DURKOPP ADLER 911 Operating & Installation Instructions Manual
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DURKOPP ADLER 911 Operating & Installation Instructions Manual

DURKOPP ADLER 911 Operating & Installation Instructions Manual

Cnc-comtrolled sewing unit with large sewing area
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CNC-controlled sewing unit with large
Postfach 17 03 51, D-33703 Bielefeld Ÿ Potsdamer Straße 190, D-33719 Bielefeld
Telefon +49 (0) 5 21/ 59 25-00 Ÿ Telefax +49 (0) 5 21/ 9 25 24 35 Ÿ www.duerkopp-adler.com
Ausgabe / Edition:
Änderungsindex
08/2010
Rev. index: 00.0
Operating Instructions
Installation Instructions
Service Instructions
Printed in Federal Republic of Germany
911
sewing area
Teile-Nr./Part.-No.:
0791 911001
1
2
3

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Summary of Contents for DURKOPP ADLER 911

  • Page 1 CNC-controlled sewing unit with large sewing area Operating Instructions Installation Instructions Service Instructions Postfach 17 03 51, D-33703 Bielefeld Ÿ Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 5 21/ 59 25-00 Ÿ Telefax +49 (0) 5 21/ 9 25 24 35 Ÿ www.duerkopp-adler.com Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:...
  • Page 2 All rights reserved. Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner, even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited. Dürkopp Adler AG - 2010 Copyright ©...
  • Page 3 Foreword This instruction manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations. The instruction manual contains important information on how to operate the machine securely, properly and economically. Observation of the instructions eliminates danger, reduces costs for repair and down-times, and increases the reliability and life of the machine.
  • Page 4 General safety instructions The non-observance of the following safety instructions can cause bodily injuries or damages to the machine. 1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate training. 2.

  • Page 5: Table Of Contents

    Page: Preface and General Safety Instructions Part 1: Operating Instructions Cl. 911 - Original Instructions (Edition 08/2010) Product Description ..........3 Designated Use .
  • Page 6 Contents Page: Error messages/Information messages Error messages ..........59 Information messages .

  • Page 7: Product Description

    Product Description CNC-controlled sewing unit based on the class 867 with large sewing area (sewing field size 300 x 200 mm) and a DAC III control unit with special software. For technical textiles manufacturers, motor vehicle equipment manufacturers, seat manufacturers (automotive), bag, case and backpack manufacturers (leather/textile), shoe manufacturers.
  • Page 8 With electronic needle thread monitor. In order to generate a clean seam pattern, the sewing unit is equipped with a multiple thread tension device, permitting to assign to various thread pulling directions the according tension value previously saved in the sewing program. The thread pulling device allows pulling the needle thread under the sewing material during the first stitch.

  • Page 9: Designated Use

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

  • Page 10: Optional Equipment

    Optional Equipment For the sewing unit 911 the following optional equipment is available: Optional equipment Order-No. Remark Reception P.-Clamp 0911 457554 Kit for the reception of the parallel clamp actuation Bow f. P.- Clamp 0911 457604 Bow holding fixture for the clamping plate P.-set of clamps HF...

  • Page 11: Technical Data

    Technical Data Type of stitch Hook type Vertical hook Needle system 134/35 Needle size [Nm] 80 until 180 Number of needles Stitch length (programmable) [mm] depending on the seam pattern up to 12.7 max. speed [min max. 3000 1/min Clamp stroke [mm] Foot lifting [mm]...

  • Page 12: Operation

    Operation 6.1 Switching on - Switching off - Safe stop - Quick stop 6.1.1 Switching on – Turn on the main switch 1. The following request occurs on the display: “Push Pedal backwards for referencing” – Step the pedal backwards to start the reference run of the sewing unit.
  • Page 13 6.1.3 Safe Stop Caution: Risk of injury! The sewing unit has to be switched off or switched to “safe stop” before carrying out any work on it. Only work in the hook area with “safe stop” activated when it is illuminated.

  • Page 15: Raising The Machine Head

    6.2 Raising the machine head The sewing head can be raised for maintenance work. The carriage drive 2 must stand at the rear. Caution: Risk of injury! Turn the main switch off! Maintenance may only be carried out with the sewing unit switched off! Raising the sewing head –...

  • Page 16: Changing The Needle

    6.3 Changing the needle Caution: Risk of injury! Turn the main switch off! The needle may only be changed with the sewing unit switched off. – Turn the machine with crank 4 until the needle bar 1 reaches its highest position. –...

  • Page 17: Threading The Needle Thread

    6.4 Threading the needle thread Caution: Risk of injury! Turn off the main switch! The needle thread may only be threaded with the sewing unit switched off. – Put the thread reel on the thread stand and lead the needle thread through the unwinder arm.

  • Page 18: Adjusting The Thread Regulator

    6.5 Adjusting the thread regulator Caution: Risk of injury! Turn off the main switch. The thread regulator may only be adjusted with the sewing unit switched off. The thread regulator 2 controls the quantity of needle thread required for stitch formation. The thread regulator must be precisely adjusted for an optimum sewing result.

  • Page 19: Winding On The Hook Thread

    6.6 Winding on the hook thread The separate bobbin winder makes it possible to wind the hook thread independently from the sewing operation. – Remove remaining thread from the bobbin hubs before winding. – Put the thread reel on the thread stand. –...

  • Page 20: Changing The Hook-Thread Bobbin

    6.7 Changing the hook-thread bobbin Caution: Risk of injury! The hook-thread bobbin may only be changed with the sewing unit in “safe stop” mode. – Remove the material holder 2 (only with change-over frame). – Press the key 1 “safe stop”. The drive carriage rides to the “bobbin change position”.

  • Page 21: Setting The Hook Thread Tension

    6.8 Setting the hook thread tension Caution: Risk of injury! Turn off the main switch. The hook-thread tension may only be adjusted with the sewing unit switched off. The necessary hook thread tension should be generated from the thread tension spring 2. Setting the tension spring –...

  • Page 22: The Control Panel

    Operating the control of the 911 7.1 The control panel The data entry is done through a touch screen monitor. USB connection USB-Stick order-no. 9805 791113 7.2 Operating the touch screen panel Activate a function by touching (with a fingertip) the symbol representing the function in question on the screen.
  • Page 23 7.2.3 Selection window On this screen, the following actions can be executed: – If the button is bright it cannot be activated. – A field, in this case the sewing program, has been selected and can be edited or appended. 7.2.4 Numeric input for a parameter The title bar indicates the parameter group.
  • Page 24 7.2.5 Numeric input for a parameter – Enter the password. 25483 – Touch the button “OK”. It will be switched over to the technician level. 7.2.6 Input of a text “ESC” Close the window “Aa” Switching from capitals to small letters “DEL”...
  • Page 25 7.2.7 Radio- button With the Radio-button the selected option is marked with a black dot. 7.2.8 “Scroll bar” Move the scroll bar 2 downwards. The lower part of the screen will be displayed.

  • Page 26: The Start Screen

    7.2.9 Check- button With the Check-button the selected option is marked with a black x. 7.3 The start screen The start screen appears after switching the sewing unit on. – Press the “Service” button in order to switch to the multitest program.

  • Page 27: The Main Screen

    7.4 The main screen Title bar Sequence name: Number of sewing programs in the sequence Time: Hour: Minute Repair mode Seam pattern size Max. sewing speed Max. thread tension Stitch length Number of stitches / Bobbin thread consumption Button bobbin change Button counter reset Slider, Tabs, Buttons for sequence control.

  • Page 28: Pop Up Menu Structure

    7.5. Pop up menu structure · File ¡ Delete ¡ Copy ¡ Open ¡ New · Seam program · Sequence ¡ Save as · Edit ¡ Machine parameters ¡ Sequence ¡ Seam program · Parameters · Contour adjustment · Testing contour ·...

  • Page 29: Menu Item "File

    7.6 Menu item “File” It is possible to sew a single sewing program several times consequently or to sew several different sewing programs one after the other in a sequence. 7.6.1 Create a new sewing program See chapter Teach-in 7.6.2 Creating a new sequence In this menu item it is possible to occupy the individual memory locations with sewing programs.
  • Page 30 – Tip onto the button “Set name”. – Enter the name. – Press the “Enter” button. – Press the “OK” button. The sequence will be memorized.
  • Page 31 7.6.3 Opening a sewing program or a sequence Via this menu item, sewing programs or sequences can be opened from the DAC and then be sewn. After opening the main screen will be updated accordingly. – Click File -> Open The following screen will appear: –...
  • Page 32 7.6.4 Copying a sewing program, a sequence or machine parameters Via this menu item it is possible to copy sewing programs, sequences or machine parameters onto the DAC control or onto a USB-Stick. And a file filter can also be selected here. Click File ->...

  • Page 33: Menu Item "Edit

    7.7 Menu item “Edit” 7.7.1 Editing a sewing program A sewing program consists of a contour and sewing parameters. The contour (shape of seam) is created via Teach-in or with the help of the DA-CAD 5000. The program parameters are divided into different groups and are modified as follows: –...
  • Page 34 Laser marking lamps Up to four laser marking lamps can be triggered in order to facilitate the aligning of the material (The optional equipment has to be activated) Needle reverse turn mode The following modes can be set: Not active The needle remains in the stopping position.
  • Page 35 Mode 5 The clamp remains closed in the feeding position. After actuating the pedal one more time the seam will be started. Feeding position (on/off) With the feeding position activated the clamp goes to the requested position in order to facilitate the feeding of the material.
  • Page 36 PP4 - Soft start Number of soft start stitches (min. = 0.. max. = 10; def. 5) Soft start speed (min. = 100 .. max. 2000; def. 300 U/min) PP5 - Sensitivity of the needle thread monitor (min.=0..max.= 99: def. 5) Is only active when enabled with the machine parameters.
  • Page 37 Center point of scaling in X direction (min. = -150.0… max. = 150.0; def. = 0.0 mm) Center point of scaling in Y direction (min. = -150.0… max. = 150.0; def. = 0.0 mm)
  • Page 38 7.7.2 Contour adaptation Via this menu item smaller changes of the contour can be adjusted directly at the sewing unit. Individual stitches can be shifted and technological operations can be adjusted. Click Edit -> Seam program -> Contour adjustment The following screen will appear: –...
  • Page 39 7.7.3 Contour test Via the menu item a contour can be checked. Click Edit -> Seam program -> Testing contour The following screen will appear: – Run along the contour with the “Reverse” (backwards) or “Forwards” (forwards) keys and check it.
  • Page 40 7.7.4 Edit the machine parameters Via the machine parameters the basic machine settings and some of the parameters for all programs are defined. – Click Edit -> Machine parameters. MP1 - Configuration Needle cooling The following modes can be set: without The needle cooler is not activated.
  • Page 41 Optional equipment Reduced clamp pressure Optional equipment that facilitates the alignment by exercising a reduced clamp pressure at the feeding moment. Laser marking lamp Optional equipment that facilitates the alignment at feeding by providing orientation lines. Here this option is only enabled and then with each program up to four laser marking lamps can be activated.
  • Page 42 MP2 - Limit values Set max. sewing speed (min. = 500 .. max. 3000; def. 3000 U/min) Limitation of all sewing programs to this speed. Set max. run empty speed (min. = 10 .. max. 100; def. 100%) Limitation of all clamp movements between seam to this value.
  • Page 43 Set return path after thread breakage (min. = 0 .. max. 20; def. 5 stitches) Number of stitches of the reverse drive effectuated after detection of thread breakage. Position of bobbin change X (min. = -300… max. = 300; def. = 230 mm) Position of bobbin change Y (min.
  • Page 44 MP6 - Counter Counter type The following possibilities available: Increment counter (def.) After each sewn program the counter will step up. Decrement counter After each sewn program the counter will step down. Increment sequence counter After each sewn sequence the counter will step up. Decrement sequence counter After each sewn sequence the counter will step down.

  • Page 45: Menu Item "Extras

    7.8 Menu item “Extras” 7.8.1 Service – Click Extras -> Service -> Adjustments – Enter the password The following screen will appear. Language – Press the requested language. – Press the “OK” button. The selected language will be adopted. Date and time –...
  • Page 46 Full screen on / off Full screen off Full screen on 7.8.3 Zoom on / off Zoom off Zoom on...
  • Page 47 7.8.2 System information – Click Extras -> Service -> System information The following screen will appear. Control unit events A list with the errors that occurred lately will appear. Log configuration This function is reserved for the Dürkopp-Adler service personnel. Log visualizer A list with the last log settings will appear.
  • Page 48 7.8.3 Multitest – Click Extras -> Service -> Multi-test . The following screen will appear. Switching input/output elements Test the input elements With this test function the functioning of the input elements will be tested. Caution: Risk of injury! Do not reach into the running machine during the function test of the input elements.
  • Page 49 Test the output elements With this test function the functioning of the output elements will be tested. Caution: Risk of injury! Do not reach into the running machine during the function test of the output elements. – Press the button “output elements”. –...
  • Page 50 Test sewing motor With this program the sewing motor is tested. CAUTION ! Pull out the threads from needles and thread lever. – Enter the sewing speed. (300 … 2000 U/min) – Enter the trimming speed. (70 .. 500 U/min) –...
  • Page 51 Feed clamp This function is reserved for the Dürkopp-Adler service personnel. Set stroke position Perform a reference run Switching between jumping and presser foot Set the drives currentless Go to a position...
  • Page 52 7.8.5 Initialization and Update – Click Extras -> Service -> Initialization and Update. – Enter the password The following screen will appear. Control unit initialization ATTENTION! All entries will be set back to factory setting. Operation panel initialization ATTENTION! All entries will be set back to factory setting. Update of the control unit 7.8.6 Manufacturer...

  • Page 53: Menu Item "Correction

    7.9 Menu item “Correction” Upon changing this parameter all seams that are sewn subsequently will be adjusted. With values below 100% all the thread tensions and sewing speeds will be reduced. With values above 100% all the thread tensions and sewing speeds will be increased. These adjustments are only scheduled for a short “trial period”...

  • Page 54: Menu Item

    7.10 Menu item “?” 7.10.1 Info This screen indicates the current software version. – Click ? -> Info. The following screen will appear.

  • Page 55: Teach-In

    7.11 Teach-in With the sewing unit 911 it is possible to create freely defined seam contours and to memorize them in the control unit. The contour data are entered at the control panel. Line not sewing Via this menu item a line can be created that will not be sewn.
  • Page 56 Thread tension value Lift stroke ( min. = 1 mm, max. = 10 mm) Thread trimming Delete Via this menu item the line/circular arc entered last can be deleted. Memo… Via this menu item the newly created seam contour is memorized. ñ...
  • Page 57 7.11.1 Creating a new seam contour Step 1 In the first step the starting point of the seam segment is determined. – Go to the desired starting point by using the arrow keys “ñ ” , “ò ” , “ñ ” or “ò ”. –...
  • Page 58 Step 2 In the second step it will be determined whether: · a non sewing line · a line or a circular arc will be sewn. – Select the desired button for the next entry. – Select the “Line sewing” or “circular arc” button. The menu for the seam parameters will pop up.

  • Page 59: Repair Mode

    7.12 Repair mode Via this button the repair mode can be called up. That way a faulty seam contour, for example after a thread breakage can be resewn from a certain point. – Switch on the repair mode. – Go to the point from where the sewing shall continue with the two buttons “Forwards”...

  • Page 60: Thread Breakage

    7.13 Thread breakage After a thread breakage the thread can be threaded in again and the sewing of the seam contour can be continued from any point. – Press the “Bobbin change” button. The work clamp will go to the bobbin change position. –...

  • Page 61: Da-Cad 5000

    DA-CAD 5000 With the program DA-CAD 5000 that is optionally available, sewing programs can be created with an ordinary PC. For the exact description please read the “Instruction manual DA-CAD 5000". Selecting the machine class In the first step the machine class is selected. Creating the seam contour In the second step the seam contour is drawn.
  • Page 62 Memorizing the seam contour In the last step the finished seam program is copied onto a USB-stick. In order to do so select the following menu item: Data transmission -> USB-Memory stick -> Memorize (PC->USB)" After successful memorizing on the USB-stick the following steps have to be effectuated on the machine: - Plug in the USB-stick and copy the desired data file onto the DAC.

  • Page 63: Error Messages/Information Messages

    Error messages/Information messages 9.1 Error messages Error code Description Remedy Sewing motor 1051 Sewing motor timeout Faulty cable to the sewing motor reference - Replace the cable switch Replace the reference switch Faulty reference switch - Check whether machine head is - Machine head rough-running or belt tension too rough-running high...
  • Page 64 Error code Description Remedy 2156 Stepping motor X-axis overheat Stepping motor seized up - Eliminate seizing Faulty stepping motor - Replace stepping motor Control faulty - Replace the control 2201 Stepping motor Y-axis time out referencing Setting reference switch faulty - Align the reference switch Faulty cable to the reference switch - Replace the cable...
  • Page 65 Error code Description Remedy 3107 Machine temperature Vent holes closed - Check the vent holes Ventilation grid soiled - Clean the ventilation grid 3109 Safe stop is switched on Switch off the safe stop 3121 Insufficient or missing compressed air Increase the flow or stabilize the compressed air 3123...
  • Page 66 Error code Description Remedy 8252 Error booting ADSP/ Booting Xilinx/ Booting - Switch the machine off and on 8257 Fault again 8258 8256 8254 8351 Error testpins - Switch the machine off and on again - Software update - Inform the DA-Service 9601 Stop during sewing on the contour OK-key = Continue sewing...

  • Page 67: Information Messages

    9.2 Information messages Info Description Remedy 8400 The control panel has no valid program for the DAC Load the current program onto the control panel with a USB-stick 8401 The control panel has no valid program for the DAC Load the current program onto the 8402 control panel with a USB-stick 8403...

  • Page 68: Maintenance

    10. Maintenance 10.1 Cleaning and Checking Caution: Risk of injury! Turn the main switch off! The maintenance may only be carried out with the sewing unit switched off! Maintenance work must be carried out no less frequently than at the intervals given in the tables (see “operating hours”...

  • Page 69: Oil Lubrication

    10.2. Oil lubrication Caution: Risk of injury! Oil can cause skin rashes. Avoid longer skin contact. After contact wash yourself thoroughly. ATTENTION! The handling and disposal of mineral oils is subject to legal regulations. Deliver used oil to an authorized collecting station. Protect your environment.
  • Page 70 Notes:...

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