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.

ATTENTION!

The hook bobbin has to be inserted so that the milling 3 is turned downwards. The area around the bobbin housing and the light barrier have to be cleared of sewing dust !

Important note

If the empty bobbin is not replaced by a full one, the signal will reappear on the monitor at the end of the next seam.

–

Wind on the bobbin thread.

This process is described in this manual.

5.18 Electro-pneumatic rapid stroke adjustment

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

The preset sewing-foot stroke can be switched on during free seam sequences by actuating the knee lever 1 or the switch 5.

Setting the function of the knee lever

The function of the knee lever is set via the tilt switch 2 (rested or pushed operation).

Switching on the maximum stroke during sewing

–

Actuate the knee lever 1 . The sewing-foot stroke is actuated as long as the knee lever 1 is being kept pushed (pushed operation) or until the knee lever is actuated the next time (rested operation).

5.19 Uninterruptible power supply (UPS)

The uninterruptible power supply is connected just before the main switch. It must not be switched off separately so that the accumulator is loaded permanently.

Switching on the UPS

–

Press the button 1.

The UPS is switched on. For more details consult the instructions of the manufacturer.

5.20 Sewing lamp

54 32

Switching on the sewing lamp 1.

–

Set the switch 5 to “1”.

–

Press the switch 3.

The sewing lamp is switched on.

–

The brightness can be altered with the switches 2 (+) and 4 (-).

6 Operating the tearing seam visualization

The program is operated by pressing the appropriate buttons on the touch panel PC 1.

The access to the program is partly protected through three security levels. (Depending on the security level some buttons on the basic screen cannot be selected).

6.1 Accessing the system

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

–

Insert the dongle 2 into the USB slot.

–

Enter “Admin” as operator.

–

Confirm with “OK”.

6.1.2 Logging in with scanner and barcode

–

Press the switch 2 under neath the table top.

The integrated lamp lights up.

–

Scan in the barcode of the operator using the hand scanner 3.

The corresponding security level is activated.

6.1.3 Logging in via the menu

“Access”

The operator can also log in manually as follows:

–

Press the button “Access”. The following screen will appear:

“Log in”

“Operator”

and

“Password”

–

Press the button “Log in”. The following screen will appear:

–

Enter operator and password.

–

Press the “OK” button. The operator is logged in.

6.1.4 Logging out of the system

“Access”

–

Press the button “Access”.

The following screen will appear:

“Log out”

–

Press the button “Log out”.

The following screen will appear:

Note:

Operators with security level 0 are automatically logged off after two minutes without action.

6.1.5 Setting a new operator

Before a new operator can use the sewing unit a user account has to be set for him. The one setting the account needs to have at least security level 2.

Note!

In “Setup” the number of digits for the card barcode has to be defined previously.

–

Press the button “Access”.

–

Press the button “New”. The following screen will appear:

–

Enter the name of the new operator and determine his security level.

–

Enter the personnel number.

–

Enter the password.

–

Repeat the password entry.

–

Press the button “Print BC”. A barcode for the log-in via scanner will be printed for the new operator.

–

Press the log-in switch (under neath the table top).

–

Enter the barcode with the hand scanner. The number will be displayed in the field “Identity number”.

–

Press the “OK” button. The entries will be adopted.

–

Memorize.

Note:

The log-in system works only with the barcode type 128. Other barcode types are not accepted by the system. The contents of the security level authorization barcode can be checked later on with the hand scanner.

6.1.6 Deleting an operator

In order to carry out this operation the user must have the user privilege of security level 2.

–

Press the button “Access”.

–

Press the button “Delete”.

The following screen will appear:

–

Select the corresponding operator.

(For example : Operator name Sam)

–

Press the button “Delete operator”.

The following screen will appear:

–

Press the button “Yes”.

The operator will be deleted from the list.

6.1.7 Displaying the operators

–

Press the button “Access”.

–

Press the button “Show users” (Dispaly users). The following screen will appear:

–

Press “User photo”. The following screen will appear:

–

Select a user photo from t he list.

–

Press “Open”. The photo will be loaded.

Note:

The user photos are memorized in the following path: C:\SABSoft\SystemDB\ -

Format: JPEG Size: < 150 KB

6.2 Seam patterns

Upon pressing the button “seam patter ns” new seam patterns can be created or existing seam patterns can be edited or deleted.

–

Press the button “Seam rec.” (Seam patter ns).

The following screen will appear:

6.2.1 Creating a new seam pattern

–

Press the button “new seam record set” (new seam pattern). A screen displaying all existing seam patterns and their alteration status will appear.

–

Press “seam par. rec.” (seam patter n code) 2. The following input screen will appear.

“Return”

–

Enter the seam patter n code.

–

Press the “Return” button.

–

Press “seam record set name” (seam pattern name) 1. The following input screen will appear.

–

Enter the name of the seam pattern.

–

Press the “Return” button. The list of all existing seam patterns and their alteration status will be displayed.

–

Press the “OK” button.

An input screen for the number of seam sections will appear.

–

Select the number of seam sections, for example “3”.

–

Press the “OK” button.

The new seam patter n will be displayed.

selected seam section

–

Select the individual seam sections by clicking on them and enter the corresponding seam parameters. The selected seam section is displayed with a raised bar.

monitored (red) not monitored

(green)

Parameter Description Free/SAB Indicates whether a free seam section

or a tearing seam is activated

Max. speed Maximum speed for the current seam

section St length stitch length in the current seam section St l corr.fac. Correction of the stitch length depending

on the material Dist. Length Distance between the two strips on the

sewing material Thread tension Tolerance range (lower value, top value)

and number of tolerance stitches Thread tens. Value of power supply in % (only with ETT) Stop at strip, stitch counting or manually (Pedal – 2) GB thread ten.

Komp file Selection of a teach-in file (only with ETT) Lift Stroke Lift stroke of the alter nating sewing feet Lift stroke knee Lift stroke upon activating the knee lever

(Rapid stroke adjustment) Bartack stitches Number of bartack stitches

(forwards/backwards) Sew-in the label Activates the seam scanner TT on/off Trims the thread at the end of the seam

section

–

After setting the seam parameters for all of the seam sections, press the button “Save”.

Inserting a seam section

–

Select the seam section following the new section that is to be inserted.

–

Press the “Insert” button. The following screen will appear.

–

Press the “OK” button. The inserted seam section 1 will be displayed.

–

Select the new seam section by clicking and enter the corresponding seam parameters.

–

After setting the seam parameters, press the button “Save”.

Deleting a seam section

–

Press the seam section that is to be deleted. For example: Seam section 1.

–

Press the button “Delete”. The following screen will appear:

–

Press the “OK” button. The seam section will be deleted. Three seam sections are displayed.

6.2.2 Editing a seam pattern

–

Press the “Edit seam par. record” (edit seam patter n) button. A list of all existing seam patterns and their alteration status will be displayed.

–

Enter the seam patter n code.

–

Press the “OK” button. The selected seam patter n will be displayed on the screen.

–

Call up the individual seam sections and effectuate the desired alterations.

–

Press the button “Save”.

6.2.3 Copying a seam pattern

–

Press the button “Copy a seam pattern”. A list of all existing seam patterns and their alteration status will be displayed.

–

Enter the code of the seam pattern that is to be copied. For example: Seam Record 220 ETT.

–

Press “seam pattern code”.

–

Enter a new number for the seam patter n code. For example: 420

–

Press the “OK” button.

–

Press “seam pattern name” and enter a new name.

–

Press the “OK” button. The following screen will appear.

–

Press the “OK” button. The seam pattern 220 has been copied to the new seam patter n

420.

6.2.4 Deleting a seam pattern

–

Press the button “Delete seam record set" (delete a seam pattern). A list of all existing seam patterns and their alteration status will be displayed.

–

Enter the seam patter n code. For example: seam 420 from 220

–

Press the button “OK”. A confirmation request will appear:

–

Confirm the request with “Yes”. The seam pattern 420 will be deleted.

6.3 Data base

The finished seams are recorded and the data are memorized in a data base.

Via the button “Data base” these recorded data can be displayed, printed and copied.

–

The selection of the desired data takes place via button 1.

“Files”

Each day a new file is created. With the “Files” button an older file can be displayed.

–

Press the “Files” button. The following menu will appear:

–

Press the requested file.

–

Press “Open”.

“Print”

If a printer is connected, the selected file can be printed via the button “Print”.

“Copy”

The selected daily file will be copied to a previously determined directory.

“Help”

A list of the error codes will appear (see chapter 6.6)

“Thread tens”

File that indicates the thread tension values of each individual stitch within the documented seam sections.

6.4 Checking

Via the button “Check” functions are available that serve to secure and restore files, to inform about sewing materials and sewing parameters as well as to test, adjust and set-up the integrated sewing unit.

“Backup System”

When this function is activated all system-relevant settings will be saved.

–

Press “Backup system”. The following screen will appear:

–

Press the “OK” button. A selection window will appear.

–

Select the backup location.

–

Press “OK”. The backup will be saved.

“Restore System”

System-relevant data are imported into the system. The requested parameters can be set previously.

For the way of proceeding see “Backup System”

“Print BC Label”

When this function is activated the label printer will print a barcode label.

“Backup Record DB”

When this function is activated all data base records of the sewing station will be saved under the corresponding machine number.

For the way of proceeding see “Backup System”.

“Data import”

Backup files of older software versions will be imported. For the way of proceeding see “Backup System”.

“Copy dump files”

When this function is activated all dump files will be copied. For the way of proceeding see “Backup System”.

“Connections”

When this function is activated all connections of the computer will be listed.

“Setup”

When this function is activated system settings can be carried out.

“General settings”

In “General settings” the language is selected, code numbers for the manufacturer and the machine are attributed, the number of relevant barcode digits determined and the sewing equipment to be used is selected.

“Components”

Here the operating equipment or the functions are activated or deactivated.

Barcode printer For the printing of barcode labels

during sewing

existing / not existing

Protocoll printer (optional) for the printing of

recorded data after sewing

existing / not existing

With batch mode Allows for repeated sewing

after one-time scanning

activated/ deactivated

Scanner needle thread Reading the needle thread barcode

with a fixed scanner (optional)

existing / not existing

Scanner hook thread Reading the hook thread barcode

with a fixed scanner (optional)

existing / not existing

Bobbin winder Automatic Bobbin winder

existing / not existing

Step motor Stitch length adjustment via

step motor

existing / not existing

Read bobbin no. with fixed scanner Bobbin identification via

barcode (optional)

existing / not existing

With seam scanner Monitoring of the end label

(optional)

existing / not existing

Cone switch for needle thread Monitoring of the thread cone

via proximity switch. The bar codes are read with the hand scanner.

existing / not existing

Cone switch for hook thread Monitoring of the thread cone

via proximity switch. The bar codes are read with the hand scanner.

existing / not existing

Multibarcodes Entering additional bar codes

besides the primary bar codes

possible/ not possible

Needle control Regular control / exchange

of the needle

activated/ deactivated

Multibarcode switch Automatic entering of additional

bar codes in batch mode

activated/ deactivated

Save individual stitch data of SAB-seam Saving the thread tension values

in a TXT-file

on/off

Stitch counting with PC card The stitch counting of t he PC

not of Efka is being considered

activated/ deactivated

Efka decorative bartack switched on Make selection according to

Efka parameter settings (decorative or regular bartack)

on/off

Thread tens. individual stitch check Definition whether the number

of tolerance stitches in a row should be outside of the tolerance or be repartitioned over the whole length

on/off

Calibration control Regular checking of the step

motor and the thread tension sensor

on/off

Thread tension graphic Visualization of the thread tension

during the sewing process

on/off

Thread tension regulator on When using an ETT nominal and

and actual values are compared and corrected (adjusted)

On/off

Edge detection Optional equipment for the

detection / controlling of the distance between needle and material edge

existing / not existing

Bartack stitches progr. for each SS Allows for different bartack

stitches for the initial and end bartack in the particular seam section

On/off

“Values”

In “Values” the scanners to be used are selected, the barcode type for the card reader is defined and the number of relevant card barcode digits is determined.

If in the field “Components” the function “Sew-in label separately” has been activated, the number of stitches for the additional seam can be determined in this function.

In order to prevent that each thread that gets into the light barrier simulates a strip, the sensibility of the light barrier can be adjusted in the function “Strip detection filter stitches”. If the value 2 is entered, thesizeofthestripmustbeextendedovertwostitchesinordertobe recognized as such.

By altering the user levels the access rights to the system can be influenced. The entered values represent the security levels that are at least required in order to carry out the program functions.

In the field “Lot size” can be entered the number of sewing procedures that a singular scanning of the entry barcode will allow for.

“Bar codes”

Via the “Barcode” field the barcode definitions can be adjusted, saved or newly loaded.

In order to do so the relevant barcode digits are defined through the setting of masks.

1 = The digit of the barcode will be read. 0 = The digit of the barcode will be ignored.

Entry of the nominal

values

Changing the barcode definition

–

Press the corresponding barcode row 1 An input screen will appear.

–

Enter the barcode definition.

–

Press the “OK” button. The new definition is adopted.

–

Press the button “Save”.

Loading a barcode definition

–

Press the “Load” button. A selection window will appear.

–

Select a file.

–

Press “Open”. The file will be loaded.

Memorizing a barcode definition

–

Press the “Save” button. A selection window will appear.

–

Enter a file name.

–

Press “Save”. The definition is memorized.

“Label”

Via the button “Label” the layout of the end label is defined. The barcode information that will be printed is determined.

Via the button “Define ext. label print" additional information can be included on the end label.

1 Determining the end label barcode type

see chapter 6.7.

2 Determining the end label layout

see chapter 6.8.

3 Determining the text to be printed

“Load”

Via this button a barcode setup file can be loaded.

–

Press “Load”. A selection window will appear.

–

Press the requested file.

–

Press “Open”. The file will be loaded.

“Save”

Via this button a barcode definition can be memorized.

–

Press “Save”. A selection window will appear.

–

Enter a file name.

–

Press “Save”. The file will be memorized.

“Define extended label printing”

Via this button an extended label print can be edited. With this function, variable information can be printed on the endlabel.

“Path + Network”

Via the button “Path+Netw.” the paths for the memorizing of the record data base and the system data base as well as the time interval for automatic saving are determined.

–

Press “Change path”. The following screen will appear:

–

Select the path.

–

Press “OK”. The path will be adopted.

Note:

When using a network connection the path for the automatic copy of the record data base will be changed to the desired path.

“Threads”

When this function is activated a data base with the thread types that have been determined for this system will be displayed.

New thread types can be entered and existing thread types can be edited or deleted.

Important note

When entering a new thread type the Ident-No. has to be entered. Through the Ident-No. the system recognizes the thread. It is made up of the predefined digits of the thread barcode.

Entering a new thread type

–

Press the button “New thread”. The thread type data base editor will appear.

–

Enter the thread barcode.

–

Scan the thread barcode.

–

Press the button “Scan”. The following screen will appear:

–

Read the thread barcode with the hand scanner.

–

Press “OK”. The thread barcode is adopted.

–

Enter further thread data and confirm with “OK”.

“Change thread type”

When this function is activated the selected thread type can be modified.

“Delete thread type”

When this function is activated the selected thread type can be deleted.

“Print DB”

When this function is activated the seam data base is printed (only if a record printer is connected and has been activated at setup)

“Display DB”

When this function is activated the seam data base will be opened and all seam parameters will be displayed.

“Bobbins”

When this function is activated all registered bobbins will be displayed. When pressing the button “Delete” selected bobbins can be deleted.

–

Press the bobbin that is to be deleted.

–

Press “Delete”. A confirmation request will appear:

–

Press “OK”. The bobbins will be deleted.

“Needle DB”

If during the setup the component „needle control“ has been activated, the operator will be asked in certain intervals to check the needle and replace it, if necessary.

These activities are recorded in the needle replacement data base.

–

Press “Exchange”. The following screen will appear:

–

Press “Checked”. The following screen will appear:

SM Cali

“SM-Cali” and “Cali”

If during the setup the component „calibration control“ has been activated, the operator will be asked in certain intervals to check the settings of the step motor and the thread tension sensor or to recalibrate them.

These activities are recorded in the thread tension and step motor calibration data base.

Cali

“SM”

When this function is activated the stitch length adjustment can be calibrated and checked.

Checking the stitch lengths

–

Pull the needle thread out of the needle.

–

Put a piece of cardboard 1 under the sewing foot.

–

Press the button “Check 2 mm”.

–

Press the foot pedal. A predetermined section will be sewn.

–

Measure the stitch length.

–

Proceed as described for the other stitch lengths.

Calibrating the stitch lengths

–

Pull the needle thread out of the needle.

–

Put a piece of cardboard 1 under the sewing foot.

–

Press the button “Cali. 1”. The following screen will appear:

–

Press the button “Enter 100 stitches + length”. The following screen will appear:

–

Press the foot pedal. A predetermined section will be sewn.

–

Measure the stitch length and enter it with the keys.

–

Press “Return”.

–

Repeat the procedure for “Cali. 2”.

–

Memorize.

“I/O”

When this function is activated the inputs and outputs of the system can be checked.

“Scanner”

When this function is activated the barcode scanners can be tested.

“Sewing motor”

When this function is activated all the functions of the Efka DC motor can be checked.

The preset settings like initial bartack, end bartack, speed, stitch length and so forth will be transmitted to the control unit via pressing the “Send” button and a seam will be released.

Note:

These entries can only be carried out via external operating panel of the type V820.

“Thread tension”

This function is for the setting of the thread tension in consideration of the preset tolerance limits, the sewing speed, the lift stroke as well as the stitch length and for the checking of the thread tension after a teach-in process in connection with an ETT. See chapter 6.6 Tolerance range of the thread tension.

“Thread tens.file”

After pressing this button a thread tension file can be loaded.

“Teach-In” (only available with ETT)

During the monitored seam sections the values of the occurring thread tensions will be compared to a preset tolerance range. If the thread tensions deviate from the tolerance range more often than desired the seam will be defined as bad seam.

Adjusting the thread tension to the required tolerance range

The value of the needle thread tension is influenced by several factors like sewing speed, material, sewing thread, seam section etc. With the function “Thread tension” the upper and lower limits for the needle thread tension can be set.

Step 1: Setting the thread tension at the operating point and at the limits.

–

Enter the corresponding values for the tearing seam into the field for “lower limit”, “upper limit” and “target value”. (Manufacturer’s data)

–

Enter the maximum speed.

–

Enter stitch length and lift stroke.

–

Press “Set Fa”. The thread tension value is adopted.

–

Check the thread tension using a thread scale.

–

Adjust the value for “Current lifting magnet” correspondingly. Lower value = Lower thread tension Higher value = Higher thread tension

–

Also check “Lower limit” and “Upper limit” (Fu, Fo).

–

Press the button “Next step”.

Step 2 Thread tension at the operating point

–

Press “Begin test seam”. The following screen will appear:

The calculated values for step 2 will be displayed.

–

Press the button “Next step”.

–

Carry out steps 3 and 4. A screen displaying all registered values will appear.

With the field “File name (NB number)” the calculated values can be memorized.

6.5 Exiting the program

–

Press the button “End”. The following screen will appear:

–

Press the button “PC off”. The program will shut down and the computer will be switched off.

Note:

If the program is exited with “Yes”, the windows level will be entered (only possible with security level 2).

6.6 Error codes

EC10000 Acknowledging an error through the supervisor EC20000 Check the thread tension, currently not in use EC21000 Forced thread trimming in a t earing seam EC21500 Received a wrong error message from the Efka motor EC21600 Received a wrong bobbin thread message from the

Efka motor EC22000 Forced bartack in a t earing seam EC22500 Wrong bartack in the seam EC22600 Wrong stitch counting motor and PC EC23000 Thread breakage in a tearing seam EC23500 Thread tension too low in a tearing seam EC23600 Thread tension too high in a tearing seam EC25000 Thread breakage within a free seam EC25500 Thread tension too low in a free seam EC25600 Thread tension too high in a free seam EC25700 Edge detection upper limit overran EC25800 Edge detection lower limit overran EC26000 Did not read the extra bar code label (additional bar code) EC27000 Hardware-error, Efka control unit does not react properly EC27500 Hardware-error, Thread tension measuring device does

not react properly EC28000 Remained below the allowed stitch area EC29000 Exceeded the allowed stitch area EC31010 Incorrect reading of the final label bar code EC31000 Incorrect reading of the final label bar code with the

manual scanner of the supervisor EC31500 Wrong final label sewn into the workpiece EC32000 A bobbin with a non approved thread has been inserted

during the sewing process EC33000 Bar code printer not ready

ECxxxxxACK The supervisor has acknowledged the error “xxxxx” ECxxxxxCNT The supervisor has released the further processing

of the workpiece despite the error “xxxxx”

6.7 Determining the endlabel barcode

In order to carry out changes in the barcode labeling system, the operator must have the user privilege of security level 2.

–

Call up “Check”.

–

Call up “Setup”.

–

Call up “Label”.

In field 1 the layout of the endlabel barcode is displayed. The meaning of the predefined codes is now explained:

D2 Current day (two digits); e.g.: June 9 = 09 M2 Current month (two digits); e.g.: June 9 = 06 Y2 Current year (two digits); e.g.: 2010 = 10 Y4 Current year (four digits); e.g.: 2010 = 2010 J3 Number of days in the year (three digits);

e.g.: February 20 = 051 H2 Current hour (two digits); e.g.: 8:52:13 = 08 U2 Current minute (two digits); e.g.: 8:52:13 = 52 S2 Current second (two digits); e.g.: 8:52:13 = 13 P1 Current personnel number (one digit); e.g.: 1234 = 1 P2 Current personnel number (two digits); e .g.: 1234 = 12 P3 Current personnel number (three digits); e.g.: 1234 = 123 P4 Current personnel number (four digits); e.g.: 1234 = 1234 E1 Current machine number (one digit); e.g.: 567 = 5 E2 Current machine number (two digits); e.g.: 567 = 56 E3 Current machine number (three digits); e.g.: 567 = 567 F1 Manufacturer code (one digit); e.g.: 1357 = 1 F2 Manufacturer code (two digits); e.g.: 1357 = 13 F3 Manufacturer code (three digits); e.g.: 1357 = 135 F4 Manufacturer code (four digits); e.g.: 1357 = 1357 N2 Daily number of pieces (two digits); e.g.: 1234 = 34 N3 Daily number of pieces (three digits); e.g.: 1234 = 234 N4 Daily number of pieces (four digits);e.g.: 1234 = 1234 N5 Daily number of pieces (five digits); e.g.: 12345 = 12345 N6 Daily number of pieces (six digits);

e.g.: 123456 = 123456

CP Number of digits and coding are defined by the mask

that is specified under “Prim.barcode mask label”. 1 = the digit will be read; 0 = the digit will be ignored

TU Number of digits and coding are defined by the mask

that is specified under “Needle thread mask label”. 1 = the digit will be read; 0 = the digit will be ignored

TL Number of digits and coding are defined by the mask

that is specified under “Hook thread mask label”.

1 = the digit will be read; 0 = the digit will be ignored WE Calender week (1 - 53) WD Weekday from 1 = Sunday to 7 = Saturday MB Element from multi-barcode KX Constant sign LR Identification left/right/L/R/U LN Identification left/right 0/1/2 SN Seam pattern number Y1 Year 1-digit CQ Part I primary barcode CR Part II primary barcode R2..R8 Resident counter V1..3 Machine number from the back CD, CE Numerics from the file

Defining the extended label print

This option allows to additionally print the information listed below on the endlabel.

The desired information is positioned on the endlabel by means of a defined program line.

When the extended label print is activated, the information will always be printed at the predefined position, regardless of the barcode set-up file that has been loaded.***********************************************************************

* * 550-867 * This is the extended label printing setup file * for customer specific printing * * Format of the control lines: * ————————————————————————* POSX , POSY , FONT , DESCRIBING TEXT , INFO-CODE * Each line, which has a “*” as first character is

* ignored. * *AvaibleInfo-Codes: * ————————————————* MB1 - MB9 : scanned mutli bar codes 1-9

*ONM:operatorname * OPN : operator personnel number * FAB : manufacturer code * MAC : machine number * TRN : needle thread barcode * TRB : bobbin t hread barcode * DPC : daily piece number * DNF : daily piece number formatted to 4 digits * DNT : daily piece number formatted to 3 digits * ERC : actual e rror code * SNM : seam record name * SRN : seam record number 00-99 *DAT:date *TIM:time * JDY : Julean Day * YR2, YR4 : Year with 2 or 4 digits *DAY:Tag * MON : Month * BON : bobbin number * PB1,PB2,PB3 : parts barcode 1,2,3 * SRT : text from the seam record * CYN : cycle number * DT2 : Date : Day, Month, Year but each with 2 digits * RC2,RC3,RC4,RC5,RC6,RC7,RC8 : resident part counter with 2..8 digits * GRP : Graphics, Print BMP-file, Filename without “.bmp” instead DESCR.TEXT

**************************************************************************

*40,33,1,,SNM *85,33,6,,DT2 *85,15,6,,DT2

6.8 Determining the endlabel layout

In order to carry out changes in the barcode labeling system the operator must have the user privilege of security level 2.

–

Call up “Check”.

–

Call up “Setup”.

–

Call up “Label”.

–

Enter the measured height of the label in the field “Label length”. For example: 25 mm

–

Enter the space between the labels in the field “Gap”. For example: 3 mm

–

Enter the desired label text into the fields 1. For example: Endlabel text 1 = Manufacturer Endlabel text 2 = Model Endlabel text left = Left-hand seat Endlabel text right = Right-hand seat

–

Set the origin for the text coordinates in the fields 2.

–

Set the position of the endlabel text 1 in the fields “Pos. text 1 X” and “Pos. text 1 Y”.

–

Set the position of the endlabel text 2 in the fields “Pos. text 2 X” and “Pos. text 2 Y”.

–

Set the position of the barcode in the fields “Pos. BC X" and “Pos. BC Y”.

–

In the field 3 the desired font is set.

–

With button 4 the set label is printed out.

6.9 Adapting barcode definitions

In order to carry out changes in the barcode labeling system the operator must have the user privilege of security level 2.

–

Call up “Check”.

–

Call up “Setup”.

–

Call up “Bar codes”.

–

Select the corresponding type in the field “Primary barcode type”. This barcode is read via hand scanner.

–

Select the corresponding type in the field “Thread barcode type”. This selection applies to both needle and hook thread.

–

Select the corresponding type in the field “Endlabel barcode type”.

–

In the following fields masks can be defined to transmit system-relevant information (entry: “1”) and ignore unimportant information (entry: “0"): “Prim. barcode identifier A” (barcode for material and colour), “Prim. barcode identifier B” (barcode for the top and bottom piece), “Prim. barcode identifier C” (barcode for theseampattern)and“Prim.barcodemaskL/R”(barcodeforthe left and right piece).

For example

Primary barcode:

(read via hand scanner)

11112233001234567890

Primary barcode identification in the field “Prim. barcode identifier

A”: (barcode for material and colour)

11110000000000000000

ID number:

1111

If only pieces with the ID number “1111” are to be processed, this number can be entered in the field “Identifier A set value”. If pieces with various ID numbers are to be processed, the ”Identifier A set value" field must remain blank.

–

The “Prim barcode identifier B” field determines whether the piece is a top, middle or bottom piece.

For example:

Primary barcode:

(read via hand scanner)

11112233001234567890

Primary barcode identification in the field “Prim. barcode identifier

B”:

00001100000000000000

ID number:

–

The ID number must be defined in one of the fields “ID piece 1”, “ID piece 2” and “ID piece 3”. It is not possible to enter the same ID number in more than one of the fields.

–

In the field “Prim. barcode identifier C” the sewing parameters are set. For example:

Primary barcode:

(read via hand scanner)

11112233001234567890

Primary barcode identification in the field “Prim. barcode identifier

C”:

0000011100000000000

ID number: 330

Via the ID number the corresponding parameters will be requested from the data base (here the seam pattern with the number 330).

Note:

Three-digit seam patterns have to be identified with seam pattern numbers between 100 – 999 (identifying numbers between 001 and 099 are not permitted.

–

The “Prim. barcode mask L/R” determines whether it is a right or left-hand seat.

For example:

Primary barcode:

(read via hand scanner)

11112233001234567890

Primary barcode identification in the field “Prim. barcode mask

L/R”:

00000000110000000000

ID number:

–

The corresponding ID number must be defined in the fields “ID left” and “ID right”.

Example with two pieces:

11112233001234567890 11112333001234567890 “Prim. barcode identifier A”: 11110000000000000000 11110000000000000000 ID number: 1111 1111 The ID numbers are identical = OK 11112233001234567890 11112333001234567890 “Prim. barcode identifier B”: 00001100000000000000 00001100000000000000 ID number: 22 23 The ID numbers are different = OK.

The piece with the ID number 22 is the top layer, the ID number 23 is the bottom layer.

11112233001234567890 11112333001234567890 “Prim. barcode identifier C”: 00000011100000000000 00000011100000000000 ID number:

330 330 The ID numbers are identical = OK.

The sewing parameters No. 330 will be requested from the data base. 11112233001234567890 11112333001234567890 “Prim.barcodemaskL/R”: 00000000110000000000 00000000110000000000 ID number: 00 00 The ID numbers are identical = OK. A right-hand seat will be sewn.

The text for a right-hand seat will be printed on the endlabel.

–

Via the field “Prim. barcode mask label” information from the initial barcode can be printed on the endlabel.

–

Via the field “Mask multi barcode on” is determined how many additional bar codes (multi bar codes) should be scanned and memorized. The desired number of bar codes is realized by selecting the corresponding digit of the primary barcode.

–

Via the field “Mask multi BC print” information from the multibarcode of the endlabel can be printed out. (See information code “MB” chapter 6.7)

7 Sewing

CAUTION !

Sewing may only be carried out with a fully-assembled sewing unit on which all protective devices have been fitted!

Switching on the engineered sewing station

–

Switch on the UPS 2.

–

Turn on the main switch 1. Windows will be loaded and the program “Soll.exe” will be started. The machine will be tested and initialized.

–

Scan needle thread cone if necessary.

–

Scan hook thread cone if necessary.

–

Insert a bobbin.

Logging in to the system

–

The log-in takes place by scanning the operator barcode.

–

The operator can also log in manually as follows:

–

Press “Access”.

–

Press “Log in”.

–

Enter operator name and password.

Sewing can only begin if the system start and the scanning of needle thread cone, hook thread cone and bobbin have been accomplished faultlessly.

Otherwise the system is not ready for sewing and instead an error message will be displayed

Sewing

–

Press “Sewing”. The following screen will appear:

–

Scan in the pieces to be sewn. Up to 9 additional bar codes can be defined in advance. All predefined bar codes must be read in.

–

The seam sections can be sewn. Green seam sections are unmonitored, the diode at the stop glows

green, in the red seam sections (monitored segments) the diode glows red.

–

If an error occurs in a monitored seam section an error message will be displayed.

–

For operators with the security level 0 sewing is blocked

–

Operators with the security level 1 or 2 can unlock the sewing process by logging in to the system (via barcode card) and pressing the field “Continue”.

7.1 Seam scanner (optional)

A seam scanner 1 can be optionally fixed onto the machine head.

At the end of the seam the scanner checks whether the correct barcode label has been sewn in.

If the label is not recognized, first a reminder appears and then the following warning:

Operators with the security level 1 or 2 can scan the label after the end of sewing manually or print out a new label.

8 Maintenance

8.1 Cleaning and Checking

Caution: Risk of injury!

Turn off the main switch. The maintenance of the sewing machine must only be done when the

machine is switched off.

Maintenance work must be carried out no less frequently than at the intervals given in the tables (see ”operating hours” column)

Maintenance intervals may need to be shorter when processing heavy-shedding materials.

A clean sewing machine is a trouble-free sewing machine.

Caution: Risk of injury!

Switch off the main switch before tilting the machine head!

Maintenance work Explanation Operating

to be carried out hours

Machine head

- Remove sewing dust, lint and thread waste (e.g. with an air blow gun)

Direct drive

Places in special need of cleaning:

- area under the throat plate 2

- area around the hook 1

- bobbin housing

- thread trimmer

- needle area

CAUTION !

Hold the air blow in a way that you avoid the sewing dust to be blown to the oil sump.

Clean motor ventilation filter 3 (e.g. with an air blow gun) from sewing dust and thread waste.

Maintenance work Explanation Operating

to be carried out hours

Sewing drive

Clean ventilation filter (e.g. with an air blow gun).

Check condition and tension of V-belt 1

Pneumatic system

Check water level in pressure regulator.

Clean filter cartridge.

Remove lint and pieces of thread from air-intake openings.

It must be possible to depress the V-belt by about 10 mm by pressing it with a finger at its mid-point.

The water level must not rise to the level of the filter cartridge 3.

- After unscrewing the drain screw 5, the

water under pressure will flow out of the water separator 4.

Dirt and condensation are separated out by the filter cartridge 3.

- Disconnect the machine from the

compressed-air supply.

- Unscrew the drain screw 5.

There must be no pressure in the machine’s pneumatic system.

- Unscrew water separator 4.

- Unscrew filter cartridge 3.

Wash the filter shell and cartridge with cleaning fluid (not solvent) and blast clean.

- Re-assemble the maintenance unit again.

160

500

Check the system for leaks.

500

8.2 Repair

When the machine is damaged or parts are wor n please contact:

DÜRKOPP ADLER AG

Potsdamer Str. 190 D-33719 Bielefeld Phone: +49 (0) 180 5 383 756 Fax: +49 (0) 521 925 2594 E-mail: service@duerkopp-adler.com Internet: www.duerkopp-adler.com

Duerkopp Adler 550-867 Operating Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual