Durkopp 911 User Manual

911

CNC-controlled sewing unit with large

sewing area

Operating Instructions

Installation Instructions

Service Instructions

Postfach 17 03 51, D-33703 Bielefeld  Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 5 21/ 59 25-00  Telefax +49 (0) 5 21/ 9 25 24 35  www.duerkopp-adler.com

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

08/2010 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 911001

All rights reser ved.

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 - 2010

Foreword

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

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

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

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

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

– Operation, including equipping, troubleshooting during the work

cycle, removing of fabric waste,

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

– Transport.

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

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

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

Never remove or disable any safety devices.

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

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

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

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

General safety instructions

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

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

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

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

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

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

instruction book and operated by persons with appropriate training.

instructions of the motor supplier.

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

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

trained persons.

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

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

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

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

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

and made only in adherence to all safety regulations.

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

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

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

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

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

It is absolutely necessary to respect the safety

instructions marked by these signs.

Danger of bodily injuries !

Please note also the general safety instructions.

Contents Page:

Preface and General Safety Instructions

Part 1: Operating Instructions Cl. 911 - Original Instructions

(Edition 08/2010)

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

2 Designated Use .................................................5

3 Subclasses ....................................................5

4 Optional Equipment ...............................................6

5 Technical Data ..................................................7

6 Operation

6.1 Switchingon-Switchingoff-Safestop-Quickstop...........................8

6.2 Raisingthemachinehead...........................................11

6.3 Changingtheneedle..............................................12

6.4 Threadingtheneedlethread .........................................13

6.5 Adjustingthethreadregulator ........................................14

6.6 Winding on the hook thread ..........................................15

6.7 Changing the hook-thread bobbin ......................................16

6.8 Setting the hook thread tension .......................................17

7 Operating the control unit of the 911

7.1 Thecontrolpanel................................................18

7.2 Operatingthetouchscreenpanel......................................18

7.3 Thestartscreen.................................................22

7.4 Themainscreen.................................................23

7.5 Popupmenustructure.............................................24

7.6 Menuitem“File”.................................................25

7.7 Menuitem“Edit” ................................................29

7.8 Menuitem“Extras”...............................................41

7.9 Menuitem“Correction” ............................................49

7.10 Menuitem“?”..................................................50

7.11 Teach-in ......................................................51

7.12 Repairmode...................................................55

7.13 Thread breakage ................................................56

8 DA-CAD 5000 ..................................................57

Contents Page:

9 Error messages/Information messages

9.1 Errormessages.................................................59

9.2 Informationmessages.............................................63

10 Maintenance

10.1 Cleaning and Checking ............................................64

10.2 OilLubrication..................................................65

1 Product Description

CNC-controlled sewing unit based on the class 867 with large sewing area (sewing field size 300 x 200 mm) and a DAC III control unit with special software.

For technical textiles manufacturers, motor vehicle equipment manufacturers, seat manufacturers (automotive), bag, case and backpack manufacturers (leather/textile), shoe manufacturers.

For the following applications:

Bartacks on load-bearing straps, lowering harnesses, safety harnesses, lashing straps; Attaching of labels and facing pieces; Decorative seams on shoes and legs of boots, decorative seams in special applications.

Material:

Straps, ropes, leather, webbing, airbag materials, leather cut, foam laminate, leather- laminate- and textile plastics

Double-lockstitch machine equipped with: Automatic sewing foot and clamp lifting, sewing stroke adjustment,

thread trimmer, needle thread monitoring, thread pulling device and multiple thread tension.

Technical specifications

The sewing unit is driven by a positioning drive. With the control unit DACIII are operated apart from the sewing drive

also two step motors needed for the X and Y motions of the seam geometry and a Z axis for the adjustment of the sewing foot.

The arm shaft of the sewing unit is directly driven by a brushless DC motor.

Max. speed 3,000 U/min.

Stitch length up to 12.7 mm.

99 program memory locations are available.

The programs can be sewn individually or in sequences.

Motor driven sewing foot lifting.

Pneumatic driven clamp opening/closing.

The maximum size of the sewing field is 300 mm in X direction and

200 mm in Y direction.

Central oil wick lubricating for the machine head and the hook.

Equipped with a vertical hook

The BFT graphical control panel OP 7000 serves as control

element.

With electronic needle thread monitor. In order to generate a clean seam pattern, the sewing unit is equipped

with a multiple thread tension device, permitting to assign to various thread pulling directions the according tension value previously saved in the sewing program.

The thread pulling device allows pulling the needle thread under the sewing material during the first stitch.

The sewing unit is equipped with a programmable stitch counter for the hook thread monitoring and a piece counter.

Integrated test and check program for service and maintenance works. In addition to the monitoring of the sewing process, it is also possible to check the motor functions, the inputs and outputs for the reference switches, the v alves and the feeding motors. The program also serves for the adjustment of machine functions and the preparing of sewing programs by the teach-in method.

Individual stitch parameter per stitch in order to control external units like:

The stroke position of the presser foot, thread trimmer, thread

clamp,

Speed, thread tension etc.

The height of the stand can be adjusted with the telescoping feet from a minimum work height of 760 mm to a maximum work height of 910 mm for stand-up working.

The foot pedal needed to operate the sewing unit can be shifted to allow an ergonomic adaption to the operator.

2 Designated Use

The class 911 is a sewing unit that is designated for the sewing of light to medium-heavy material. Such material is generally made of textile fibers, composite materials but it may also consist of leather. Suchlike material is used in the clothing industry and for domestic and motor-vehicle upholstery.

This sewing unit can also be used to produce so-called technical seams. In this case however, the operator must assess the possible dangers which may arise (DÜRKOPP ADLER AG will be happy to offer its assistance), since such applications are relatively rare and at the same time can be so varied that no single set of criteria can cover them all. The outcome of this assessment may require appropriate safety measures to be taken.

Generally only dry material may be sewn with this sewing unit. The material may be no thicker than 4 mm when compressed by the lowered workclamp. The material may not contain any hard objects.

The seam is generally produced with textile-fibre s ewing thread (cotton threads, synthetic yarns of covering yarns) with the following dimensions: Class 911 thread thickness 15/3 - 120/3 Before using any other thread the possible dangers arising have to be assessed and appropriate safety measures if necessary taken.

This sewing unit 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 who work on our products will have received training at least sufficient to acquaint them with all normal operations and with any hazards which these may involve.

3 Subclasses

Cl. 911-210 CNC-controlled sewing unit based on the class 867 with large sewing

area (sewing field size 300 x 200 mm) and a DAC III control unit with special software.

4 Optional Equipment

For the sewing unit 911 the following optional equipment is available:

Optional equipment Order-No. Remark

Reception P.-Clamp 0911 457554 Kit for the reception of the parallel

clamp actuation Bow f. P.- Clamp 0911 457604 Bow holding fixture for the clamping plate P.-set of clamps HF 0911 417604 parallel set of clamps HF (bow bracket) P.-set of clamps prg.1 0911 417634 Finished set of clamps f. parallel

clamp act. prg.1 P.-set of clamps prg.2 0911 417644 Finished set of clamps f. parallel

clamp act. prg.2 P.-set of clamps prg.3 0911 417654 Finished set of clamps f. parallel

clamp act. prg.3 L-bracket f. P.-Clamp 0911 457614 Kit L-bracket for reception of the divided

clamp (parallel) P.-set of clamps HF div. 0911 417614 P.-set of clamps HF, divided, fastening with L-bracket P.-set of clamps div. prg.1 0911 417664 Finished P.-set of clamps for divided clamp pgr.1 P.-set of clamps div. prg.2 0911 417674 Finished P.-set of clamps for divided clamp pgr.2 P.-set of clamps div. prg.3 0911 417684 Finished P.-set of clamps for divided clamp pgr.3 P.-set of clamps HF div. 0911 417624 P.-set of clamps HF, divided, fastening w. L-bracket

closed frame P.-set of clamps div. prg.1 0911 417694 Finished P.-set of clamps, div., with

closed frame prg.1 P.-set of clamps div. prg.2 0911 417704 Finished P.-set of clamps, div., with

closed frame prg.2 P.-set of clamps div. prg.3 0911 417714 Finished P.-set of clamps, div., with

closed frame prg.3 Reception f. change-over clamp 0911 457564 Kit for the reception of the change-over clamp C.-set of clamps HF 0911 417524 Change-over s et of clamps HF C.-set of clamps prg.1 0911 417554 Finished change-over set of clamps prg.1 C.-set of clamps prg.2 0911 417564 Finished change-over set of clamps prg.2 C.-set of clamps prg.3 0911 417574 Finished change-over set of clamps prg.3 Kit reduced pressure 0911 597544 Kit barcode reader 0911 597554 Set throat plate 0911 597504 Throat plate for processing thin materials Set presser foot 0911 597514 Presser foot Jumping foot 0467 220283 For thin material Sewing lamp complete 9822 510026 Table clamp 9822 510027 Pneumatic connection package 0797 003031 Height adjustment 0911 407524 Table top height adjustable from 800mm to 1050mm

5 Technical Data

Type of stitch 301

Hook type Vertical hook

Needle system 134/35

Needle size [Nm] 80 until 180

Number of needles 1

Stitch length (programmable) [mm] depending on the seam pattern up to 12.7

max. speed [min

Clamp stroke [mm] 20

Foot lifting [mm] 20

Sewing field size [mm] 300 x 200

Number of free contour programs 99

Operating pressure [bar] 6

Air consumption [NL] 4

-1

] max. 3000 1/min

Table height (adjustable manually via spindle)

-min [mm] 760

-max [mm] 910

Length, Width, Height [mm] 1200 x 1200 x 1150 (+120mm spindle length)

Weight (mounted) [kg] 225

Rated voltage [V] 230

Frequency [Hz] 50 / 60

Rated load [W] 450

Noise:

Lc = dB (A)

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

Sewing length: __ mm Stitch: __ Speed: _____ min

-1

Material: G1 DIN 23328 2 plies Sewing cycle: 1.3 sec. on and 1.0 sec. off

6 Operation

6.1 Switching on - Switching off - Safe stop - Quick stop

6.1.1 Switching on

6.1.2 Switching off

–

Turn on the main switch 1. The following request occurs on the display: “Push Pedal backwards for referencing”

–

Step the pedal backwards to start the reference r un of the sewing unit. The main menu appears in the display.

–

Turn off the main switch 1. All the drives and the control unit are immediately separated from the mains.

43 2

6.1.3 Safe Stop

Caution: Risk of injury!

The sewing unit has to be switched off or switched to “safe stop” before carrying out any work on it.

Only work in the hook area with “safe stop” activated when it is illuminated.

Switching on “safe stop”

–

Press key 2. The key must snap in! The sewing unit is in “safe stop” mode. The lamp in the key shines. The foot is moved to the lower position. The area surrounding the hook cover 3 will be illuminated.

Switching off “safe stop”

–

Press key 2 again. The key must be released.

6.1.4 Quick stop

The safety system of the sewing unit provokes the immediate stopping of the unit in case of faulty operation, needle breakage etc. w ith the following options:

Press the program-stop switch 4.

The running operations on the sewing unit will immediately be aborted.

Turn the main switch 1 counter-clockwise.

The sewing unit will immediately be dead.

6.2 Raising the machine head

The sewing head can be raised for maintenance work. The carriage drive 2 must stand at the rear.

Caution: Risk of injury!

Turn the main switch off!

Maintenance may only be carried out with the sewing unit switched

off!

Raising the sewing head

–

Release the locking lever 1 underneath the table top.

–

Raise the machine head in the area of the face cover 3 and swing it up carefully. Additionally, the latch 4 will also snap in. The space under the machine table can be accessed for cleaning now.

Caution: Risk of injury!

Keep clear of the area within the table top cutout when the machine head is tilted up.

Swinging the machine head back

–

Keep hold of the machine head in the area of the face cover 3.

–

Release the latch 4.

–

Swing the machine head back carefully.

ATTENTION: Danger of breakage!

Keep hold of the sewing head until it has reached its final position.

–

Engage the locking lever 1 under neath the table top.

6.3 Changing the needle

Caution: Risk of injury!

Turn the main switch off! The needle may only be changed with the sewing unit switched off.

–

Turn the machine with crank 4 until the needle bar 1 reaches its highest position.

–

Loosen screw 2.

–

Pull the needle downwards out of the needle bar 1.

–

Insert the new needle into the hole of the needle bar 1 and push it until it stops.

Caution!

The needle scarf 3 must point towards the hook.

–

Tighten screw 2.

ATTENTION!

When changing to another needle size, the distance between hook and needle must be readjusted (see service instructions).

Ignoring the above mentioned hint can cause the following errors:

Use of a thinner needle:

Missed stitches

Thread damage

Use of a thicker needle:

Damage on the hook tip.

Damage of the needle

6.4 Threading the needle thread

Caution: Risk of injury!

Turn off the main switch! The needle thread may only be threaded with the sewing unit switched off.

7654

–

Put the thread reel on the thread stand and lead the needle thread through the unwinder arm. The unwinder arm must be in vertical position above the thread reels.

–

Thread in the thread through threading guide 1.

–

Conduct the thread counter-clockwise around the pre-tensioner wheel 2.

–

Conduct the thread clockwise around the pre-tensioner wheel 3.

–

Conduct the thread through threading guides 4 and 5.

–

Conduct the thread clockwise around the deflector 6.

–

Pull the thread underneath the thread take-up spring 7 and conduct it through the threading guide 9, the thread regulator 10 to the thread lever 11.

–

Conduct the thread through the thread lever 11 a nd the threading guide 8.

–

Conduct the thread through the needle thread monitor 12, the thread clamp 13 and the threading guides 14 and 15.

–

Thread the thread into the needle eye.

6.5 Adjusting the thread regulator

Caution: Risk of injury!

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

The thread regulator 2 controls the quantity of needle thread required for stitch formation. The thread regulator must be precisely adjusted for an optimum sewing result.

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

–

Loosen screw 1.

–

Adjust the position of the thread regulator 2. Thread regulator to the left = more thread Thread regulator to the right = less thread

–

Tighten the screw 1.

Adjustment information:

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

6.6 Winding on the hook thread

43 2

The separate bobbin winder makes it possible to wind the hook thread independently from the sewing operation.

–

Remove remaining thread from the bobbin hubs before winding.

–

Put the thread reel on the thread stand.

–

Thread the thread through the drill-hole 1 of the unwinder arm.

–

Conduct the thread through threading guide 4.

–

Conduct the thread through the bobbin thread tension 2.

–

Wind up the thread to the right.

Press the bobbin retainer 3 against the bobbin hub. The bobbin winder starts. After reaching the set bobbin filling level the bobbin winder stops automatically. See Service instructions for setting the bobbin filling level.

6.7 Changing the hook-thread bobbin

32 1

Caution: Risk of injury!

The hook-thread bobbin may only be changed with the sewing unit in “safe stop” mode.

–

Remove the material holder 2 (only with change-over frame).

–

Press the key 1 “safe stop”. The drive carriage rides to the “bobbin change position”. The cover plate 4 will pivot to the side. The foot is moved to the lower position.

–

The light 5 is switched on.

10 9

Remove the empty bobbin.

–

Rise up the flap 6 and remove the empty bobbin.

Insert a full bobbin.

–

Insert the bobbin 7 in a way that it moves in the opposite direction of the hook when unwinding.

–

Close the flap 6.

–

Conduct the thread through slot 8 and under neath the spring 9.

–

Pull the hook thread through the threading guide 10 and continue pulling until it stands out about 3 cm.

–

Release key 1 “safe stop”. The cover plate 4 will pivot back into its original position.

6.8 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 unit switched off.

The necessary hook thread tension should be generated from the thread tension spring 2.

Setting the tension spring

–

Set the tension spring 2 by turning the adjustment screw 1 until the needed tension value is reached.

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