Duerkopp Adler 550-867 Operating Instruction

550-867

Engineered work station for

side airbag tearing seam

Instruction manual

Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com

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

01/2011 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 550102

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 - 2011

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.

Index Page:

Preface and General Safety Instructions

Part 1: Operating Instructions Class 550-867 – Original Instructions

(Edition 01/2011)

1 Product Description ........................................... 5

2 Designated Use .............................................. 8

3 Optional Equipment ........................................... 8

4 Technical Data .............................................. 9

5 Operating

5.1 Threadingtheneedlethread....................................... 10

5.1.1 Machineswithelectronicallycontrolledneedlethreadtension(ETT)............... 11

5.1.2 Machines with mechanically set needle thread tension and with

electromagnetictensionrelease..................................... 12

5.2 Adjustingtheneedle-threadtension(mechanically)......................... 13

5.3 Adjustingtheneedle-threadtension(ETT)............................... 13

5.4 Adjustingthethreadregulator...................................... 14

5.5 Winding on the hook thread ....................................... 15

5.6 Threading in the hook thread....................................... 16

5.7 Inserting the hook thread bobbin with machines equipped with residual thread monitor. . . 17

5.8 Setting the hook thread tension ..................................... 18

5.9 Changingtheneedle............................................ 19

5.10 Liftingthesewingfeet........................................... 20

5.11 Lockingthesewingfeetinliftedposition............................... 20

5.12 Settingthesewing-footstroke...................................... 21

5.13 Sewing-footpressure........................................... 21

5.14 Settingthestitchlength.......................................... 22

5.15 Switch-keyonthemachinearm..................................... 22

5.16 LEDsonthetensionplate ........................................ 25

5.17 Residual-threadmonitorRFW20–7.................................. 25

5.18 Electro-pneumaticrapidstrokeadjustment.............................. 27

5.19 Uninterruptiblepowersupply(UPS) .................................. 28

5.20 Sewinglamp ................................................ 28

6 Operating the tearing seam visualization

6.1 Accessing the system ........................................... 29

6.1.1 Accessing the system for the first time (DA service personnel) .................. 29

6.1.2 Logging in with scanner and barcode ................................. 30

6.1.3 Logging in via the menu.......................................... 31

6.1.4 Logging out of the system ........................................ 32

6.1.5 Settinganewoperator .......................................... 33

6.1.6 Deletinganoperator............................................ 34

6.1.7 Displayingtheoperators......................................... 35

6.2 Seampatterns ............................................... 36

6.2.1 Creatinganewseampattern ...................................... 37

Index Page:

6.2.2 Editingaseampattern .......................................... 42

6.2.3 Copyingaseampattern.......................................... 43

6.2.4 Deletingaseampattern.......................................... 44

6.3 Database.................................................. 45

6.4 Checking................................................... 47

6.5 Exitingtheprogram............................................ 70

6.6 Errorcodes................................................. 71

6.7 Determiningtheendlabelbarcode................................... 72

6.8 Determiningtheendlabellayout.................................... 75

6.9 Adaptingbarcodedefinitions ...................................... 76

7Sewing

7.1 Seamscanner(optional) ......................................... 83

8 Maintenance

8.1 Cleaning and Checking .......................................... 84

8.2 Repair .................................................... 86

1 Product Description

The DÜRKOPP ADLER class 550-867 is a sewing unit designed for documented airbag tearing seams.

Single needle flat bed double lockstitch sewing machine class 867 with bottom feed, needle feed and alternating upper feed.

With electromagnetic actuated thread trimmer and sewing foot lifting. Electromotor driven stitch length setting and seam bartacking.

Technical specifications sewing unit

Extra-large, two-piece vertical hook (XXL)

The maximum fabric clearance under neath the sewing feet is

20 mm.

The remaining thread length after thread trimming is about 7 mm

with a short thread trimmer equipment.

The snap fit coupling prevents the displacing and damaging of the

hook at thread deflection

Automatic wick lubricating with an inspection glass on the arm for

the machine and hook lubrication.

Stitch length setting via step motor

Multi-position cylinder for the adjustment of the sewing-foot

stroke

Rapid stroke adjustment with automatic speed adaption

Electronically controlled needle thread tension (ETT= electronic

controlled needle thread tension) or mechanically set needle thread tension and with electromagnetic tension release

Residual thread monitor RFW 20–7

Thread tension sensor

Motor driven bobbin winder with automatic wind on

Specially designed bobbin in order to prevent errors through the

insertion of inadequate bobbins

Stand is adjustable in height

Monitoring of the throat plate slide at bobbin change

Fabric edge guide with integrated glass fibre optics light barrier in

order to recognize the strip on the cuts and LED to recognize the seam segment (tearing seam = red, free seam = green)

Upper feed pressure can be locked

Barcode printer

15" industrial touch panel PC

Needle and hook thread cone monitoring via proximity switch

Manual scanner

Reel stand for 6 thread cones

Technical specifications software

Intuitive user interface

Sewing programs with up to 30 seam segments

Switching over via strip detection, stitch counting or manually

Different setup masks and endlabel masks can be memorized

Teach-in function for ETT (electronically controlled needle thread

tension)

Test window for the thread tension

Display of the thread tension during sewing

Recognition of the needle and hook thread via barcode scanning

(if the option is available)

Recognition of the material part 1 and / or part 2 (resp. part 3) via

manual scanning

Alle seam sections can be defined with various parameters

The following parameters are automatically suppressed in the

rupture seam segment

RS function (bartacking via step motor)

HP function (pneumatic stroke adjustment)

FA function (thread trimmer)

Optical indicator “tearing seam” in the visual field of the operator

(LED - red)

Evaluation of the collected material data

Monitoring and active adjustment of the needle tread tension (only

ETT (electronically controlled needle thread tension))

Automatic thread breakage recognition

Deviations from the nominal values during a seam are recognized

and lead to a sewing stop

The sewing process can be stopped in the segment of the lateral

airbag by the seamstress. In order to do this the “FA” button has to be pressed a nd additionally the foot pedal has to be pushed into position 2. The message “not O.K.” will be automatically issued for this seat.

After completing the last seam section all sewing parameters will

be memorized and the request to scan the next material bar codes appears

Data entry in a data base or in a ASCII file

Different levels authorized for operators, supervisors and

production manager

Data backup also during power outage via UPS (Uninterruptible

power supply)

Data entry

Date

Time

Line number

Endlabel barcode

Entrance barcode 1 - 3

Barcode needle thread

Barcode hook thread

Additional barcode information (max. 9)

Bobbin number

Bobbin winder information

Bobbin insertion information

Operator name

Number of seam sections

Set stitch length per seam section

Absolute seam section length

Calculated stitch length

Thread tension window

Stitch counting

Name of seam pattern

Machine number

Manufacturer’s identification number

Cycle time

Error code

Cycle number

Thread tension data for individual stitches

Daily number

2 Designated Use

The class 550-867 is an configured sewing station designed for the sewing of light to medium-heavy material. Such material is generally made of textile fibers, but it may also be leather.

These materials are used in the clothing industry and for domestic and motor-vehicle upholstery.

It is also possible to produce so-called technical seams with this configured sewing station. In this case, however, the operator must assess the possible dangers which may arise (DÜRKOPP ADLER AG would be happy to assist with this assessment), since such applications are on the one hand relatively unusual and, on the other, so varied that no single set of criteria can cover them all. The outcome of this assessment may require to take appropriate safety measures.

Generally only dry material may be sewn with this sewing machine. The material must not be thicker than 10 mm when compressed by the lowered sewing feet. The material may not contain any hard objects. Otherwise the machine may only be operated with an eye-protection device. Such an eye-protection device is currently not available.

The seam is commonly sewn with sewing threads made from textile fibers of the dimensions up to 11 / 3 NeB (cotton threads), 11 / 3 Nm (synthetic threads) or 11 / 4 Nm (core threads). If other types of thread aretobeused,thepossibledangersarisingfromithavetobe assessed and, if necessary, safety measures have to be taken.

This configured sewing station may be set up and operated only in dry, well-maintained premises. If the sewing unit is used in premises which are not dry and well-maintained, it may be necessary to take further precautions which should be agreed in advance (see EN 60204-31:1999).

As manufacturers of industrial sewing machines we proceed on the assumption that personnel that works 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 Optional equipment

For the class 550-867 the following optional equipment is available:

Order-No. Optional equipment

9800 330010 Control panel V 820 0867 590724 Head cover scanner incl. holder to check the endlabel 0867 590904 Scanner with holder (2x) to enter the needle- and hook

thread cone bar codes

0867 590924 Scanner (2x) for the bobbin monitoring via barcode on

the bobbin winder and hook 0867 590014 Needle cooling NK 20-1 0867 590054 Needle cooling NK 20-5

4 Technical data

Noise: Lc = dB (A)

Workplace-related emission value in accordance with DIN 45635-48-A-1-KL-2

Speed: min Material:

Sewing stitch type: 301 / double lock stitch

Number of needles: 1

Needle system: 134/35

Needle size : [NM] 90 - 140

Needle thread size

- Cotton: [NeB] 20/3

- Synthetic sewing thread: [Nm] 20/3

- Core thread [Nm] 20/3

Bobbin wind-on capacity with synthetic sewing thread

- 60/3: [m] 98

-1

Number of stitches:

- with HP equipment: [min

- factory setting: [min

-1

] 3400

-1

] 3400

Stitch length: Forwards and backwards [mm] 0 - 6 (9)

Lift stroke of sewing feet:

- max. [mm] 9

Clearance underneath sewing feet

- Sewing [mm] 10

- Lifted: [mm] 20

Operating pressure: [bar] 6

Air consumption: about [NL] 0.7

Length, width, height (incl. PC) [mm] 1600 x 920 x 1550

Weight: [kg] about 194

Rated voltage: [V, Hz] 1~ 190 - 240 V, 50/60 Hz

Input power: [KVA] 1 kVA

5 Operating

5.1 Threading the needle thread

Caution: Risk of Injury !

Turn off the main switch! The needle thread may only be threaded with the sewing machine

being switched off.

32 1

Before putting in the needle thread cones they need to be scanned with the hand scanner.

With thread barcode scanner equipment (optional):

–

Unscrew the ball 1.

–

Put the cone 2 on the stand and make sure that the barcode 4 on the thread reel can be read by the optional thread barcode scanner 5. If the scanner does not recognize the barcode an error message will appear on the monitor.

–

Tighten the reel with ball 1 and washer 3.

–

Lead the needle thread through the unwinder arm 6. The unwinder arm must be in vertical position above the thread reels.

–

Conduct the needle thread through the guiding tube 7.

5.1.1 Machines with electronically controlled needle thread tension (ETT)

765

–

Conduct the thread through the threading guide 1 and clockwise around the pretensioner 2.

–

Conduct the thread counter-clockwise around the tensioner 3.

–

Conduct the thread clockwise around the tensioner 4.

–

Conduct the thread through threading guide 5.

–

Pull the thread underneath the thread take-up spring 7 and conduct it through the thread regulator 6 to the thread lever 9.

–

Conduct the thread through the thread lever 9 and the thread tension sensor 8.

–

Conduct the thread through the thread clamp 10 and the threading guides 11 and 12 on the needle bar.

–

Thread the thread into the needle eye 13.

5.1.2 Machines with mechanically set needle thread tension and with electromagnetic tension release

765

–

Conduct the thread through the threading guide 1 and clockwise around the pretensioner 2.

–

Conduct the thread counter-clockwise around the tensioner 3.

–

Conduct the thread clockwise around the tensioner 4.

–

Conduct the thread through threading guide 5.

–

Pull the thread underneath the thread take-up spring 7 and conduct it through the thread regulator 6 to the thread lever 9.

–

Conduct the thread through the thread lever 9 and the thread tension sensor 8.

–

Conduct the thread through the thread clamp 10 and the threading guides 11 and 12 on the needle bar.

–

Thread the thread into the needle eye 13.

5.2 Adjusting the needle-thread tension (mechanically)

The tension is to be set according to the values given by the seat cover manufacturers. The cross-over point should lie in the center of the material.

–

The pretensioner 1 is preset.

–

Unscrew the locking plate 3.

–

Set the main tensioner 2 and 4.

–

Mount the locking plate 3 again.

5.3 Adjusting the needle-thread tension (ETT)

The thread tension is set via the machine’s software.

5.4 Adjusting the thread regulator

32 1

Caution: Risk of injury!

Turn off the main switch. The thread regulator may only be adjusted with the sewing machine

switched off.

The thread regulator 1 controls the quantity of needle thread required for stitch formation. The thread regulator must be precisely adjusted for an optimum result.

With correct setting the needle-thread loop must slide with low tension over the thickest point of the hook.

–

Loosen screw 2.

–

Adjust position of the thread regulator 1. Thread regulator to the left = more thread Thread regulator to the right = less thread

–

Tighten screw 2.

Adjustment information:

If the maximum quantity of thread is required, the thread-tensioning spring 3 must be pulled upwards about 0.5 mm from its lower limit position. This is the case, when the needle-thread loop passes the maximum hook diameter.

5.5 Winding on the hook thread

ATTENTION!

Only use bobbins that are specially designed for this machine type!

65 4

–

Put the hook thread cone on the thread stand.

–

Conduct the hook thread through the threading guide on the unwinder arm and through the tube 1.

–

Conduct the thread counter-clockwise around the tensioner 3.

–

Conduct the thread through threading guide 2 to the bobbin 4.

–

Pull the thread beginning behind the tear-off knife 6 and tear it off.

–

Swivel the winder lever 5 against the empty bobbin.

–

Enter the number of the bobbin via touch screen on the monitor. When the bobbin is filled, the winding will be automatically stopped by the winder lever 5.

Caution!

Please make sure that the entered number corresponds to the bobbin number before actuating the “Return” key.

“Return”

5.6 Threading in the hook thread

654

Caution: Risk of injury!

Turn off the main switch! The hook thread may only be threaded with the sewing machine being

switched off.

–

Raise up the flap 1 and remove the empty bobbin 2.

–

Insert the bobbin 2 in a way that it moves in counter-clockwise direction when unwinding the thread.

–

Conduct the thread through slot 3 and underneath the spring 4.

–

Pull the thread through the slot 6 and continue pulling until it stands out about 3 cm.

–

Close the flap 1 and pull the thread through the thread guiding 5 of the flap 1.

5.7 Inserting the hook thread bobbin with machines equipped with residual thread monitor

ATTENTION!

The hook bobbin has to be inserted so that the milling 1 is turned downwards. The area around the bobbin housing and the light barrier has to be cleared of sewing dust !

Winding on the bobbin thread

ATTENTION!

When winding the thread on, the milling 1 has t o be positioned towards the machine so that the thread is first wound into the reservegroove2.

5.8 Setting the hook thread tension

Caution: Risk of injury!

Turn off the main switch. The hook thread tension may only be adjusted with the sewing

machine switched off.

Setting the tension spring 2

–

Set the tension spring 2 by turning the adjustment screw 1. Increase the hook thread tension = Turn screw 1 clockwise

Decrease the pressure = Turn screw 1 counter-clockwise.

5.9 Changing the needle

Caution: Risk of injury!

Turn off the main switch! The needle may only be threaded in and changed with the sewing

machine being switched off.

–

Turn the handwheel until the needle bar is in its upper dead center.

–

Loosen screw 1.

–

Remove the needle.

–

Insert the new needle aligning it, so that the needle scarf points to the hook and push it to the top as far as it will go.

–

Tighten screw 1.

ATTENTION!

If a needle with a different size is inserted, the settings have to be adjusted as mentioned in the Service Instructions.

Otherwise missed stitches or thread damage may occur when a thinner needle is used.

When using a thicker needle the hook tip or the needle may be damaged.

5.10 Lifting the sewing feet

The sewing feet can be lifted electro-pneumatically by actuating the pedal 1.

–

Press the pedal 1 half-way back. The sewing feet are lifted with the machine at a halt.

–

Press the pedal 1 all the way back. The thread trimmer is actuated and the sewing feet are lifted.

5.11 Locking the sewing feet in lifted position

–

Swivel the lever 1 downwards. The sewing feet are locked in lifted position.

–

Swivel the lever 1 upwards.

The sewing feet are unlocked. Or Lift the sewing feet pneumatically via foot pedal.

The lever 1 then swivels back into its initial position.

5.12 Setting the sewing-foot stroke

The lift stroke 1 of the sewing foot can be set to eight levels (0 – 7) via the touch screen monitor in the menu item “seam pattern”.

The maximum stroke can be switched on during sewing in free seam segments by actuating the knee switch 2. For the documented seam sections this function is disabled.

Important note

Sewing-foot stroke and number of stitches are interdependent. Through this potentiometer the control unit recognizes the set sewing-foot stroke and limits the number of stitches. The values are predetermined by the control unit.

5.13 Sewing-foot pressure

The required sewing-foot pressure is set with the rotary knob 3.

–

Unscrew the locking device 4.

–

To increase the sewing-foot pressure Turn the rotary k nob 3 clockwise

–

Decrease the sewing-foot pressure Turn the rotary knob 3 counter-clockwise.

–

Mount the locking device 4 again.

5.14 Setting the stitch length

The setting of the stitch length is effectuated via touch screen monitor in the menu item “seam pattern”.

For each seam section different stitch lengths can be programmed.

5.15 Switch-key on the machine arm

12345 6

Key Function

Manually sewing backwards. The machine sews backward stitches as long as the key 1 is being pushed.

Setting the needle in high or low position. The function of the key can be defined with the parameter F-140. 1 = Needle high, 2 = Needle high/low, 3 = Single stitch, 4 = Single stitch with 2nd stitch length/ short stitch 5 = Needle high, when outside position 2 The factory setting is 1 = needle high.

Activating or suppressing the initial or final bartack. If the initial and final bartacks are generally switched on, the next bartack is switched off by actuating the key. If the initial and final bartacks are generally switched off, the next bartack is switched on by actuating the key.

6 Quickstrokeadjustment

Forced break-off of the airbag tearing seam

98 71

LED Function

8and9

With the screw 7 under neath the keys the respective function can be set as “favorite function” for key 10.

–

Select a function. Example: 1 = Manually sewing backwards

–

Turn in the screw underneath the key 1 and tur n it 90° to the right (the slot stands vertically). The function can now be called via both keys 1 and 10.

ATTENTION!

–

Before assigning a new function to key 10 the previous function must be deactivated.

Display for an empty bobbin with residual thread monitor (left/ right bobbin)

LED display “power on”

5.16 LEDs on the tension plate

The red LED shines = a tearing seam is sewn The green LED shines = a non-tearing seam is sewn

red

green

5.17 Residual-thread monitor RFW 20 - 7

The residual thread monitor monitors the quantity of the thread on the bobbin. A signal is issued on the PC announcing that only a small quantity of thread remains.

The operator can finish the seam and insert a new bobbin. This way undesirable repairs or damage to the material are avoided.

Function and operation of the residual thread monitor

If the light beam from the light barrier is reflected by the surface 1 on the bobbin core during sewing, a signal is issued on the PC and the sewing process will be interrupted.

–

Confirm the message on the PC screen.

–

Release the pedal and then push it forward again. The seam will be continued. Generally the quantity of thread left in the reserve groove 2 of the bobbin will be sufficient to finish the seam.

–

At the end of the seam push the pedal back. The thread will be cut.

–

Terminate the sewing mode with “Back” on the PC.

Caution: Risk of injury!

Turn off the main switch! The bobbin may only be changed with the sewing machine being

switched off.

–

Replace the bobbin.

–

Reactivate the sewing mode on the PC with “Sew”. A new seam can be started.

+ 61 hidden pages

Duerkopp Adler 550-867 Operating Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual