DURKOPP ADLER 969 ECO, 969 Classic Operating Manual

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969 ECO / CLASSIC

Operating manual

Any reuse of these contents, including excerpts, is prohibited without the prior written consent of Dürkopp Adler AG.

Contents

1 About this manual...................... ... ......................... ... ......................... .3

1.1 Scope....................................................................................................3

1.2 For whom is this operating manual intended?.......................................3

1.3 Representation conventions – symbols and characters........................3

1.4 Other documents.......................... ......................... ... ......................... ... .5

1.5 Liability ..................................................................................................5

1.5.1 Transport...............................................................................................5

1.5.2 Proper use.................................................. ... ......................... ... ............6

2 Technical Specifications ....................................................................7

2.1 Characteristics.......................................................................................7

2.2 Declaration of conformity.......................................................................7

2.3 Technical data.......................................................................................8

2.4 Additional equipment.............................................................................9

3 Safety information............................................. .. .......................... .. ..11

3.1 General safety information..................................................................11

3.2 Signal words and symbols used in safety information.........................13

4 Machine Description .........................................................................15

5 Operation ...........................................................................................19

5.1 Switching power supply on and off......................................................19

5.2 Inserting and replacing needle............................................................20

5.3 Threading the needle ............................ .............................. ................22

5.3.1 Threading thread in reel holder...........................................................22

5.3.2 Threading thread in m achine...............................................................24

5.4 Threading and winding on the hook thread.........................................27

5.5 Replacing the hook thread bobbin.......................................................30

5.6 Needle positioning...............................................................................33

5.7 Thread tension .................. ............................... ............................... ....35

5.7.1 Setting the needle thread tension........................................................36

5.7.2 Setting hook thread tension.................................................................39

5.8 Setting thread limiter ...........................................................................41

5.9 Raise the presser foot.........................................................................43

5.10 Raising presser foot with hand lever...................................................46

5.11 Setting presser foot pressure..............................................................47

5.12 Setting presser foot stroke ..................................................................50

5.12.1 Limitation of sewing speed..................................................................50

5.12.2 Limiting presser foot stroke.................................................................51

5.12.3 Setting presser foot stroke ..................................................................51

5.12.4 Quickly switching presser foot stroke with foot switch.........................53

5.13 Stitch length..................................... ......................... ... ........................54

5.13.1 Setting stitch length.............................................................................54

5.13.2 Sewing with 2 stitch lengths................................................................55

5.13.3 Reverse sewing and seam bar tacking ...............................................56

5.14 Quick functions on keypad..................................................................59

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Contents

5.14.1 Activating function keys.......................................................................59

5.14.2 Transferring a key function to the auxiliary switch........................... .. ..61

5.15 Thread cutting and securing against unraveling..................................62

5.16 Operating the controller.......................................................................63

5.16.1 Control panel.......................................................................................63

5.17 Swinging out the table plate ................................................................66

6 Maintenance.......................................................................................69

6.1 Cleaning the machine..........................................................................69

6.2 Checking oil level ................................................................................72

6.3 Checking pneumatic system ...............................................................75

6.4 Customer Service................................................................................77

7 Installation .........................................................................................79

7.1 Checking delivery................................................................................79

7.2 Removing transport securing devices.................................................80

7.3 Assembling the frame..........................................................................81

7.4 Assembling the standard frame...........................................................81

7.4.1 Assembling frame components...........................................................81

7.4.2 Assembling components on underside of table plate..........................82

7.4.3 Mounting the frame on the table plate and mounting the pedal ..........83

7.4.4 Setting frame height and pedal position..............................................84

7.4.5 Placing the machine upper section on the frame................................86

7.5 Assembling the special frame .............................................................88

7.5.1 Assembling frame components...........................................................88

7.5.2 Assembling components on underside of table plate..........................89

7.5.3 Mounting the frame on the table plate and mounting the pedal ..........90

7.5.4 Placing the machine upper section on the frame................................92

7.6 Assembling thread reel holder.............................................................94

7.7 Electrical connection ...........................................................................95

7.7.1 Checking mains voltage......................................................................95

7.7.2 Connecting the lighting........................................................................95

7.7.3 Connecting control unit........................................................................96

7.8 Connecting the pneumatic system ......................................................97

7.8.1 Fitting the maintenance unit................................................................97

7.8.2 Setting operating pressure..................................................................98

7.9 Lubrication...........................................................................................99

7.10 Sewing test........................................................................................101

8 Disposal ...........................................................................................103

9 Appendix..........................................................................................105

9.1 Drawings for creating table plate.......................................................105

9.2 Component layout on underside of table plate..................................107

9.3 Wiring diagram ................................ ... ... .............................. ..............109

9.4 Table of maximum machine speeds..................................................110

9.5 Table: Maximum presser foot stroke...................................... ... ... .....110

2 Operating manual 969 - 00.0 - 08/2014

About this manual

1 About this manual

Please contact us if you find any discrepancies or have any suggestions,  6.4 Customer Service, page 77.

The operating manual is to be regarded as part of the product and must be stored in a readily accessible location. Be sure to read the manual completely before using the product for the first time. If you pass the product on to someone else, please be sure to give them the operating manual.

1.1 Scope

This manual describes the intended use and the set-up of the special sewing machine 969.

1.2 For whom is this operating manual intended?

The operating manual is intended for the following persons:

• Operators:

This group of persons is familiar with the machine and has access to the operating manual. Especially  Chapter 5: Operation is important for this group of persons.

• Technicians:

This group has the appropriate technical training qualifying them for performing maintenance on the sewing machine or repairing malfunctions. Especially  Chapter 6 Installation is important for this group of persons. A service manual will be provided separately.

Also observe the information in  Chapter 3 Safety Information with regard to the minimum qualifications required and other requirements placed on the operating personnel.

1.3 Representation conventions – symbols and characters

Various information in this operating manual is represented or highlighted by the following characters in order to facilitate easy and quick understanding:

Correct setting

Indicates proper setting.

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About this manual

2. ...



Malfunctions

Lists the malfunctions that can occur if the setting is incorrect.

Process steps during operation (preparing the machine and sewing with the machine)

Steps to be performed for servicing, maintenance, and installation

Steps to be performed via the software control panel

The individual steps are numbered:

1. First step

2. Second step

The steps must always be performed in the specified sequence.

Result of performing the task

Changes to machine or display

Attention

Special attention must be paid to this information when performing the process step.

Additional information

Additional information, such as alternative operating options.

Order

Indicates what work must be performed before or after configuring settings.

References

 Indicates a reference to another section of text.

Safety Important warnings for the machine operator are specially desig-

nated. Since safety is of special importance, the safety symbols, safety levels and associate keywords are specially descri b e d in  Chapter 3 Safety Information.

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About this manual

Orientation If an illustration does not provide any explicit orientation infor-

mation then "right" or "left" are alwa ys with respect to the p osition of the operator.

1.4 Other documents

This equipment includes components from other manufacturers. Each manufacturer has performed a hazard assessment for these purchased parts and confirmed their design compliance with applicable European and national regulations. The proper use of these components is described in each manufacturer's manual.

1.5 Liability

All information in this operating manual has been compiled with consideration to the state of the art, and applicable standards and regulations.

The manufacturer cannot be held liable for damages resulting from:

• Breakage or other damage occurring during transport

• Failure to observe the operating manual

• Improper use

• Unauthorized modifications to the machine

• Use of untrained personnel

• Use of unapproved replacement parts

1.5.1 Transport

Dürkopp Adler cannot be held liable for breakage and transport damages. Inspect the delivery immediately upon receiving it. Report any damage to the last transport manager. This applies even if the packaging is undamaged.

Leave machines, equipment and packaging material in the condition in which they were found when the damage was discovered. This will ensure any claims against the transport company.

Report all other complains to Dürkopp Adler immediately after receiving the product.

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About this manual

1.5.2 Proper use

The Dürkopp Adler 969 machine is intended for sewing heavy to very heavy material (max. material thickness is 20 mm). Heavy and very heavy material require a needle strength of 120-280 Nm.

The machine is intended only for use with dry material. The material must not contain any hard objects.

The stitching is produced using core spun threads, polyester fibers, or cotton threads.

The sewing machine is intended for industrial use. The machine may only be set up and operated in dry conditions

in well-maintained premises. If you operate the machine in rooms that are not dry and are not maintained then additional measures as per the EN 60204-31:1999 standard may need to be taken.

Only authorized/trained personnel may operate the machine. The manufacturer cannot be held liable for damages resulting from

improper use.

WARNING Risk of electric shock, crushing and punctures!

Improper use can result in in jury.

Be sure to observe all instructions in the manual.

ATTENTION Improper use can result in material damage.

Be sure to observe all instructions in the manual.

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Technical Specifications

2 Technical Specifications

2.1 Characteristics

The Dürkopp Adler 969 is an extra heavy-duty arm sewing machine for double lockstitches.

Upper machine section

• Single-needle double lockstitch

2.2 Declaration of conformity

The machine complies with the EU regulations specified in the declaration of conformity or in the declaration of incorporation.

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Technical Specifications

2.3 Technical data

Workplace-specific emission value as per DIN EN ISO 10821: Lc = 74 dB (A) ± 0.83 dB (A) using the following parameters:

• Stitch length: 9.6 mm

• Presser foot stroke: 6 mm

• Speed: 1,000 rpm

• Material: Band with a thickness of 15 mm

Characteristic 969-190180 969-190382

Stitch type 301 Hook type Horizontal barrel shuttle, large (XL) Number of needles 1 Needle system 794 (1,000 hrs) Needle strength [Nm] 120 - 280 Needle thread 20/3 - 5/3 Hook thread 20/3 - 5/3 Stitch length, forwards/backwards [mm] 15 / 15

-1

Maximum stitch count [min

Stitch count when delivered [min Presser foot stroke [mm] 0 - 12 Manual presser foot stroke [mm] 14/20 Pneumatic presser foot stroke [mm] 30 Operating pressure [bar] 6 Air consumption [NL] 0.7

]

-1

]

1250

1000

Length/width/height [mm] 700/250/420 Weight [kg] 100/145 Voltage [V/Hz] 230/(50/60) Power consumption [kVA] 375

8 Operating manual 969 - 00.0 - 08/2014

Technical Specifications

The table shows the configurable range of the machine's parameters. The actual values for stitch co unt/min. or presser foot stroke must be adjusted through a practical sewing test to suit the properties of the material and thread. Improper parameter values can be determined through increased noise or needle heating and thread burn-out.

2.4 Additional equipment

A flexible system of additional equipment allows the special sewing machine to be optimally equipped for any application at low cost.

 = Standard equipment  = Optional expansion

Order number Additional equipment

9780 000108 WE-8 maintenance unit for additional pneumatic

equipment

0797 003031 Pneumatic connection package for connecting

frames with maintenance unit

9822 510003 Halogen sewing lamp for upper sewing machine

section 9880 867100 Sewing lamp attachment kit 0798 500088 Sewing lamp transformer for halogen sewing

lamp 9880 867103 Single-diode sewing lamp with attachments 9880 967001 Integrated diode sewing lamp 9850 001089 Power supply for integrated sewing lamp and

single-diode sewing lamp

969190180





969190382



9850 867001 Circuit board for oil monitoring 0967 590014 Set for electro-pneumatic reverse sewing 0967 590024 Electro-pneumatic top-down needle cooler 0967 590034 Thread clamp with thread wiper function

(Set FK)

Operating manual 969 - 00.0 - 08/2014 9







Technical Specifications

Order number Additional equipment

N800 080040 Edge stop, right, with roller, vertical pivot N800 080041 Combined roller and straight stop, right, vertical

pivot, vertically adjustable N800 080042 Edge stop, right, vertical pivot N800 080022 Ruler, for mounting on base plate 9835 901005 MemoDongle, external storage for data transfer

and the DAC classic control unit 9850 001211 Dongle connector, USB to dongle interface 9081 300002 Tool set for H-type MG56 400094 Folding frame

Table plate 1160 x 600 mm with pedal (MG 56-2) MG58 400534 Frame with cutout

Table plate 1160 x 600 mm with pedal (MG 58-3)

969190180



969190382

Visit our website for more information: www.duerkopp-adler.com

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Safety information

3 Safety information

This section contains basic information for your safety. Read the information carefully before setting up, programming, maintaining, or operating the machine. Make sure to follow the information included in this section. Failure to follow these instructions can lead to severe injuries and damage to property.

3.1 General safety information

Only authorized personnel should use the machine. Anyone working on the machine should read the operating manual first.

The machine should only be used as described in this manual.

The operating manual should be available at the machine's location at all times.

Also observe the safety information and operating manual provided by the drive motor's manufacturer.

Observe the generally applicable safety and accident prevention regulations and the legal regulations concerning industrial safety and environmental protection.

All warnings on the machine should be kept in legible condition at all times and should not be removed. Missing or damaged labels should be replaced immediately.

The machine must be deactivated either by pressing the power switch or removing the power cable from the socket when performing the following work:

• Threading

• Replacing the needle or other sewing tools

• Leaving the workplace

• Performing maintenance or repairs When using the machine, inspect it for externally visible signs of

damage. Stop working if you notice any changes to the machine.

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Safety information

Report any changes to your supervisor. A damaged machine must no longer be used.

Machines or machine parts whose working life has expired must no longer be used. They must be properly disposed of according to legal regulations.

The machine may only be set up by qualified technicians.

Maintenance work and repairs may only be carried out by qualified technicians.

Safety equipment must not be removed or disabled. If this hinders repair, safety equipment must be immediately reinstalled and reactivated once repairs are complete.

Electrical equipment may only be serviced by qualified electricians.

The power cable must be fitted with a power plug approved for use in the respective country where the machine is used Only qualified electricians may attach plugs to power cables.

Working on live components and equipment is prohibited. Exceptions are defined in the DIN VDE 0105 standard.

Incorrect or defective replacement parts can negatively affect safety and damage the machine. Make sure you only use original replacement parts from the manufacturer.

12 Operating manual 969 - 00.0 - 08/2014

Safety information

3.2 Signal words and symbols used in safety information

Safety information is outlined by colored bars. Signal words indicate the degree of risk:

Signal word Degree of risk

DANGER Will result in serious injury or death. WARNING Can result in serious injury or death. ATTENTION Can result in minor or moderate injury. NOTE Can result in property damage.

The following symbols indicate the type of risk to personnel:

Signal word Type of risk

General risk

Risk of electric shock

Risk of puncture injuries from pointed objects

Risk of crushing

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Safety information

Examples of safety information layout in manual:

DANGER Type and source of risk

Consequences of non-observance

Measures for avoiding the risk

This is what a warning looks like for a hazard that will result in serious injury or even death if ignored.

WARNING Type and source of risk

Consequences of non-observance

Measures for avoiding the risk

This is what a warning looks like for a hazard that can result in serious injury or even death if ignored.

WARNING Type and source of risk

Consequences of non-observance

Measures for avoiding the risk

This is what a warning looks like for a hazard that can result in moderate or light injury if ignored.

NOTE Type and source of risk

Consequences of non-observance

Measures for avoiding the risk

This is what a hazard note looks like for a hazard that can result in property damage if the note is not observed.

ENVIRONMENTAL PROTECTION Type and source of risk

Consequences of non-observance

Measures for avoiding the risk

This is what an environmental protection note looks like for a hazard that could result in environmental damage if the note is not observed.

14 Operating manual 969 - 00.0 - 08/2014

Machine Description

①

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⑦

⑧ ⑨

⑩ ⑪

⑫

⑬

⑭

⑮

⑯

⑰

⑱

⑲

⑳

(1) - Hand lever (2) - Adjusting wheel for the increased sewing foot stroke (3) - Adjusting wheel for the normal sewing foot stroke (4) - Adjusting wheel for the sewing foot pressure (5) - Bobbin winder for the hook thread (6) - Thread tensioners (7) - Electroni c ha ndwheel (8) - Keypad on the machine arm

(9) - Thread clamp (10) - Sewing foot with needle (11) - Hook (12) - Cover (13) - Locking lever for the machine head in the working position (14) - Stitch adjustment lever (15) - Adjusting wheel fo r the larger stitch length (16) - Adjusting wheel for shorter stitch length (17) - Sight glass for the oil level (18) - Handwheel (19) - OP 1000 control panel (20) - Thread reel holders

4 Machine Description

Fig. 1: General overview – part 1

Operating manual 969 - 00.0 - 08/2014 15

Fig. 2: General overview – part 2

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⑦

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⑧

③

④

⑪

(1) - Drawer (2) - Plate bracket (3) - Setpoint transducer (4) - Foot switch (5) - Operating pedal (6) - Maintenance unit (7) - Oil container for used oil (8) - Sewing lamp transformer

(9) - DAC control unit (10) - Main power switch (11) - Switch for the sewing lamp

Machine Description

16 Operating manual 969 - 00.0 - 08/2014

Machine Description

Function key assignment

Fig. 3: Function keys

Key Function

Reverse sewing key (2) When this key (2) is activated, the machine sews in reverse. Needle positioning

key (3)

Start and end bar tack key (4)

Stitch length key (5) When this key (5) is selected, the machine sews with the larger

When this key(3) is activated, the needle moves to a specific position. This position is individually defined by the setting of the parameters. The machine is supplied configured so that activating key (3) will raise the needle. There are two needle positions that can be defined via the control unit, one for the position when stopping during sewing of the seam and one for the position after ending the seam

 Needle positioning, page 33).

( You can use key (3) to manually switch from one position to the other.

The key (4) disables the basic setting for sewing the start and end bartacks. When reverse sewing is set then the key (4) suppresses further reverse sewing. If reverse sewing is nit enables then pressing the key (4) will initiate another reverse sewing. For information on the general settings for sewing start and end bartacks read the basic/classic control unit.

stitch length set on the upper stitch adjusting wheel.

 Operating Manual for the DAC

Key for the additional thread tension (6)

Key for an additional function associated with optional equipment (7)

Operating manual 969 - 00.0 - 08/2014 17

The key (6) switches on the additional thread tension.

Using the machine's electronic control unit, this key can be assigned to activate any optional equipment. For example, a needle cooler.

Machine Description

18 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Indicator lamp on machine arm (2) - Indicator lamp on the controller (3) - Main power switch (4) - Switch for the sewing lamp

①

②

③

④

5 Operation

5.1 Switching power supply on and off

Fig. 4: Switching power supply on and off

To switch power on:

1. Turn the power switch (3) to the I position.

 Indicator lamps (1) and (2) illuminate.

To switch power off:

1. Turn the power switch (3) to the 0 position.

 Indicator lamps (1) and (2) turn off.

Operating manual 969 - 00.0 - 08/2014 19

Operation

5.2 Inserting and replacing needle

WARNING Risk of injury from needle and moving parts.

Turn the sewing machine off before replacing the needle.

Do not touch the tip of the needle.

Order

After switching to a different needle size, adjust the distance between the hook and the needle ( Service manual).

ATTENTION Damage to the machine, needle breakage, or thread dam-

age is possible due to incorrect distance between the needle and hook tip.

Check the distance to the hook tip after inserting a new needle with a different size. Reset distance if necessary.

Incorrectly setting the needle height can damage the machine.

Checking needle height is absolutely necessary when changing the needle for another system.

Incorrectly setting the allowance for clearance be tween needle and hook tip can result in the following defects:

After inserting a thinner needle:

• Missing stitches

• Thread damage

After inserting a thicker needle:

• Damage to the hook tip

• Damage to the needle

20 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Needle bar (2) - Fastening screws

(3) - Needle (4) - Groove for the needle

④

③

②

①

Changing

the needle

Incorrectly setting needle bar height can result in the following malfunctions:

After inser ting a shorter needle:

• Damage to the hook tip

• Damage to the needle

After inserting a longer needle:

• Damage to the hook tip

• Damage to the needle

ATTENTION Incorrect alignment of the needle can damage the

machine.

Make sure the hook tip does not come into contact with the needle.

Fig. 5: Changing the needle

1. Turn handwheel until the needle (3) is at top dead center.

2. Loosen the screws (2).

3. Pull the needle (3) down and out.

4. Insert the new needle.

Operating manual 969 - 00.0 - 08/2014 21

5. Important: Align the needle so the groove in the needle shaft

6. Tighten the screws (2).

(4) is facing the hook and is parallel to the hook tip's direction of movement.

Operation

5.3 Threading the needle

WARNING Risk of injury from needle and moving parts.

Turn off the sewing machine before threading the thread.

5.3.1 Threading thread in reel holder

ATTENTION An incorrect tube height causes the thread to wind onto

the needle tube resulting in irregular needle thread tension. This can result in an uneven seam and uneven thread lengths after cutting!

Check that the tube height is set correctly.

On all submodels, the thread is fed through the machine from a reel on a reel holder.

22 Operating manual 969 - 00.0 - 08/2014

Operation

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(1) - Thread guide (2) - Hole in the pre- tensioner (3) - Hole in the tube

(4) - Nut (5) - Bobbin (6) - Tube

10-15 mm

Fig. 6: Threading thread in reel holder

1. Slide reel on bobbin (5)

2. Release the nut (4).

3. Important: Adjust the height of the tube (6) according to the illustration, so that it projects 10 to 15 mm above the thread bobbin.

4. Turn the tube so that the opening in the tube (3) faces the thread guide (1).

5. Tighten the nut (4).

6. Feed the thread into the pipe (6), through the opening (3), through the thread guide (1) and into the opening on the pretensioner (2).

Operating manual 969 - 00.0 - 08/2014 23

5.3.2 Threading thread in machine

(1) - Hand lever for lifting presser foot (2) - Positioning key

①

②

Fig. 7: Threading thread in machine

Operation

1. Lift presser foot with hand lever (1).

2. Use the positioning key (2) to set the upper needle position,  Needle positioning, page 33.

3. Turn off machine power switch.

24 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Thread guide (2) - Additional tensioner (3) - Primary tensioner (4) - Balancing spring

(5) - Thread guide (6) - Balancing spring arm (7) - Preliminary tensione r (8) - Thread guide

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⑦

⑧

Fig. 8: Threading – part 1

4. Guide thread through the pre-tensioner (7).

5. Guide thread through guides (8)and (1).

6. Feed the thread counter-clockwise over the auxiliary tensioner (2).

7. Feed the thread clockwise over th e main tensioner (3).

8. Feed the thread into the thread guide (5): Feed the thread clockwise and run around the axle of the balancing spring (4) until the balancing spring arm( 6) turns and the thread moves behind the thread guide (5).

Operating manual 969 - 00.0 - 08/2014 25

Fig. 9: Threading – part 2

(9) - Thread lever (10) - Thread guide (11) - Thread guide (12) - Thread clamp

(13) - Thread guide (14) - Thread guide (15) - Thread guide on the needle bar (16) - Needle eye

⑨

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⑯

Operation

9. Feed the thread through thread guide (10).

10.Feed the thread through the eyelet of thread take-up lever (9).

11. Fee d the thread through the thread guide (11).

12.Feed the thread counterclockwise around the thread clamp (12).

13.Feed the thread through the guides (13) and (14).

14.Pull the thread behind the thread guide so that it latches into place in the thread clamp (12).

15.Feed the thread into the guide on the needle bar (15).

16.Feed the thread through the needle eye (16) from left to right.

26 Operating manual 969 - 00.0 - 08/2014

Operation

10-15 mm

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⑥

(1) - Tube (2) - Hole in the pre-tensioner (3) - Thread guide

(4) - Hole in the tube (5) - Nut (6) - Bobbin

5.4 Threading and winding on the hook thread

WARNING Risk of injury from needle and moving parts.

Turn off the machine before threading the thread.

ATTENTION An incorrect height can cause the thread to wind onto the

tube!

Check that the tube height is set correctly.

Threading hook

thread

Fig. 10: Threading thread in reel holder

1. Slide reel on bobbin (6)

2. Release the nut (5).

Operating manual 969 - 00.0 - 08/2014 27

Operation

(1) - Cutter (2) - Thread guide

(3) - Tensioner

①

②

③

3. Important: Adjust the height of the tube (1) according to the illustration, so that it projects 10 to 15 mm above the thread bobbin.

4. Turn the tube so that the opening in the tube (4) faces the thread guide (3).

5. Tighten the nut (5).

6. Feed the thread into the tube (1), through the opening (4), through the thread guide (3) and into the opening on the pretensioner (2).

Fig. 11: Threading hook thread

7. Guide thread through tensioner (3).

8. Guide thread through thread guide (2).

9. Press the thread onto the tensioner (3) by hand, move the end

28 Operating manual 969 - 00.0 - 08/2014

of it underneath the cutter (1) and cut it by pulling it against the blade of the cutter (1).

Operation

(1) - Symbol for turning bobbin win de r on /o ff (2) - Bobbin winder switch (3) - Bobbin winder shaft (4) - Bobbin (5) - Bobbin driving pin

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②

Winding Fig. 12: Winding hook thread

1. Place the bobbin (4) onto the bobbin winder shaft (3)and onto

2. Bring the bobbin winder to position I according to symbol (1)

 Bobbin winder starts.

Once the bobbin winder starts, the thread will begin winding automatically – the bobbin winder is driven by a separate motor. You can still sew while the hook thread is winding.

Operating manual 969 - 00.0 - 08/2014 29

the bobbin driving pin (5).

by pressing the bobbin winder switch (2).

5.5 Replacing the hook thread bobbin

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②

③

(1) - Thread end in needle (2) - Cover (3) - OP1000 control panel

WARNING Risk of injury from needle and moving parts.

Turn off the sewing machine before replacing the bobbin.

Fig. 13: Changing the hook thread bobbin

Operation

1. Press theF key on the OP1000 control panel (3).

 The machine automatically turns to the position required for

2. Manually pull the needle thread out of the needle eye until the

3. Press the cover (2) at the position marked with an arrow until

 An opening for replacing the hook thread bobbin opens.

30 Operating manual 969 - 00.0 - 08/2014

changing the hook thread bobbin. It is not possible to operate the machine with the pedal at this time (Safe Stop).

end of the thread (1) is approx. 200 mm long.

it bends and can be turned.

Operation

(1) - Flexible snap (2) - Bobbin housing

①

②

Fig. 14: Replacing hook thread bobbin – part 1

4. Press on the elastic latc h (1).

 The bobbin housing (2) tilts and the internal spring pushes

the bobbin housing (2) upwards.

Operating manual 969 - 00.0 - 08/2014 31

Fig. 15: Replacing hook thread bobbin – part 2

(2) - Bobbin housing (3) - Slo t in bo bb in housing (4) - Pressure spring slot

(5) - Hook thread pressure spring (6) - Hook thread bobbin (7) - Bobbin hole

②

③

④

⑤

⑦

⑥

Operation

5. Remove the empty hook thread bobbin.

6. Insert the wound hook thread bobbin (6) with the bobbi n hole (7) facing up.

7. Press on the bobbin housing (2) until the snap clicks into place.

8. Feed the end of the hook thread into the slot (5) under the pressure spring (4) up to the slot (3). Hold the hook thread bobbin with a finger while doing this.

9. Pull out the hook thread until 100 to 150 mm protrudes out of the slot (3).

10.Place the opening cover for changing the hook thread back to its original position.

1 1. Use your fingers to hold the end of the needle thread and turn

the handwheel until the needle disappears in the needle plate, keep turning until the needle reappears and the thread lever is at the top dead point.

12.Pull on the end of the needle thread and pull out the end of the hook thread.

13.Cut both ends to approx. 70 mm by han d.

14.Press the F key again.

 The machine is ready for use again.

32 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Electronic handwheel (2) - Key for positioning the needle

up/down

(3) - OP1000 control panel

(4) - Operating peda l (5) - Belt cover (6) - Handwheel

①

②

③

④

⑤

⑥

5.6 Needle positioning

The machine is equipped with manual, semi-automatic and automatic needle positioning.

WARNING Risk of injury from needle and moving parts.

Protect yourself against accidents caused by the needle tip and moving foot.

Fig. 16: Needle positioning

Operating manual 969 - 00.0 - 08/2014 33

Operation

Manual needle positioning

Manual needle positioning is primarily intended for machine setup.

WARNING Risk of injury from needle and moving parts.

Switch off the machine before manually positioning the needle so that it cannot accidentally start during the positioning procedure.

1. Raise the presser foot using the hand lever and remove any material so the machine can run out.

2. Turn the handwheel (6) until the needle is correctly positioned. Important: The correct direction of rotation is marked from

the back by an arrow on the belt cover (5).

Semi-automatic needle positioning

Works when the machine is on by using the electronic handwheel (1) and is used to power the machine while the operating pedal (4) is released.

Turning the electronic handwheel drives the machine using the motor's torque. This allows you, e. g., to sew a seam to the desired position without the risk of going too far.

1. Switch on the machine at the main switch. Important: The electronic handwheel is not immediately activated once the machine is turned on. Therefore:

2. Activate the electronic handwheel (1) either with a one-quarter turn or by briefly pressing the operating pedal forwards.

3. Turn the electronic handwheel (1) until the needle is correctly positioned.

34 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Identical needle thread and hook thread tension (2) - Hook thread tension higher than needle thread tension (3) - Needle thread tension higher than hook thread tens ion

①

②

③

Automatic needle positioning for seam start

The needle should be very close to the material before starting in order to find the exact position for the start of the seam. In order to adjust the needle height to the material thickness, the needle can be slowly lowered downward by pressing on the electronic handwheel (1) in the axis direction of the needle.

1. Press down on electronic handwheel (1).

2. Only let go once the tip of the needle is at the desired height.

3. Confirm the new setting by pressing down on the wheel again.

5.7 Thread tension

The tension of the needle thread and hook thread determines where the thread interlaces.

Correct setting

The threads should normally interlace in the exact middle of the material. When setting, typically only the tension of the needle thread is altered, while the tension of the hook thread remains unchanged.

Operating manual 969 - 00.0 - 08/2014 35

Operation

(1) - Additional tensioner (2) - Primary tensioner

(3) - Preliminary tensioner

①

②

③

Thread tension for decorative stitching

When using a decorative stitch, a thicker thread is normally used with a relatively thinner material. Then the thread interlace is not buried in the material. In this instance, the tension is set so the threads interlace on the back side – see (2).

5.7.1 Setting the needle thread tension

The 3 adjusting wheels on the tensioning screw triangle determine the needle tension.

On the basic setting, the top side of one adjusting wheel is flush with the screw in the middle.

Fig. 17: Setting the needle thread tension

General

To increase the tension:

1. Turn adjusting wheel clockwise.

To reduce the tension:

1. Turn adjusting wheel counterclockwise.

36 Operating manual 969 - 00.0 - 08/2014

Operation

①

② ③

(1) - Additional te nsioner (2) - Primary tensioner (3) - Key on keypad for switching thread tension (4) - Preliminary tensioner

④

Setting needle thread tension on Classic machines

On Classic machines, the key (3) can be used while sewing to switch to a second thread tension, e.g. if different material should be used in the middle of a seam.

Fig. 18: Setting needle thread tension on Classic machines

1. Set the tension on the pre-tensioner (4), sew a test seam and cut the thread.

 The end of the thread in the needle should be between

60 - 80 mm. If the thread is shorter than this: Gradually reduce the tension on the auxiliary tensioner until the desired length is reached.

If the thread is longer than this:

Gradually increase the tension on the pre-tensioner until the desired length is reached.

2. Press the key for switching thread tensio n ( 3) until th e LED turns off.

 The auxiliary tensioner (1) is automatically activated.

3. Sew the material requiring a lower needle tension and regulate the tension on the main tensioner (2) until the correct thread interlace is achieved.

4. Press the key (3) for switching the thread tension.

 The key lights up and activates the auxiliary tensioner (1).

5. Sew the material requiring a higher needle tension and regu-

Operating manual 969 - 00.0 - 08/2014 37

late the tension on the main tensioner (1) until the correct thread interlace is achieved.

Operation

(1) - Additional tensioner (2) - Primary tensioner

(3) - Preliminary tensioner

①

②

③

Adjusting the needle thread tension on Eco machines

On Eco machines, a second tension can be activated while sewing. Thread tension is always the total tension of all three tensioners.

Fig. 19: Adjusting the needle thread tension on Eco machines

1. Set the pre-tensioner (3) so the needle thread is slightly tensioned after it.

2. Set the auxiliary tensioner (1) so the tension it creates is always much less than the tension created by the primary tensioner (2).

ATTENTION Risk of thread popping out if auxiliary tension is too high.

If the auxiliary tensioner (1) applies too much tension, the thread can pop out of the auxiliary tensioner while sewing, which suddenly reduces overall tension.

Make sure the auxiliary tensioner (1) is not set too high.

38 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Bobbin housing (2) - Hook thread

(3) - Adjusting screw

①

②

③

5.7.2 Setting hook thread tension

WARNING Risk of injury from moving parts.

Turn off the machine before tensioning the hook thread.

ATTENTION Pulling the thread in the wron g direction while measuring

tension can result in incorrect tension measure ment results.

Be sure to pull the thread in the proper direction.

ATTENTION If the needle thread tensi on is too low, the tension of the

hook thread will also b e too low. At higher sewing speeds, the needle thread will not be pulled properly and will get stuck in the hook. This manifests itself through increased noise and can result in damage to the machine.

Set the lower tension properly or reduce sewing speed.

Fig. 20: Adjusting the hook thread tension

Operating manual 969 - 00.0 - 08/2014 39

Operation

1. Turn the handwheel until the bobbin housing (1) is in the illustrated position.

To increase the tension:

1. Turn the adjustment screw (3) clockwise (the 2 mm hexagonal screwdriver included in the machine accessories can be used for this).

To reduce the tension:

1. Turn the adjustment screw (3) counterclockwise.

The hook thread tension is set at the factory to 350 to 400 cN.

1cN = 1g

40 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Balancing spring (2) - Thread limiter (3) - Direction to press when unlocking limiter (4) - Limiter slot (5) - Limiter hole

①

②

③

④

⑤

5.8 Setting thread limiter

WARNING Risk to injury to finger from moving thread lever.

Turn off the machine before setting the thread limiter.

Together with the balancing spring, the thread limiter produces suitable tension on the needle thread as it moves over the bobbin housing. The thread is limited more when sewing thin material s and less when sewing thick materials.

Correct setting:

The needle thread should be slightly tensioned when threading the loop over the bobbin housing. Slight movement in the balancing spring indicates proper tensioning.

Fig. 21: Adjusting the thread limiter

Operating manual 969 - 00.0 - 08/2014 41

Operation

1. Turn the thread limiter (2) in direction (3) until it moves to the right side of the opening (5).

2. Move the thread limiter (2) into or ou t of the machine.

• For thin materials:

Move the thread limiter (2) out of the machine.

• For thick materials:

Move the thread limiter (2) into the machine.

3. Adjust the thread limiter (2) so that the slot (5) clicks into the tensioning plate.

4. Sew to test whether or not the thread limiter setting is correct.

42 Operating manual 969 - 00.0 - 08/2014

Operation

(+1) - Sewing position (0) - Idle position (-1) - Presser foot raised position (-2) - Cutting and bar tacking position (3) - Pedal (4) - OP1000 control panel

③

④

(+1) (0) (-1)

(-2)

5.9 Raise the presser foot

The foot pedal is used while sewing to raise the presser foot, e.g., to move the material. The machine's electronic control unit allows various operating modes to be preset.

Fig. 22: Pneumatically raising presser foot with pedal

ATTENTION Risk of damage to machine from collision between needle

bar and presser foot.

Before raising the presser foot, use the electronic control panel to position the needle in the upper or lower idle position.

Operating manual 969 - 00.0 - 08/2014 43

Operation

Standard operating mode: The presser foot always remains lowered.

1. Turn off keys (13) and (14) on the OP1000 control panel (4),

 5.16 Operating the controller, page 63.

 Their signal diodes turn off – see  Operating manualfor

Basic/Classic DAC control panel.

2. Press the pedal (3) to position (-1).

 P resser foot rises.

3. Release the pedal to position (0).

 Presser foot lowers.

4. When a seam is complete, press the pedal to position (-2).

 The machine cuts the thread and the presser foot rises.

5. Release the pedal to position (0).

 Presser foot lowers.

ATTENTION Avoid premature cutting of the thread before the seam is

finished through unintentional pressing of the pedal into position -2.

Otherwise the seam will not be properly finished.

Operating mode: After completing the seam, the presser foot rises automatically.

1. Press the key on the OP1000 control panel (4) to raise the presser foot after the thread is cut.

 Their signal diodes turn off – see  Operating manualfor

Basic/Classic DAC control panel. Presser foot rises.

2. Press the pedal (3) to position (+1).

 Presser foot lowers and machine starts up.

3. Release the pedal to position (0).

 M achine stops.

4. Press the pedal to position (-1).

 P resser foot rises.

5. Press the pedal to position (+1).

 Presser foot lowers and machine starts up.

44 Operating manual 969 - 00.0 - 08/2014

Operation

6. Press the pedal to position (–2).

 Thread is cut and presser foot rises.

7. Release the pedal to position (0).

 Presser foot remains raised until another seam is started.

Operating mode: Presser foot rises automatically every time the machine stops.

1. Press both presser foot position keys on the OP1000 control panel (4).

 Their signal diodes light up – see  Operating manualfor

Basic/Classic DAC control panel. Presser foot rises.

2. Press the pedal (3) to position (+1).

 Presser foot lowers and machine starts up.

3. Release the pedal to position (0).

 Machine stop s and presser foot automatically rises.

4. Press the pedal to position (+1).

 Presser foot lowers and machine starts up.

5. Press the pedal to position (-2).

 Thread is cut and presser foot rises.

6. Release the pedal to position (0).

 Presser foot remains raised until another seam is started.

There is a time delay between starting the presser foot and the machine starting in order to ensure the material is pressed by the presser foot by the time sewing begins. This delay can be set using operating parameters – see  Operating manual for Basic/ Classic DAC control panel.

Operating manual 969 - 00.0 - 08/2014 45

Operation

(0) - Hand lever at position 0 (1) - Hand lever at position 1 (2) - Hand lever at position 2

⓪

①

②

5.10Raising presser foot with hand lever

CAUTION Risk of crushing when low ering the sewing foo t.

Make sure your hand is not underneath the presser foot when it is lowered by the pedal or lever.

The presser foot can be manually raised when setting up the machine or to remove the material from under the presser foot in an emergency if the compressed air supply has been disconnected from the machine.

Fig. 23: Raising presser foot with hand lever

Raising presser foot:

1. Turn the hand lever from position (0) to position (1).

 Presser foot rises up to 14 mm above the needle plate and

2. Turn the hand lever to position (2).

 Presser foot rises up to 20 mm above the needle plate and

46 Operating manual 969 - 00.0 - 08/2014

remains raised. The machine can be run at idle while in this position.

remains raised.

Operation

Lowering presser foot:

The presser foot can be lowered in two ways:

1. Manually turn hand lever to position(0).

2. Raise presser foot with pedal. Presser foot rises slightly, the hand lever lock disengages and the internal spring moves the hand lever back to position (0).

5.11Setting presser foot pressure

The adjusting wheel at the top left of the machine arm determines the contact pressure of the sewing foot on the material to be sewn. The pressure can be adjusted continuously by turning the adjusting wheel.

WARNING Risk to injury to eyes.

Loosening the adjusting wheel too much can cause it to unscrew and be shot off by the spring underneath.

Never exceed a value of H = 55 mm, see fig. 24.

Correct setting

Set the pressure of the presser foot as low as possible, but high enough so that the material can pass through evenly without slipping through.

Defects due to incorrect setting

• Pressure too high: Material is torn by the feed dogs. Feed is very loud.

• Pressure too low:

• Material slipping through causes an uneven stitch length.

• When moving up, the needle also takes some of the mate-

rial from the presser foot due to friction.

Operating manual 969 - 00.0 - 08/2014 47

Fig. 24: Setting presser foot pressure

(1) - Adjusting screw (2) - Counternut

(3) - Auxiliary spring

①

②

③

Operation

To increase presser foot pressure:

1. Release the counternut (2).

2. Turn adjusting wheel (1) to the right until the desired pressure is reached.

3. If the pressure is insufficient even when the adjusting wheel is fully tightened, use the auxiliary spring (3) provided in the machine accessories.

4. Completely unscrew adjusting wheel (1).

WARNING Risk to injury to eyes.

Loosening the adjusting wheel too much can cause it to unscrew and be shot off by the spring underneath.

Always loosen with the presser foot lowered (less spring tension). Loosen the screw with one hand, pressing down with the other to prevent it from coming off.

48 Operating manual 969 - 00.0 - 08/2014

Operation

ATTENTION The auxiliary spring greatly increases pressure depending

on material thickness. This can cause defects when sewing soft material or sewing over thicker areas in the material.

If an auxiliary spring is not absolutely necessary due to the presser foot rising when the needle moves up, do not use one.

5. Insert auxiliary spring (3).

6. Screw in adjusting screw (1) and adjust the presser foot pressure.

7. Tighten the counternut (2).

ATTENTION The use of the auxiliary spring in conjunction with maxi-

mum machine speed can damage the machine.

Limit the maximum machine speed when using the auxiliary spring.

Reducing pressure:

1. Release the counternut (2).

2. Turn adjusting wheel (1) to the left until the desired pressure is reached.

ATTENTION Unscrewing the adjusting wheel too far will damage the

machine.

A slot on this screw indicates the maximum distance that the adjusting wheel may be unscrewed. This slot must never be higher than the upper edge of the counternut (2).

3. Tighten the counternut (2).

Operating manual 969 - 00.0 - 08/2014 49

Operation

5.12Setting presser foot stroke

The presser foot stroke has twelve levels of 1 mm each.

Correct presser foot stroke setting

Set the presser foot stroke as low as possible, but enough so that the material can pass through evenly with a consistent stitch length. In general, the thicker the material and the greater the changes in thickness over the course of the seam, the higher the pressure foot stroke should be.

Defects due to incorrect setting

• Stroke too high: The heavy impact of the presser foot can damage the material and the machine is unusually loud.

• Stroke too low: Stitch is shortened – its length is much shorter than the length set by the adjusting wheel. Specifically, the machine does not feed material properly at places where the material thickness suddenly changes.

5.12.1 Limitation of sewing speed

If the pressure foot stroke is high, the operator must limit sewing speed to the maximum RPM according to the table, regardless of material,  Table of maximum machine speeds, page 110.

ATTENTION The machine can be da ma g ed if the sewing speed is too

high for the presser foot stroke.

Make sure the permitted sewing speed in the table in the Appendix is not exceeded.

50 Operating manual 969 - 00.0 - 08/2014

Operation

5.12.2 Limiting presser foot stroke

When the pressure foot contacts the material, dynamic force is generated that increases with thinner and harder materials. This force puts great strain on the machine and manifests itself through noise. The operator can adjust the pressure foot stroke to suit the material thickness according to the table,  Table: Maximum presser foot stroke, page 110.

ATTENTION The machine can be damaged if the presser foot stroke is

too high for the thickness and hardness of the material.

Test presser foot stroke when sewing thinner materials and reduce it accordingly.

5.12.3 Setting presser foot stroke

Classic machines have 2 adjusting wheels for adjusting the presser foot stroke.

The left adjusting wheel (1) adjusts the normal presser foot stroke. The right adjusting wheel (2) adjusts the increased presser foot stroke.

Normal stroke is designed for high sewing speed. Increased stroke is designed for sewing over thicker areas in the material. Eco machines only have the left adjusting wheel.

Important: The increased presser foot stroke should not be lower than the normal presser foo t stroke. The machi ne is designed so the right adjusting wheel cannot set a lower stroke than the left adjusting wheel.

ATTENTION Machine can be damaged if the adjusting wheels are

forced.

Do not attempt to force the right adjusting wheel to set a lower stroke than the left adjusting wheel.

Operating manual 969 - 00.0 - 08/2014 51

Fig. 25: Presser foot stroke adjusting wheels

(1) -Adjusting wheel for the normal sewing foot stroke (2) -Adjusting wheel for the increased sewing foot stroke

①

②

Operation

To increase presser foot stroke:

1. Turn adjusting wheel clockwise.

To reduce presser foot stroke:

1. Turn adjusting wheel counterclockwise.

52 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Foot switch

①

5.12.4 Quickly switching presser foot st roke with foot

switch

If the machine is equipped with an optional foot switch, this can be used to quickly switch the presser foot stroke between two preset levels without having to stop sewing.

Fig. 26: Foot switch

Activating increased presser foot stroke

• Press foot switch (1) backwards with heel.

 Increased stroke remains engaged as long as the foot switch

is depressed.

Deactivating increased presser foot stroke

• Release foot switch (1).

Operating manual 969 - 00.0 - 08/2014 53

Operation

(1) - Key on keypad for sti tch length (2) - Marks labeling selected stitch lengths (3) - Bottom adjusting wheel for shorter stitches (4) - Top adjusting whee l for the larger stitch length

①

②

③

④

5.13Stitch length

5.13.1 Setting stitch length

Depending on the equipment, the machine has 1 or 2 adjusting wheels for stitch length.

The stitch length is continuously adjustable over a range of 0– 15 mm.

Fig. 27: Stitch length adjusting wheels

Top adjusting

wheel

Bottom adjust-

ing wheel

54 Operating manual 969 - 00.0 - 08/2014

To reduce stitch length:

1. Turn adjusting wheel clockwise.

To increase stitch length:

1. Turn adjusting wheel counterclockwise.

To reduce stitch length:

1. Turn adjusting wheel counterclockwise.

To increase stitch length:

1. Turn adjusting wheel clockwise.

Operation

(1) – Stitch length key on keypad (2) - Marks labeling selected stitch lengths (3) - Bottom adjusting wheel for shorter stitches (4) - Top adjusting whee l for the larger stitch length

①

②

③

④

5.13.2 Sewing with 2 stitch lengths

Fig. 28: Sewing with 2 stitch lengths

On machines with adjusting wheels for 2 stitch lengths, the top adjusting wheel (4) is for longer stitch lengths and the bottom adjusting wheel (3) is for shorter stitch lengths. The mark (2) on the left of the adjusting wheel indicates the stitch length selected.

Important: The larger stitch length must not be shorter than the smaller stitch length. Do not set a stitch length on the top adjusting wheel (4) that is shorter than the stitch length on the bottom adjusting wheel (3).

ATTENTION Machine can be damaged if the adjusting wheels are

forced.

The machine is designed so the top adjusting wheel cannot be set at a lower stitch length than the bottom adjusting wheel.

Do not attempt to force the top adjusting wheel to set a lower stitch length.

Operating manual 969 - 00.0 - 08/2014 55

Operation

①

②

③

④

⑤

(1) – Seam bar tacker key on keypad (2) - OP1000 control panel (3) - Foot switch

(4) - Operating pedal (5) - Stitch adjustment lever

Switching stitch length:

Stitch length can be switched be tween the values set on the adjusting wheels (3) and (4) while the machine is stopped or running.

1. Press the key (1).

 Stitch length switches from the current length to the second

length and the key illuminates/turns off. If the key illuminates, the longer stitch length set on the top adjusting wheel (4) is used.

5.13.3 Reverse sewing and seam bar tacking

On Eco machines, seam bar tacking can only be done by hand. If desired, Eco machines can be retrofitted with an automatic bar tacker. In all cases the seam bartacking can be activated when the machine is stopped and also when the machine is running.

Fig. 29: Operating the seam bar tacker

56 Operating manual 969 - 00.0 - 08/2014

Operation

Manual seam bar tacking:

1. Move stitch adjusting wheel (5) to the bottom.

 The machine feeds the material in reverse as long as the

adjusting wheel is depressed.

Partially depressing the stitch adjustment lever (5) shortens the stitch length in proportion to the distance of the adjustment lever from its middle position. In middle position, feed is stopped completely. In the lower end position, the machine sews in reverse with the stitch length currently set at the adjusting wheels.

Automatic seam bar tacking:

Only Classic machines come with semi-automatic and automatic seam bar tacking. If desired, Eco machines can also be retrofitted.

Semi-automatic seam bar tacking:

1. Press key (1) on the machine keypad.

 The machine feeds the material in reverse as long as the key

is depressed.

Semi-automatic seam bar tacking with foot switch

1. Press foot switch (3) forward with toes.

 The machine feeds the material in reverse as long as the

foot switch is depressed.

Automatic seam bar tacking:

The machine's electronic control unit allows automatic seam bar tacking to be activated. To do this, read the  Operating manual for the DAC basic/ classic control system.

Operating manual 969 - 00.0 - 08/2014 57

Operation

1. Enter seam bartacking at the start of the seam and end of the seam via the control panel (2).

2. Press operating pedal (4) down with toes.

 Machine automatically sews a bar tack at the start of the

seam.

3. Finish the seam, then press the operating pedal (4) completely backwards at the end of the seam.

 Machine automatically sews a bar tack at the end of the

seam.

Selecting type of seam bar tacking and stitch count with automatic seam bar tacking:

The machine's control unit allows selection between a single, double or multiple (quadruple) bar tack. The type of bar tack

is selected using the keys on the OP1000 control panel – see  Operating manual for Basic/Classic DAC control unit.

Selecting seam bar tacking style with automatic seam bar tacking:

Seams can be bar tacked either normally or decoratively.

Decorative style With a decorative seam bar tack, all forward and backward needle

stitches in the bar tack area go in the same needle holes while sewing.

Normal style With a normal seam bar tack, the insertions can be offset from

one another. Since normal seam bar tacking is faster, the machine is delivered with normal seam bar tacking preset by default.

The seam bar tacking style can be selected using the electronic control panel parameters – see  Operating manual for Basic/ Classic DAC control unit.

58 Operating manual 969 - 00.0 - 08/2014

Operation

(1) - Auxiliary switch

Keys for:

(2) - Reverse sewing (3) - Needle position (4) - Start and end bar tack

(5) - Stitch length (6) - Additional thread tension (7) - Additional function (optional) (8) - Screws for the assignment of

the additional swit ch (1)

①

②

③

④

⑤

⑦

⑧

⑥

5.14Quick functions on keypad

Depending on the submodel, the machine has a keypad on the machine arm for activating specific functions while sewing.

5.14.1 Activating function keys

Fig. 30: Keypad for quick functions

Activating a key function

1. Press the key.

 The function is activated. The key illuminates.

Deactivating a key function

1. Press the key again.

 The function is deactivated. The key turns of f.

Operating manual 969 - 00.0 - 08/2014 59

Operation

Fig. 31: Function keys

Key Function

Reverse sewing key (2) When this key (2) is activated, the machine sews in reverse. Needle positioning

key (3)

When this key(3) is activated, the needle moves to a specific position. This position is determined individually via the parameter settings. The machine is supplied configured so that activating key (3) will raise the needle. There are two needle positions that can be configured on the control unit for stopping during a seam and after a seam,

 Needle positioning, page 33.

The key (3) allows the operator to manually switch from one position to the other.

Start and end bar tack key (4)

Stitch length key (5) When this ke y (5) is selected, the machine sews with the larger

Auxiliary thread tensioning key (6)

The key (4) disables the basic setting for sewing the start and end bartacks. If bar tacks are on, pressing the key (4) skips the next bar tack. If bar tacks are off, pressing the key (4) sews the next bar tack. For the general setting for sewing start and end bartacks, refer to the classic control system.

stitch length set on the upper stitch adjusting wheel. This key (6) activates the auxiliary thread tensioner.

 Operating Manual fo r the DAC basic/

Auxiliary function key for optional equipment (7)

60 Operating manual 969 - 00.0 - 08/2014

Using the machine's electronic control unit, this key can be assigned to activate any optional equipment. For example, the needle cooler.

Operation

(1) - Auxiliary switch (2) - Screw activates auxiliary switch (3) - Original positio n

①

②

③

5.14.2 Transferring a key function to the auxiliary

switch

You can transfer one of the key functions to the auxiliary switch. Select a function that you frequently use so that you can switch it on faster while sewing.

Fig. 32: Keypad for quick functions

The key function is transferred by turning the screw under the key until it is vertical. Only one function can be assigned to the auxiliary switch (1). Thus, only one screw can be set vertically. All screws must be turned back to their original horizontal position before transferring a new function.

Operating manual 969 - 00.0 - 08/2014 61

Operation

(+1) - Sewing position (0) - Idle position (-1) - Presser foot raised position (-2) - Cutting and bar tacking position (3) - Pedal (4) - OP1000 control panel

③

(+1) (0)

(-1)

(-2)

To transfer a key function:

1. Bring all screws to their original positions (3), so that the slots are horizontal.

2. Turn the screw under the desired key by 90° so that the slot is vertical (2 threads and protection against separation)

5.15Thread cutting and securing against unrav-

eling

1. Press the pedal completely backwards to position (-2) at the end of the seam.

 If the machine was idle, it will perform a half or full rotation,

cut both threads and then stop.

Fig. 33: Cutting the thread

Cutting can also be started while the machine is running. In this case, the machine first reduces speed when the pedal is pressed back. Once the machine has reached cutting speed, the thread is cut and the machine stops.

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Operation

① ? ③ ④ ⑤ ⑥⑦⑧⑨⑩

⑪⑫⑬

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Overview table provided below.

5.16Operating the controller

The machine is operated with the Basic/Classic DAC control unit. Operating the controller is described in an individual  Operating Manual.

The Basic/Classic DAC operating manual is included in the control unit pack. It can also be found in the "Downloads" section at

www.duerkopp-adler.com.

5.16.1 Control panel

The Basic/Classic DAC control unit is equipped with the OP1000 control panel.

Fig. 34: Control unit panel

Switch on/off function

1. Press the appropriate key.

Operating manual 969 - 00.0 - 08/2014 63

 The LED on the key indicates the status.

Important: The functions on the machine only work if the proper equipment is available.

Overview of control panel functions

Key Function Status LED display

1 Thread cutter Off LED off

On LED on

2 Thread clamp Off LED off

On LED on

3 Start bar tack Off LED off

Single bar tack Lower right LED on Double bar tack Both LEDs on

4 Multiple start bar tack Off LED off

On LED on

5 Soft start Off LED off

On LED on

6 End bar tack Off LED off

Operation

Single bar tack LED top left on Double bar tack Both LEDs on

7 Multiple end bar tack Off LED off

On LED on

8 Reduced sewing speed

Input with +/- keys

stitch length

Off LED off On LED on Off LED off On LED on

10 Sewing program I Off LED off

On LED on

11 Sewing program II Off LED off

On LED on

12 Sewing program III Off LED off

On LED on

13 Light barrier Off LED off

On LED on

14 Presser foot rises after sewing stop Presser foot down LED off

15 Presser foot position after cutting the

thread

16 Needle position after sewing stop Needle down LED off

F Threading help

64 Operating manual 969 - 00.0 - 08/2014

Presser foot up LED on Presser foot down LED off Presser foot up LED on

Needle up LED on

Operation

Key Function Status LED display

ESC Escape key, cancel P Programming key Ready to be pro-

grammed

+ Increase the value

- Decrease the value OK Confirmation Reset Bobbin supply

LED on

Operating manual 969 - 00.0 - 08/2014 65

Operation

(1) - Machine head (2) - Swingable part of the table plate

(3) - Clamp (4) - Fixed part of the table plate

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5.17Swinging out the table plate

If the machine is equipped with a special frame, part of the table plate can be folded down to create space under the lower arm for sewing larger pieces.

WARNING Risk of injury from moving parts.

Switch off the machine before swinging out the table plate.

Fig. 35: Swinging out the table plate

1. Fold the machine head (1) to the rear in the direction of the

2. Release both clamps (3) fastening the folding part of the table

66 Operating manual 969 - 00.0 - 08/2014

arrow.

plate (2) to the fixed part of the plate (4).

Operation

3. Slide the folding part of the table plate (2) approx. 10 mm to the left and then fold it to the rear in the direction of the arrow .

4. Fold the machine head (1) back to the working position.

ATTENTION When returning the folding part of the plate (2) back to the

normal working position, set the position of the clamps (3) so that the plate is not damaged by colliding w ith the clamps.

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Operation

68 Operating manual 969 - 00.0 - 08/2014

Maintenance

6 Maintenance

This section describes simple maintenance work that needs to be carried out on a regular basis. This maintenance work can be carried out by the operating personnel. Additional maintenance work may only be performed by specially trained and qualified technicians. The additional maintenance work is described in the  Service manual.

6.1 Cleaning the machine

Lint and thread remnants must be removed after every 8 hours of operation, using a compressed-air pistol or a brush. When sewing very fluffy materials the machine must be cleaned more often.

WARNING Risk of injury from flying particles.

Turn off the power switch before cleaning. Swirled up dirt particles can get into the eyes and

cause injury. Hold the compressed-air pistol so that particles do

not fly toward persons. Make sure no particles fly into the oil pan.

ATTENTION Malfunctions can occur due to a dirty machine.

Lint and thread remnants can impair th e operation of the machine.

Clean the machine at regular intervals according to the instructions in the manual.

Operating manual 969 - 00.0 - 08/2014 69

(1) - Area around the needle (2) - Thread cutter (3) - Feed-dog

(4) - Hook (5) - Cover (6) - Cover

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Maintenance

Fig. 36: Areas requiring special attention when cleaning- Part 1

70 Operating manual 969 - 00.0 - 08/2014

Maintenance

(7) - W ind e r cut ter

⑦

Fig. 37: Areas requiring special attention when cleaning- Part 2

Areas particularly susceptible to soiling:

• Winder cutter (7)

• Area between needle plate and feed dogs (3)

• Hook (4)

• Cutters (2), (5)

• Area around the needle (1)

Cleaning steps:

1. Shut off power by turning off power switch.

2. Unscrew needle plate.

3. Remove the covers (5) and (6) so that dust and thread remnants can fall out of the normally covered openings.

4. Remove any lint and thread remnants using a compressed-air pistol or a brush.

ATTENTION Damage to the paintwork due to solvent-bas ed cleaners.

Solvent-based cleaners will damage paintwork on the machine.

Only use solvent-free substances when cleaning the machine.

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Maintenance

6.2 Checking oil level

WARNING Skin damage due to contact with oil.

Oil can cause a rash if it comes into contact with skin.

Avoid any skin contact with the oil. If oil gets on your skin, wash the affected areas

thoroughly.

ATTENTION Machine damage possible due to in co rrect oil level.

Too little or too much oil can damage the machine. Check the oil level on a daily basis, adding enough oil so oil

level is always between the minimum and maximum marks.

72 Operating manual 969 - 00.0 - 08/2014

Maintenance

(1) - Filler opening (2) - Maximum level marking (3) - Minimum level marking

MAX

MIN

1 2

(1) - Filler opening (2) - Maximum level marking (3) - Minimum level marking

Fig. 38: Oil level indicator

1 2

MAX

MIN

Checking oil level

1. Check the oil level indicator every day:

Important: The oil level must always be between the minimum level mark (3) and the maximum level mark (2).

Fig. 39: Oil level indicator

Refilling oil

Pour in oil through the filler opening (1) as required:

1. Switch off the sewing machine at the main power switch.

2. Top up the oil to the maximum level mark (2).

3. Press the power switch again to turn the sewing machine

CLASSIC

equipment

Note for machines with CLASSIC equipment:

On CLASSIC machines, if the oil level falls below the minimum level marking (3), the oil level indicator lights up red.

1. Turn the sewing machine off, then on again after refilling oil.

 The red light will turn off.

Operating manual 969 - 00.0 - 08/2014 73

back on.

Maintenance

Required oil:

The machine should only be filled with DA10 lubricating oil or equivalent, with the following properties:

• Viscosity at 40 °C: 10 mm²/s

• Flash point: 150 °C

ATTENTION Machine damage possibl e du e to in correct oil.

An incorrect oil type can cause damage to the machine. Only use oil specified in the operating manual.

ENVIRONMENTAL PROTECTION Risk of environmental damage from oil.

Oil is a pollutant and must not enter the sewage system or the soil.

Carefully collect waste oil and dispose of the waste oil and oil-contaminated machine parts in the legally prescribed manner.

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Maintenance

(1) - Standard value: 6 bar (2) - Pressure gage

6.3 Checking pneumatic system

ATTENTION Machine damage possible due to incorrect pressu r e.

Incorrect pressure can result in damage to the machine. Check the pressure on a daily basis. Have the pressure adjusted by qualified specialists if the

pressure deviates from the reference value.

Fig. 40: Pressure indicator on maintenance unit

Check pressure:

1. Check the pressure and pressure gage (2) every day. Standard value: 6 bar

Important: The pressure must never deviate from the standard value by more than 1 bar.

Operating manual 969 - 00.0 - 08/2014 75

Maintenance

(1) - Filter element (2) - Water separato r (3) - Drain screw

Water condensation will accumulate in the water separator of the maintenance unit.

Fig. 41: Water level in the maintenance unit

Check water level:

1. Check the water level every day.

Important: Water condensation must not rise up to the filter element (1).

ATTENTION Machine damage possible if there is too much water.

Too much water can result in damage to the machine. Check the water level every day and drain the condensation

water if there is too much water in the water separator.

Drain water as required:

1. Switch off the sewing machine at the main power switch.

2. Place the collection tray under the drain screw (3).

3. Remove the compressed air hose from the compressed air supply .

4. Completely unscrew the drain screw (3)

5. Allow water to drain into the collection tray.

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Maintenance

6. Re-tighten the drain screw (3).

7. Connect the compressed air hose to the compress ed ai r supply .

8. Press the power switch again to turn the sewing machine back on.

6.4 Customer Service

Contact for repairs if machine is damaged:

Dürkopp Adler AG Potsdamer Str. 190 33719 Bielefeld, Germany Phone: +49 (0) 180 5 383 756 Fax: +49 (0) 521 925 2594 Email: service@duerkopp-adler.com Internet: www.duerkopp-adler.com

Operating manual 969 - 00.0 - 08/2014 77

Maintenance

78 Operating manual 969 - 00.0 - 08/2014

Installation

7 Installation

WARNING Risk of injury.

The machine may only be set up by qualified technicians.

7.1 Checking delivery

Important: The scope of delivery depends on the order.

Delivery consists of standard equipment and optional equipment.

1. Check that all parts are present before setup.

Stan da rd eq uipment:

• Machine upper section (1)

• Accessories – tools (not illustrated)

• Plate bracing (9)

• Lighting transformer (with the CLASSIC version) (11)

• DAC control unit (10)

• Thread reel holders (12)

• Connectors (not illustrated)

Optional equipment:

• Table plate (2)

• Drawer (3)

• Frame (4)

• Foot switch (6)

• Pedal (7)

• Compressed air regulator unit (8)

• Lighting transformer (with the Eco version) (11)

Operating manual 969 - 00.0 - 08/2014 79

Fig. 42: Scope of delivery

(1) - Machine upper section (2) - Table plate (3) - Drawer (4) - Frame (5) - Setpoint transducer (6) - Foot switch

(7) - Pedal (8) - Compressed air regulator unit (9) - Oil pan (10) - DAC control unit (11) - Lighting transformer (12) - Thread reel holder

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Installation

7.2 Removing transport securing devices

All transport securing devices must be removed prior to setup.

1. Remove the lashing straps and wooden blocks from the upper machine section, table and frame.

2. Remove the support wedges between the machine arm and needle plate.

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Installation

(1) - Head sections of the inner bars (2) - Inner bars (3) - Frame bars (4) - Cross bars

(5) - Adjusting screw (6) - Frame foot struts (7) - Cross strut (8) - Oil can holder

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7.3 Assembling the frame

Two different types of frame can be supplied with the machine, depending on the version ordered:

• Standard frame with fixed table plate

• Special frame with partially swingable table plate

The frame can be supplied assembled or dismantled.

7.4 Assembling the standard frame

7.4.1 Assembling frame components

Fig. 43: Assembling frame components

1. Screw the cross bars( 4) to the frame bars (3).

2. Screw the oil can holder (8) to the frame bar (3).

3. Screw the cross strut (7) to the foot struts (6).

Operating manual 969 - 00.0 - 08/2014 81

Installation

(1) - Hinge connecting rod (2) - Lighting transformer (3) - Setpoint transducer (4) - Oil pan (5) - Drawer (6) - Frame mounting holes

(7) - Cable duct (8) - Screw-mounted power cable

mounting clamp

(9) - Nailed mounting clamps

(10) - DAC control unit

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4. Screw the inner bars (2) to the frame bar (3) so that both headpieces (1) are at the same height.

5. Important: Turn th e adjustment screw (5) so the frame is standing evenly on the floor.

7.4.2 Assembling components on underside of table

plate

The table plate is optional. If you wish to manufacture your own table plate then use the drawing provided in the appendix,  Drawings for creating table

plate, page 105.

Fig. 44: Assembling components on underside of table plate

82 Operating manual 969 - 00.0 - 08/2014

1. Turn the table plate over so the underside is facing up.

2. Fasten the components as shown in the image. The position of each component is to scale on the drawing,  Component

layout on underside of table plate, page 107.

Installation

(1) - Foot switch (2) - Frame (3) - Setpoint transducer

(4) - Pedal connecting rod (5) - Pedal

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3. Fasten the power cable mounting clamp (8) screws.

4. Nail down the cable clamps (9).

5. Pre-drill the holes in the plate for mounting the frame (6) according to the drawing,  Component layout on underside of table plate, page 107.

If the machine is equipped with a sewing lamp, first connect the sewing lamp transformer to the control unit,  Connecting the lighting, page 95. Then screw the control unit to the table plate (the connection terminal is only accessible when the control unit is removed).

7.4.3 Mounting the frame on the table plate and

mounting the pedal

Fig. 45: Mounting frame and pedal

1. Screw the frame (2) at the pre-drilled holes.

2. Screw the foot switch (1) to the vertical cross bar of the frame,

3. Screw on the pedal (5).

Operating manual 969 - 00.0 - 08/2014 83

as close as possible to the left bar.

Installation

(1) - Table plate (2) - Frame height adjustment screws

(3) - Pedal (4) - Pedal connecting rod couplings

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②

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③

4. Connect the lugs on the ends of the connecting rod (4) to the ball pins on the sensor (3) and pedal (5).

7.4.4 Setting frame height and pedal position

WARNING Risk of occupational illness (musculoskeletal

damage) to operating personnel from failure to comply with ergonomic requirements.

Adjust the frame height to the height of the person operating the machine.

Position the pedal so that the middle of the pedal lies in the axis of the needle with a maximum deviation of 15 mm.

The frame can be adjusted continuously to any height between 770 and 910 mm.

Fig. 46: Setting frame height and pedal position

84 Operating manual 969 - 00.0 - 08/2014

Installation

WARNING Risk of crushing

Loosening the screws on the lower frame bars can result in the table plate collapsing under its own weight. This is more likely if the upper machine section has already been mounted. Make sure your hand does not get crushed while loosening the screws.

1. Loosen the adjustment screws (2) on the frame bars.

2. Set the table plate (1) to the desired height. Important: Use a tape measure to make sure the table plate

is level.

3. Tighten the screws (2) on the frame bars.

4. Set pedal (3) so that the middle is directly in line with the needle –  Mounting the frame on the table plate and mounting the pedal, page 83.

5. Use the pedal connecting rod (4) couplings to set the angle as desired by the machine operator.

Operating manual 969 - 00.0 - 08/2014 85

Installation

(1) - Suspension screw with eyelet (2) - Machine upper secti on (3) - Table plate

(4) - Fastening screws (5) - Oil hose with end piece (6) - Fabric washer

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7.4.5 Placing the machine upper section on the frame

Fig. 47: Placing the machine upper section on the frame

CAUTION Risk of crushing

The upper machine section is very heavy. Make sure your hands do not get crushed while

mounting the upper machine section.

1. Remove the plug from the top of the upper machine section (2) and screw in the suspension screw with eyelet (1) included in the machine accessories.

86 Operating manual 969 - 00.0 - 08/2014

Installation

WARNING Risk of injury.

The eyebolt is only designed for lifting the machine head. Lifting the entire machine including the frame via this eyebolt is not permitted.

2. Lift the machine upper section with a crane and, from below, screw on the hose with the end piece (4) and the fabric washer (5) included in the machine accessories.

3. Lower the machine upper section (2) onto the table plate (3) and fasten using the screws (4) included in the machine accessories.

Operating manual 969 - 00.0 - 08/2014 87

7.5 Assembling the special frame

(1) - Rear bar plate (2) - Table plate folding holder (3) - Upper left side pl ate (4) - Holder for the setpoint trans-

ducer (5) - Plate holder hinge (6) - Oil can holder (7) - Rear cross bar

(8) - Hinge for the left side plate

(9) - Front cross bar (10)- Lower left side plate (11)- Cross strut (12)- Adjustment support (13)- Side plates of the frame bar (14)- Head piece

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7.5.1 Assembling frame components

Fig. 48: Assembling frame components

Installation

1. Screw both frame bar plates (13) to the rear bar plate (1) and

2. Screw on the head piece (14).

3. Screw on the rear cross bar (7) and screw in all screws in the

4. Screw on the plate holder hinge (5) including the folding table

88 Operating manual 969 - 00.0 - 08/2014

the front cross bar (9) and the lower left side plate (10) using only the lower screws and screw these tight.

rear bar plate (1).

plate holder (2).

Installation

(1) - Pins (2) - Buffer (3) - Fastening clamps for the high

voltage connection

(4) - Drawer (5) - Fastening clamps (6) - Lighting transfor mer (7) - DAC control unit

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③

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5. Screw on the hinge for the upper left side plate (8).

6. Screw on the holder for the setpoint transducer (4).

7. Turn the frame with the underside upwards and screw the cross bar (11) to the frame si de plates.

8. Important: Set the adjustment support (12) so that the frame stands level on the floor.

9. From the rear, screw on the oil can holder (6).

7.5.2 Assembling components on underside of table

plate

The table plate is optional. If you wish to manufacture your own table plate then use the drawing provided in the appendix,  Drawings for creating table

plate, page 105.

Fig. 49: Assembling components on underside of table plate

1. Turn the table plate over so the underside is facing up.

2. Hammer in the pin (1).

1. Fasten the components as shown in the image. The position

Operating manual 969 - 00.0 - 08/2014 89

of each component is to scale on the drawing,  Component

layout on underside of table plate, page 107.

Installation

(1) - Holes for fastening the machine

upper section to the fram e (2) - Table plate folding holder (3) - Left side plate (4) - Knee switch

(5) - Setpoint transducer (6) - Pedal connecting rod (7) - Foot switch (8) - Pedal

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2. Fasten the power cable mounting clamp (3) screws.

3. Fasten the cable clamps (5) with nails.

7.5.3 Mounting the frame on the table plate and mounting the pedal

Fig. 50: Mounting the frame on the table plate and mounting the pedal

1. Turn the table plate over so the underside is facing up.

2. Screw the left side plate (3) and the folding holder of the table

90 Operating manual 969 - 00.0 - 08/2014

plate (2) to the plate so that the holes for fastening the machine upper section (1) lie in the same axis as the holes in the table plate.

Installation

3. Screw on the foot switch (7) as close as possi b l e to the left

side plate (3).

4. Screw on the pedal (8) as close as possible to the foot switch

(7). If the machine is equipped with a pedal then the middle of the pedal must lie in the axis of the needle.

5. Screw the setpoint transdu cer (5) onto the holder.

6. Install the pedal connecting rod (6) and the move the pedal

ball pin holder so that the connecting rod lies in the axis of the setpoint transducer (5).

7. Screw on the knee switch (4).

Operating manual 969 - 00.0 - 08/2014 91

Installation

(1) - Eyebolt (2) - Machine upper secti on (3) - Table plate (4) - Fastening screws (5) - Holder for the reservoir

(6) - Used oil reservoir (7) - Front frame bar pla te (8) - Oil hose with end piece (9) - Fabric washer

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7.5.4 Placing the machine upper section on the frame

Fig. 51: Placing the machine upper section on the frame

CAUTION Risk of crushing

The upper machine section is very heavy. Make sure your hands do not get crushed while

mounting the upper machine section.

92 Operating manual 969 - 00.0 - 08/2014

Installation

1. Remove the plug from the top of the upper machine section

(2) and screw in the eyebolt (1) included in the machine accessories.

WARNING Risk of injury.

The eyebolt is only designed for lifting the machine head. Lifting the entire machine including the frame via this eyebolt is not permitted.

2. Lift the machine upper section with a crane and, from below,

screw on the hose with the end piece (8) and the fabric washer (9) included in the machine accessories.

3. Lower the machine upper section (2) onto the table plate (3)

and fasten using the screws (4) included in the machine accessories.

4. Screw on the reservoir holder (5)

5. Screw on the used oil reservoi r (6).

6. Slide in the front frame bar plate (7) at an angle and screw in

place.

Operating manual 969 - 00.0 - 08/2014 93

7.6 Assembling thread reel holder

(1) - Thread reel holder arm (2) - Thread reel holder arm screws (3) - Thread reel holder (4) - Holes in thread reel holder (5) - Thread reel holder screws (6) - Machine upper section

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Fig. 52: Assembling thread reel holder

Installation

1. Use the screws (5) included in the machine accessories. to

2. After loosening the screws (2) the thread reel holder arm (1)

94 Operating manual 969 - 00.0 - 08/2014

fasten the thread reel holders (3) to the machine upper section (6).

can be tilted for operating the machine. The thread reel holder arm (1) can also be slid into a lower position and screw tight in the holes (4).

Installation

7.7 Electrical connection

DANGER Risk of death from electric shock.

The machine should only be connected to power by qualified electricians.

Disconnect the power plug before carrying out w ork on the electrical equipment.

Make sure the power plug is not accidentally plugged back in.

The voltage on the type plate of the sewing drive must correspond to the mains voltage.

7.7.1 Checking mains voltage

Important: The voltage on the type plate of the sewing drive must

correspond to the mains voltage.

1. Check mains voltage before connecting the machine.

7.7.2 Connecting the lighting

Connecting the transformer to the control unit

DANGER Risk of death from electric shock.

Supply voltage for the sewing lamp remains on even if the sewing machine is turned off through the power switch.

Unplug the sewing machine before assembling and connecting the sewing lamp to the transformer.

Make sure the power plug is not accidentally plugged back in.

Operating manual 969 - 00.0 - 08/2014 95

Installation

1. Remove the control unit (2)

2. Unscrew the cover (1).

3. Connect the cable as specified in the circuit diagram.

4. Screw on the cover (1).

7.7.3 Connecting control unit

DANGER Risk of death from electric shock.

Disconnect the power plug before connecting the control unit.

Make sure the power plug is not accidentally plugged back in.

Connect the control unit as follows:

• Insert the plug of each connecting cable into the sockets on

the back of the control unit. The sockets for each connector plug are labeled with

pictograms.

• Connect the control unit to the power supply using the power

cable.

Important: Read the  Operating Manual for the eco/classic DAC control unit. The manual is included with the control unit. The Operating Manual is also available in the document download area at www.duerkopp-adler.com.

96 Operating manual 969 - 00.0 - 08/2014

Installation

(1) - Cross bar (2) - System connection hose

(3) - Maintenance unit (4) - Machine hose

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7.8 Connecting the pneumatic system

7.8.1 Fitting the maintenance unit

A pneumatic connection package for connecting the pneumatic maintenance unit is available,  Additional equipment, page 9. It includes:

• System connection hose

(length 5 m, diameter 9 mm)

• Hose glands and couplings

• Connection plugs and sockets

Correct setting

The pressure in the pneumatic system network is 8 – 10 bar.

ATTENTION Machine damage possible due to incorrect pressu r e.

Incorrect pressure can result in damage to the machine. Make sure that the system pressure is set to 8 – 10 bar before

mounting the pneumatic system.

Fig. 53: Installing the maintenance unit pneumatic system

1. Attach the maintenance unit (3) to the upper cross bar (1) of

the frame using the bracket, screws and clip.

2. Plug the hose (4) coming out of the machine upper section

securely into the upper right of the maintenance unit (3).

3. Connect the system supply hose (2) to the pneumatic system.

Operating manual 969 - 00.0 - 08/2014 97

Installation

(1) - Adjustment knob (2) - Pressure gage

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7.8.2 Setting operating pressure

Correct setting

The operating pressure of the pneumatic system is 6 bar.

ATTENTION Machine damage possible due to incorrect pressu r e.

Incorrect pressure can result in damage to the machine. Make sure the operating pressure is set correctly before

starting the machine.

Fig. 54: Setting operating pressure

1. Pull the adjustment knob (1) up.

2. Set the operating pressure so the pressure indicator (2) shows

3. Push the adjustment knob (1) down.

98 Operating manual 969 - 00.0 - 08/2014

6bar:

• To increase pressure: Turn the adjustment knob (1) clockwise.

• To reduce pressure: Turn the adjustment knob (1) counterclockwise.

DURKOPP ADLER 969 ECO, 969 Classic Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual