: 511

Version: A01

Date: 01-07-08

Check sum: 0x1234 Ok

This testing function checks the read memory (ROM) of the microprocessor.

–

Start testing function with the “OK” key. The display shows the following test results:

- ROM size,

- machine class,

- software version,

- software date,

- check sum and status

Note:

The details will vary depending on the software version.

–

Press the function key “ESC”. The testing is finished. The menu Multitest appears on the display.

Events

Event memory

Latest events

=== Event memory ====

E4304: 3 x E8254: 1 x

=== Latest events ===

1 E4304 Z 1154889

S 263

1 E4304 Z 1152558

S 263

1 E8254 Z 1150034

S 263

In the event of a malfunction, this menu can give important hints regarding the cause.

Event memory

(example)

This menu item displays all events which have occurred. –

Exit the menu item by pressing the “ESC”key.

–

Continued display by pressing the “ò”key.

Most recent events

(example)

In this menu item, the events that occurred most recently are indicated: Z = milliseconds after the machine has been switched on S = machine piece counter E = Event/Error number –

Exit the menu item by pressing the “ESC”key.

–

Continued display by pressing the “ò”key.

Initialization (Init)

Event memory

Progr./Sequ. Mach./User p. Free Contours Maschine cpl.

This is the selection of the sub-menu for the initialization of the event memory and the permanent data.

Event memory

Using this menu item, the event memory can be r eset.

Seam pattern programs (variants) and sequences

Using this menu item, seam pattern programs and sequences can be deleted.

Machine parameters

This menu item is used to reset factory default settings for the following: the machine parameters, soft start driving speeds, timings, user configuration, hook thread counter data options and the availability of a monitoring switch for clamping foot.

Free seam contours

Using this menu item, all free seam contours can be reset (deleted).

Note

The reset may cause seam pattern programs and sequences to be deleted. The numbers of subsequent programs and sequences may also be altered.

Machine complete

Using this menu item, all permanent data can be reset. After resetting, the machine will automatically be restarted.

Note

After the restart of the machine, a new selection of the clamp numbers and the equipment must be carried out (refer to Installation Instructions, chapter 9).

8.6.4.4 Free contours

Design

Edit: 0 Delete: 0 Copy

No.pat.av.: 8

No.st.av.:4900

With the automatic bartacker 510, up to nine freely-defined seam contours can be created and sewn. The entry of the coordinates is carried out at the control panel.

Creating

Using this menu item, a new seam contour can be created.

Note

The number of the seam contour is assigned automatically.

Altering

After selection of the seam contour to be altered, the sub-menu for altering the seam contour will appear.

Delete

Using this menu item, a selected seam contour can be deleted.

Copy

Any basic seam pattern number or free seam contour can be copied and altered. After selection of the seam pattern number, the sub-menu “Alter seam contour” appears.

Select the desired function with the “ñ” and “ò”keys. Choose the selected function with the “OK” key.

Note

The number of the seam contour is assigned automatically.

Number of available stitches:

The number of the stitches still available is displayed (max. 5000)

Number of available seam patterns:

The number of the seam patterns still available is displayed (max. 9)

Determining the seam pattern coordinates

When creating a seam contour, every individual stitch has to be entered in the control unit along with its position in the coordinate system (X- and Y-axis). Therefore the individual coordinate points have to be pre-determined.

This can be done with the help of millimetre-scaled graph paper.

Maximum sewing area Stitch to be determined (grey field)

Sketched seam contour

Machine zero point

Coordinate system with X- and Y-axis

Note

The seam contour should be laid out in such a way that the machine neutral point is as close to the middle of the contour as possible.

–

Sketch the maximum sewing field size on the millimetre-scaled graph paper (X = max. 40 mm, Y = max. 20 mm).

–

Draw the coordinate system in the centre of the sewing field.

–

Draw in seam contour.

–

Determine the X- and Y- coordinates for every desired stitch.

–

Enter X- and Y-coordinates in the control unit (refer to next page).

Create seam pattern

X1: 0.0

Y1: 0.0

X2: 0.0

Parameters

Y2: 0.0

X3: 0.0

Y3: 0.0

Append stitch

In this menu, the X- and Y-coordinates are entered for each individual stitch.

Note

In order to enter stitch operations (e.g. intermediate cutting), first complete the seam pattern (entering of the coordinates) and then insert the stitch operation through editing in the menu “Changing seam pattern”.

X1:

Input of the X-coordinate for stitch 1 Input: -20.0 – +20.0

Y1:

Input of the Y-coordinate for stitch 1 Input: -10.0 +10.0

Note:

The value X1 can be changed according to the description in Chapter 8.3.1.

After confirming the value for X1 with the “OK” key,usethe“ò“keyto

select the menu item Y1.

The values for Y1, X2, Y2, X3 and Y3 can be altered similarly as described for the value X1.

After confirming the input for Y3 with the “OK” key,usethe“ò”keyto

select the menu item “Add stitch”.

After selection of this line with the “OK” key, the next coordinates Xn+1 and Yn+1 (here: X4 and Y4) are given in the two upper menu lines. The selection bar changes to the line Xn+1 (here: X4) automatically. The values Xn+1 and Yn+1 can be altered as described above when required. This procedure can be repeated until the stitch coordinates are all entered.

Add stitch

Function for adding a stitch. The coordinates for the first three stitches (here: X1/Y1, X2/Y2 and

X3/Y3) are shifted upwards and the display shows Xn+1/Yn+1 (here: X4/Y4).

Sub-menu parameter

Std.rpm: 1500

Orig. X: 0.0 Orig. Y: 0.0

Selection of the sub-menu for entering the seam pattern parameters

Standard speed:

Standard speed Input: 100 – 2700 rpm

orig. X:

Reference point X for change of size Input: -20.0 – +20.0

Frame of clamping foot

Seam pattern after change of size

Reference point for change of size

orig. Y:

Reference point Y for change of size Input: -10.0 – +10.0

The reference point for the change of the seam pattern size is individually and internally defined for every seam pattern. Normally it is the machine zero point.

The following illustration shows the principle of size change in relation to the reference point:

Example seam pattern 1 Example seam pattern 2

Seam pattern before change of size

Change seam pattern

Stitch coordin

Del.St.: 0 Ins.St.: 0 Append stitch

No.st.av.:4900

Parameter

No.stich: 100

Design

Edit: 0 Delete: 0 Copy

No.pat.av.: 8

No.st.av.:4900

–

Select desired menu item with the “ñ” and “ò”keys.

–

Press the “OK” key.

–

Select free seam contour with the “ñ” and “ò”keys.

–

Confirm by pressing the “OK” key. The menu “Change seam pattern” is displayed.

Stitch coordinates

Selection of the sub-menu for altering the stitch coordinates.

Delete stitch:

Delete stitch. Input: Number of stitch to be deleted

Add stitch:

Add stitch. Input: Number of the stitch in front of which a new stitch is to be added. The sub-menu for altering the stitch coordinate appears.

Add stitch (at the end)

The sub-menu for altering the stitch coordinate appears.

Parameter

Selection of the sub-menu for altering the seam pattern parameters.

Sub-menu stitch coordinates

If the seam pattern to be altered has less than 99 stitches, the sub-menu appears immediately.

If the seam pattern to be altered has more than 99 stitches, the following menu appears first:

–

Select the desired range of stitches with the “ñ ”or“ò”keys.

–

Select the range of stitches with the “OK”key. The sub-menu “Stitch coordinates” appears

–

Select the desired stitch with the “ñ ”or“ò”keys.

–

Select stitch with the “OK” key. The sub-menu for altering a stitch coordinate appears.

If a stitch has a s titch operation attributed to it, it will be marked with an asterisk (*) instead of a slash (/).

Sub-menu “Alter stitch coordinate”

This sub-menu appears when selecting a stitch coordinate from the menu “Stitch coordinates” and after adding or altering a stitch.

(example)

Op1

Altering the movement operation for stitch 10 Input: r efer to the table below

Op2

Altering the thread-tension operation for stitch 10 Input: r efer to the table below

Op3

Altering the speed operation for stitch 10 Input: r efer to the table below

Note:

The stitch operation entered will be executed after the stitch.

Type of operation Operation Description

Movement operation (Op1) Intermediate thread

cutting

Thread-tension operation (Op2"

Speed operation (Op3) Speed 200

Thread tension 1 Thread tension 2

Thread tension 3

Thread tension 4

Thread tension 5

Speed 400

Speed 600

Speed 800

Speed 1000

The intermediate cutting can be programmedupto10timeswithina seam pattern. At least 3 stitches must be sewn between two intermediate cuttings.

Thread tension area 1 Thread tension area 2

Thread tension area 3

Thread tension area 4

Thread tension area 5

Speed reduction to 200 1/min

Speed reduction to 400 1/min

Speed reduction to 600 1/min

Speed reduction to 800 1/min

Speed reduction to 1000 1/min

Speed 1200

Speed 1400

Speed 1600

Speed 1800

Speed 2000

Speed 2200

Speed 2400

Speed 2600

Standard speed

If “No operation” is selected, the corresponding stitch operation is deactivated.

Speed reduction to 1200 1/min

Speed reduction to 1400 1/min

Speed reduction to 1600 1/min

Speed reduction to 1800 1/min

Speed reduction to 2000 1/min

Speed reduction to 2200 1/min

Speed reduction to 2400 1/min

Speed reduction to 2500 1/min

Set the standard speed

Delete seam pattern

Design

Edit: 0 Delete: 0 Copy

No.pat.av.: 8

No.st.av.:4900

–

Select the menu item “Delete” with the “ñ” and “ò”keys.

–

Press the “OK” key.

–

Select desired seam pattern number with the “ñ” and “ò”keys.

–

Confirm by pressing the “OK” key. The seam pattern will be deleted.

CAUTION !

If you delete a free seam contour, the numbering of the seam pattern programs or sequences can also be deleted and thus changed.

Copying a seam pattern

Stitch coordin

Del.St.: 0 Ins.St.: 0 Append stitch

4858

Parameter

No.stich: 42 No.st.av.:

Design

Edit: 0 Delete: 0 Copy

No.pat.av.: 8

No.st.av.:4900

–

Select the menu item “Copy” with the “ñ” and “ò”keys.

–

Press the “OK” key.

–

Select the desired seam pattern number (1-50, 91-99) with the “ñ” and “ò”keys.

–

Confirm by pressing the “OK” key. The seam pattern will be copied and the “Change seam pattern” menu will be displayed.

The procedure for changing the seam pattern should be c arried out according to the instructions in the “Changing the seam pattern” section.

8.6.4.5 Memory dongle

Dongle index

Load Save

Format

With this sub-menu, data can be transferred from the machine to the dongle or vice versa.

Dongle contents

With this menu item, the content of a dongle connected to the control unit can be displayed.

Load

With this menu item, program data (seam pattern programs and sequences), machine parameters and free seam contours can be uploaded from the dongle to the machine.

Save

With this menu item, program data (seam pattern programs and sequences), machine parameters and free seam contours can be saved to a data dongle.

Format

Before saving data to a dongle, it must be formatted as a data dongle.

The dongle should be inserted into the port on the control unit labelled “Dongle” (X110).

Display dongle contents

Class: 511 Subclass: 000 Version: A01 Date: 010708

P01: 51

P02: 52

Boot dongle

If a boot dongle is inserted, information is sent to the machine program.

(example)

In order to display the dongle information, a boot dongle with a machine program for any machine class can be inserted.

Data dongle:

If a data dongle formatted for the machine class 510 is inserted, then the saved seam pattern programs or free seam contours are displayed.

Output of saved seam pattern programs

(example) Use the “ð ” key to switch between the display for the saved seam

pattern programs and the display for the free seam contours.

Output of saved free seam contours

F01: Data1

F02: Kontur02 F03: Kontur03 F04: cont. 94

Dongle index

Progr./Sequ. Machine param. Machine cpl.

Free contours

(example)

Data dongle for a different machine class

The following is displayed if a dongle from another machine class is inserted.

(example)

Upload data from the dongle to the machine

Here, program data (seam pattern programs and sequences), machine parameters or all free seam contours can be uploaded from the dongle to the machine.

(example)

Contents

With this menu item, the content of a memory dongle connected to the control unit c an be displayed.

Before the following four data types are loaded, a confirmation window is displayed.

–

Press the “ï” key (no) in order to abort the process. Press the “ð” key (yes) in order to continue with the process.

The time needed for the upload depends on the number of seam pattern programs and free seam contours.

Free seam contours

The loading of all free seam contours can be started with this menu item. A confirmation window will be shown for confirming your selection.

All free s eam contours on the machine will be deleted when uploading from the dongle!

Seam pattern programs and sequences

The loading of all seam pattern programs and sequences can be started with this menu item.

All seam pattern programs and sequences on the machine are overwritten when loading from the memory dongle.

If seam pattern programs or sequences refer to unavailable free seam contours, then they are deleted after they are loaded! In such a case, the free seam contour should be loaded first or use the “Machine complete” menu item!

Machine parameters

The loading of the machine parameters can be started with this menu item.

The following data is loaded from the memory dongle: cutting speed, reference speed, loading positions, maximum sewing

speed, stop position, current seam pattern number, current standard seam pattern data (in the event that the equipment corresponds).

All machine parameters on the machine are overwritten when uploading from the memory dongle.

Machine complete

The loading of all the data ranges listed above can be started with this menu item.

All data on the machine is overwritten when uploading from the memory dongle.

Saving data on the dongle

Dongle index

Progr./Sequ. Machine param. Machine cpl.

Free contours

Here, program data (seam pattern programs and sequences), machine parameters or all free seam patterns can be downloaded from the machine to the dongle.

Contents

With this menu item, the content of a memory dongle connected to the control unit c an be displayed.

Before the following four data types are saved, a c onfirmation window is displayed.

–

Press the “ï” key (no) in order to abort the process. Press the “ð” key (yes) in order to continue with the process.

The time needed for saving depends on the number of seam pattern programs and free seam patterns.

Free seam contours

The save process for all free seam contours can be started with this menu item.

All free s eam contours on the dongle will be deleted when saving!

Seam pattern programs and sequences

The save process for all seam pattern programs and sequences can be started with this menu item.

All seam pattern programs and sequences on the memory dongle are overwritten when saving.

A confirmation window will be shown for confirming your selection.

Data Dongle

Start with ‘P’

–

Press the “ï” key (no) in order to abort the process. Press the “ð” key (yes) in order to continue with the process.

The program data and machine parameters on the dongle will be deleted when saving!

Note

The time needed for saving the data depends on the number of seam pattern programs on the machine.

Format a dongle

Before a dongle can be used to save data, it must be formatted as a data dongle.

Data dongle

This menu item is used to start the dongle format. –

Press the “P” key to start the process.

A confirmation window will be shown for confirming your selection.

–

Press the “ï” key (no) in order to abort the process. Press the “ð” key (yes) in order to continue with the process.

During the format, all data saved to the dongle w ill be deleted!

Error messages

Icon Designation Possible cause Action

Dongle missing No dongle is inserted

Dongle empty No data is saved on the

dongle

Wrong dongle type The dongle is incorrectly

formatted for the desired function

Wrong machine class

Format-ID error • Dongle has been

Unknown dongle type

Data dongle is not formatted for Class 511

incorrectly formatted

• Dongle defective

• Dongle has been incorrectly formatted

• Dongle defective

Insert the dongle in the control unit

Save data to the dongle

• Use another dongle

• Format dongle

• Use another dongle

• Format dongle

• Reformat dongle

• Use a different dongle

• Reformat dongle

• Use a different dongle

8.7 Distributor PCB

The distributor PCB is located at the back of the machine below the clamping foot magnet. All control unit inputs and outputs are accessible from here. The rear cover must be removed in order to gain access to the terminals.

Description of the outputs

Output number Output Assignment

Y1 (FW/FK) 24V / 4 A Thread clamp magnet / optional: Thread wiper

magnet

Y2 24V / 0.5 A -

Y3 24V / 3 A -

Y4 (FS) 24V / 4 A* Thread tension magnet

Y5 24V / 0.5 A Optional: Magnetic valve for the “separated

clamping foot 1"

Y6 24V / 0.5 A Optional: Magnetic valve for the “separated

clamping foot 2"

Y7 - Y12 24V / 0.5 A -

Y13 (FA) 24V / 3 A* Thread trimmer magnet

Y14 - Y17 24V / 0.5 A -

Y18 - Y19 24V / 6.5 A* -

Y21 - Y23 24V / 0.2A Optional: Laser marking light 1 – 3

Y24 - Y28 24V / 0 .2A -

Y31(X11/ X12: FL) 60V / 8A(2A) Clamping foot magnet

*: Output is PWM-compatible

Magnets and magnetic valves are connected between +24V (X9) and the corresponding output (X8, X10).

Description of inputs

Input number Input Assignment

S1 24V Optional: Hand switch 1

S2 24V Optional: Hand switch 2

S3 - S10 24V -

S12 (N-Ref.) 24V Reference switch for the sewing motor

S14 24V Pedal A

S15 24V Pedal B

S16 24V Pedal C

S17 24V Pedal D

S21 - S24 24V -

S25 (X-Ref.) TTL Reference switch for the step motor, X axis

S26 (Y-Ref.) TTL Reference switch for the step motor, Y axis

S27 - S28 TTL -

S1 - S17: The lower switching threshold is 7.2V.

The upper switching threshold is 16.8V.

S21 - S24: The switching threshold is 1.5V.

8.8 Error messages

If an error occurs with the control system or the seam pattern program, the display shows a symbol and an error number.

The following table can help in troubleshooting these errors.

8.8.1 Error categories

No. Icon Name Description

1 Critical error An emergency shut-off will be carried out.

The automatic bartacker must be turned off and then back on.

2 Error The user must confirm the error

before continuing work.

3 Caution The user must confirm the error

before continuing work.

8.8.2 Application messages

Icon Description Category Action

Capacity counter is zero Note

Handwheel turned manually

The contour overlaps the clamping-foot inner frame in the X or Y direction.

The contour overlaps the clamping-foot inner frame inthe–Xor+Xand+Y direction.

The contour overlaps the clamping-foot inner frame

in the +X and –Yor+Y direction.

The contour overlaps the clamping-foot inner frame

in the X and –Yor+Y direction.

The contour overlaps the clamping-foot inner frame

in the –Y or +Y direction.

Time expired without operator input

Caution

Caution • No sewing start is possible

Caution

• The clamping foot can be lowered only after pressing the “OK” key.

• The message disappears after the key is pressed.

• After pressing the key, the capacity counter is reset to its starting value.

After aborting the sewing process:

• No further sewing is possible

• Abort the sewing process by pressing back on the pedal.

• Confirm with hand switch 1 (clamps) or with the “ESC” key on the control panel.

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the X offset in the appropriate direction

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the X offset in the appropriate direction

• Decrease the seam pattern in the Y direction

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the X offset

• Decrease the Y offset in the appropriate direction

• Select another clamping foot

• Select another seam pattern

• Decrease the X offset

• Decrease the Y offset in the appropriate direction

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the seam pattern in the X direction

• Decrease the Y offset in the appropriate direction

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the Y offset in the appropriate direction

• The clamping foot is lowered

Icon Description Category Action

The contour overlaps the clamping-foot inner frame in the X direction

The contour overlaps the clamping-foot inner frame in the Y direction

The contour overlaps the clamping-foot inner frame in the X and Y direction.

Seam pattern is locked

Thread-tension magnet overheated

Caution

Note

Caution

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the seam pattern in the X direction

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the seam pattern in the Y direction

• No sewing start is possible

• Select another clamping foot

• Select another seam pattern

• Decrease the seam pattern in the X and Y direction

• No sewing start is possible

• Select another seam pattern

• Unlock seam pattern

• Current regulator (thread tension) will be turned off

8.8.3 Machine faults/errors

Error code Description Possible cause Remedy

1051 Sewing motor timeout - Cable to sewing-motor

- Reference switch is defective

- Sewing motor is defective

- Mechanics are sluggish

1055 Sewing motor

overload

1342 – 1343

2101 Step motor, X-axis,

2103 Step loss-Test:

2165 – 2167

2201 Step motor, Y-axis,

2203 Step loss-Test:

2265

2267

2911 2914

3100 Machine control

3101 Machine power

Sewing motor error Internal error - Switch machine off and on again

Timeout Referencing

Step loss X-axis

Step motor data X-axis

Timeout Referencing

Step loss Y-axis

Step motor data X-axis

Step motor error Internal error

voltage

- The sewing motor is

blocked or sluggish

- Sewing motor is defective

- Control unit defective

- Cable to reference switch

is defective

- Reference switch is defective

- Step motor is defective

- Mechanics are sluggish

- Stitch length within the

contour in the X direction too big

Internal error

- Cable to reference switch

is defective

- Reference switch is defective

- Step motor is defective

- Mechanics are sluggish

- Stitch length within the

contour in the Y direction too big

Internal error

Short-term mains voltage drop

- Check the cable

Check the reference switch

- Check the sewing motor

- Check the mechanics

Fix the blockage or sluggishness

Check the sewing motor Check the control unit

- Software update

- Inform DA Service

- Check the cable

- C heck the reference switch

- C heck the step motor

- Check the mechanics

- Reduce the speed

- R educe the scale of the contour in the X direction

- R educe the stitch length within the contour in the X direction.

- Switch the sewing machine off and on again

- Software update

- Inform DA Service

- Check the cable

- C heck the reference switch

- C heck the step motor

- Check the mechanics

- Reduce the speed

- R educe the scale of the contour in the Y direction

- R educe the stitch length within the contour in the Y direction.

- Switch the sewing machine off and on again

- Software update

- Inform DA Service

- Switch machine off and on again

- Software update

- Inform DA Service

Check the mains voltage

Error code Description Possible cause Remedy

3104 24V switching power

- Overload 24V output

supply: overload

- Short circuit output distribution board

- Cable connection to the distribution board damaged

3301 3320

3322 3330

3332 3340

Error process – controller / test process / step motor – test process / switch-on process / sewing process / winding process / Adjust-help process

Internal error

3341 3350

3351 3353 3360 3361 3400 3401 3403

3358 Sewing procedure:

Handwheel turned during the interruption

3500

3506

Error Command Interpreter / Motor synchronization

The handwheel has been turned manually during sewing interruption

Internal error

3520

3530 3540 3721 3722

3830 Program Additional

- Interference

Board: Update error

- Additional Board faulty

3840 No response from the

- Interference

additional board after the update attempt

- Additional Board faulty

4301 Dongle missing No dongle is inserted

4302 Dongle empty No data is saved on the

dongle

4304 Wrong dongle type The dongle is incorrectly

formatted for the desired function

4307 Wrong machine class Data dongle is not

formatted for Class 511

4311 Format-ID error - Dongle has been

incorrectly formatted

- Dongle faulty

- Check the output element or the other outputs

- Check the connections, fix the short circuit.

- Check the cable connections

- Switch machine off and on again

- Software update

- Inform DA Service

Cancel the sewing procedure: Step the pedal backwards

- Switch machine off and on again

- Software update

- Inform DA Service

- Switch machine off and on again

- Replace the control unit

- Switch machine off and on again

- Replace the control unit

- Insert the dongle in the control unit

- Save data to the dongle

- Use another dongle

- Format a dongle

- Use another dongle

- Format a dongle

- Reformat dongle

- Use a different dongle

Error code Description Possible cause Remedy

4312 Unknown dongle type - Dongle has been

incorrectly formatted

- Dongle faulty

4530

4537 4900

5101 NV-RAM empty Control unit is new, no

5104 NV-RAM checksum

5804 Free contours:

5808 Error: free seam

5809 Free contours:

5810 Free contours:

5900 Sequences error –

6152

6154 6204

6351

6354

6551 6554 6651 6751

6759

7460 Communication test

Menu system / user message error

error

Checksum incorrect

contour, stitch number cannot be determined

Max. number of partial contours

Min. number of stitches per partial contour

Invalid sequence number

Input/output error Internal error

C error

Upper position error / AD converter / Processor error / Step motor driver

interface

Internal error

data available. Control unit is from another machine class, data is not compatible

- NV-SRAM faulty

- Malfunction

- NV-SRAM faulty

- Malfunction

Internal error

Max. number of partial contours (intermediate cuttings) exceeded

Min. number of stitches per partial contour not present

Internal error

Control unit faulty Check the control unit

Internal error

- Line interference

- Cable to test interface is faulty

- Internal error

- Reformat dongle

- Use a different dongle Turn machine off and then on again.

Software update. Inform DA service

Data reset to factory settings

- C heck w ith Multitest. Check control unit

- Turn machine off and on again. Data reset to factory settings

- C heck w ith Multitest

- C heck control unit

- Switch machine off and on again. Data reset to factory settings

- Switch machine off and on again

- Software update

- Inform DA Service

Delete the intermediate cutting operations in the free contours

Change the intermediate cutting operations in the free contours

- Switch machine off and on again

- Software update

- Inform DA Service

- Switch machine off and on again

- Software update

- Inform DA Service

- Switch machine off and on again

- Software update

- Inform DA Service

- Switch off source of interference

- Check the cable

- Switch machine off and on again.

Error code Description Possible cause Remedy

7551

7559

7556 7557

7700 Protocol:

7701 Protocol error Internal error

8151 8700 8702 8800 – 8806 8890 8891

9100 – 9105 9200 9201 9900 9902 9903 9905

Communication control panel interface

Max. number of repetitions

Test pin error / Key simulation / Signal / Event processing / Memory wrapper / List functions

Seam pattern admin. error / Seam pattern program / Seam pattern authorization / Equipment / Key processing / Memory event version

Internal error

- Line interference

- Cable to control panel interface is defective

- Line interference

- Cable to test interface is defective

Internal error

- Switch machine off and on again

- Software update

- Inform DA Service

- Switch off source of interference

- Check the cable

- Switch off source of interference

- Check the cable

- Switch machine off and on again

- Software update

- Inform DA Service

- Switch machine off and on again

- Software update

- Inform DA Service

- Switch machine off and on again

- Software update

- Inform DA Service.

If error 9100 occurs repeatedly, reset the seam pattern program and sequences with the Initialization menu (refer to page 60).

If an error occurs, the corresponding component can be tested for proper functioning via the Service/Multitest function (compare to page 49). The Service menu can be reached from the Technician level.

It can also be reached by pressing the F key when the DA logo appears turning machine boot-up. (entry code: 25483).

9. Sewing

Sequence of operations and functions during sewing:

Sewing process Operation / Explanation

Before the start of sew ing

Starting position - Pedal is in the resting position.

The automatic bartacker is at rest. Needle is up, fabric clamps are up.

Load the workpiece

Sewing - Push the pedal to the front to level 1.

The clamps are lowered.

- Let up on pedal.

The clamps raise up again. The workpiece can be re-positioned.

- Step forward on the pedal fully. The automatic bartacker sews with the specified speed.

In the sewing cycle

Abort sewing process - Step the pedal backwards.

The automatic bartacker halts. The clamps stay down.

Continue with the sewing process - Press all the way forwards on the pedal.

10. Maintenance

10.1 Cleaning and checking

Caution – Risk of Injury !

Turnthemainswitchoff. Maintenance work of the automatic bartacker must only be carried out when the machine is switched off.

All maintenance work must be carried out before or at the maintenance intervals defined in the table (refer to the “operational hours” column).

When working with materials that are thick and fibrous, shorter maintenance intervals may be required.

A clean automatic bartacker helps to prevent malfunctions.

Maintenance required Explanation Operational interval Maintenance work

Machine head

- Remove sewing dust and residual thread (you can use compressed air).

Control box

Important points to be cleaned:

- The area under the throat plate

- The area around the hook 1

- The bobbin enclosure

- The thread trimmer

- The area around the needle 2

- Clean fan grill

10.2 Oil lubrication

Caution – Risk of Injury !

Oil can cause skin rashes. Avoid prolonged skin contact. If oil or grease contacts your skin, wash yourself thoroughly.

CAUTION !

The handling and disposal of mineral oils is subject to legal constraints. Deliver used oil to an authorized reception point. Protect your environment. Take care not to spill any oil.

Oil the automatic bartacker exclusively with the lubricating oil DA-10 or equivalent oil w ith the following specification:

Viscosity at 40° C: 10 mm²/s Flash point: 150° C

DA-10 can be purchased at sales branches of DÜRKOPP ADLER AG, under the following part numbers:

250-ml container: 9047 000011

1-litre container: 9047 000012 2-litre container: 9047 000013 5-litre container: 9047 000014

Maintenance required Explanation Operational interval, hours

Lubricating the automatic bartacker

The automatic bartacker is equipped with central oil wick lubrication. The bearings are supplied by the oil reservoirs 2 and 3.

- The oil level must not drop below the red marking of both reservoirs.

- Fill up oil though the drill-hole 1, up to the red mark.

11. Standard Seam Patterns

Tack No. Stitch diagram Number Seam size (mm) Clamping type of stitches foot no.

142162.01,2

242102.01,2

342162.51,2

larger Cross 4 42 24 2.5 3 tack

5281021,2

628162.51,2

7361021,2

836162.51,2

Tack No. Stitch diagram Number Seam size (mm) Clamping type of stitches foot no.

9562433 larger crosstack

10 64 24 3 3

11 21 6 2.5 4, 8

smaller crosstack

12 28 6 2.5 4, 8

13 36 6 2.5 4, 8

14 15 8 3 4

15 21 8 2 4

16 28 8 2 4

Tack No. Stitch diagram Number Seam size (mm) Clamping type of stitches foot no.

17 21 10 0 1, 2

18 25 10 0 1, 2

19 27 25 0 3

Straightline crosstack

20 36 25 0 3

Longitudinal tack

21 41 25 0 3

22 43 35 0 7

23 29 4 20 5

24 41 4 20 5

Tack No. Stitch diagram Number Seam size (mm) Clamping type of stitches foot no.

25 48 4 20 5

Longitudinal tack

26 56 4 20 5

27 18 0 20 5

Straightline longitudinal tack

Circular tack

28 21 0 10 5

29 21 0 20 5

30 27 0 10 5

31 29 12 12 9

32 52 12 12 9

Tack No. Stitch diagram Number Seam size (mm) Clamping type of stitches foot no.

Circular tack 33 76 12 12 9

Stitched eyelet 34 101 Outer Ø 9 9

Inner Ø 3

35 42 10 7 10

Dtack

36 57 10 7 10

37 42 10 7 12

38 57 10 7 12

39 42 10 7 12

40 57 10 7 12

Tack No. Stitch diagram Number Seam size (mm) Clamping type of stitches foot no.

41 42 7 10 11

42 57 7 10 11

Dtack

43 42 7 10 11

44 57 7 10 11

Imitated 45 102 19 2,6 3 Button eyelet tack

46 120 20 3,8 3

47 47 17 10 6

Cross-over tack

48 103 40 20 7

Tack No. Stitch diagram Number Seam size (mm) Clamping type of stitches foot no.

49 44 12 10 13

Tri-tack

50 44 12 10 13

Duerkopp Adler 511 Operating Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual