DURKOPP ADLER 969 ECO, 969 Classic Operating Manual

969 ECO / CLASSIC
Operating manual
All rights reserved. Property of Dürkopp Adler AG and protected by copyright.
Copyright © Dürkopp Adler AG – 2014
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
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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
1.
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.
4 Operating manual 969 - 00.0 - 08/2014
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
10 Operating manual 969 - 00.0 - 08/2014
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.
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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
⑧ ⑨
⑩ ⑪
(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
(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
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
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
(1) - Thread guide (2) - Hole in the pre- tensioner (3) - Hole in the tube
(4) - Nut (5) - Bobbin (6) - Tube
10-15 mm
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
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
① ②
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
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
10-15 mm
(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
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).
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