550-767 Gestalteter Arbeitsplatz für Seitenairbag - Sollreißnaht Engineered work station for side airbag tearing seam Bedienanleitung / Operating instructions Aufstellanleitung / Installation instructions Postfach 17 03 51, D-33703 Bielefeld Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 5 21/ 9 25-00 Telefax +49 (0) 5 21/ 9 25 24 35 www.duerkopp-adler.com Ausgabe / Edition: 10/2007 Änderungsindex Rev. index: 01.0 Printed in Federal Republic of Germany Sprache: D/ GB Teile-Nr./Part.-No.
Übersicht Summary Bedienanleitung Aufstellanleitung Operating Instructions Installation Instructions Serviceanleitung (0791 767651) Service Instructions (0791 767651) Bauschaltplan Interconnection-diagram 9890 550004 B 9890 550004 B Alle Rechte vorbehalten. Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG verboten. All rights reserved.
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.
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. Before putting into service also read the safety rules and instructions of the motor supplier. 3. The machine must be used only for the purpose intended. Use of the machine without the safety devices is not permitted.
Contents Page: Preface and general safety instructions Part 1: Operating Instructions, Class 550-767 (Edition: 10.2007) 1. Items delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2- Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3. 3.1 3.2 Equipment Basic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional equipment . . . .
1. Product description The DÜRKOPP ADLER class 550-767 is an engineered sewing station with the following features: · flat-bed double-lockstitch sewing machine with underfeed, needle feed and alternating-foot overfeed. · · single-needle machine with thread cutter under the throat plate. · · maximum clearance of 16 mm under the sewing feet when raised.
3. Equipment 3.1 Basic equipment The class 550—767 sewing unit is supplied with the following basic equipment: RAP 13-2 Electro-pneumatic bar tack and sewing-foot lift, foot-operated. HP 13-10 Electro-pneumatic rapid stroke adjustment by knee switch (switch and touch operation) to maximum stroke height with simultaneous stitch-rate limit. Automatic infinitely-variable stitch-rate limit as a function of the stroke height set.
4. Technical data Stitch type: Number of needles: Needle system: 1 Needle size : 1 Thread thicknesses - Cotton: - Synthetic sewing thread: - Covering thread: Bobbin capacity with synthetic sewing thread 301 / double lockstitch 1 134-35 110-170 Nm 12/3 NeB 11/3 Nm? 11/3 Nm - 30/3 - 11/3 max. 35 m max.
5. Operation 5.1 Threading the needle thread CAUTION: DANGER OF INJURY! Turn off the main switch! The needle thread may only be threaded with the machine turned off. 2 1 Versions with switch 2: Before placing the needle-thread cones on the stand they must be scanned by the manual scanner. If a needle-thread bobbin is removed, this is recognised by the control via switch 2 and the scanning process is to be repeated.
7 8 1 9 2 10 3 4 11 5 6 1 – – – – – – Pass the thread through guide 7 and anti-clockwise around prethread-tensioning spring-tensioner 8. Pass the thread through guide 7 again. Pass the thread around guide 10 and then anti-clockwise around the main tensioner 9. Pass the thread clockwise around main tensioner 11. Pass the thread clockwise around the thread tensioning unit 4, past the check spring 3 and through the guide 2. Pass the thread through take up lever 1 and through guides 2, 5 and 6.
5.2 Adjusting the needle thread tension 1 2 3 The tension must be set according to the requirements of the manufacturer of seat-covers. The cross-over point should be in the centre of the material. – Adjust the pre-tension 1. The pre-tensioning should be set lower than at the main tensioners 2 and 3. – Adjust the main tension 2 and 3. – Adjust the tolerance range 4 (window) for seam monitoring via the Touch Screen Monitor. – 0 = monitoring deactivated.
5.3 Opening the needle-thread tension The needle-thread tension is automatically opened when the thread is cut. – Press button 2 manually or press down the upper right-hand corner of cover 1. The needle-thread tension remains opened for as long as the button or cover is held down.
5.4 Winding on the hoo thread CAUTION: Only special bobbins suitable for this type of machine may be used! The matt side of the bobbin 3 4 5 2 1 6 – – – – – Place the needle-thread cone onto the thread stand. Pass the needle thread through the thread guide on the take-up arm and through pre-tensions 1 and 2 as shown in the illustration.
5.5 Threading the bobbin thread 2 1 7 6 5 4 3 1 CAUTION: danger of injury! Turn off the main switch! The bobbin thread may only be threaded when the sewing machine is switched off. – – – – – – Raise flap 1 and remove the empty bobbin using a magnet. Insert bobbin 2 so that it turns anti-clockwise when the thread is drawn off. Pass the thread through slit 4 and pull beneath spring 5. Pass the thread through slit 6 and pull out approx. 3 cm of thread.
5.7 Replacing the needle CAUTION: danger of injury! Turn off the main switch! The needle may only be threaded and replaced when the sewing machine is switched off. 1 – – – – – Turn the handwheel until the needle bar has reached its top dead centre. Undo screw 1. Remove needle. Insert the new needle with its channel towards the hook and push it up as far as it will go. Tighten screw 1.
5.8 Lifting and locking the sewing feet The sewing feet can be raised mechanically or pneumatically. 2 3 1 Mechanical operation – Swivel lever 2 downwards. Pneumatic operation – Push pedal 3 half-way back (first position back). Once raised mechanically or pneumatically, the sewing feet can be secured in raised position using lever 2. – Swivel lever 2 downwards. The sewing feet are secured in the raised position. – Swivel lever 2 downwards. The sewing feet are released.
5.9 Adjusting the sewing-foot stroke 1 2 The stroke height 1 of the sewing-foot can be adjusted via the Touch Screen Monitor in the “seam types” menu in four steps (0, 1, 2, 3). The maximum stroke can be activated during sewing in free seam sections with the knee switch 2. This function is not available in documented seam sections. HINT! The sewing-foot stroke and stitch rate are interdependent.
HINT! The sewing-foot pressure can only be altered when knob 3 (clamping block) is released: see the Servicing instructions. 5.11 Adjusting the stitch length The stitch length is adjusted in the ”Seam types” menu on the Touch Screen Monitor. 5.
5.13 RFW 13–3 bobbin thread monitor The bobbin thread monitor monitors the quantity of thread on the bobbin. A signal is issued on the PC when only a small quantity of thread remains. The operator can finish the seam and fit a new bobbin, thus avoiding damage to the material and the need for repairs.
Hint If the empty bobbin is not replaced by a full one, the signal reappears on the monitor at the end of the next seam. – Wind on the bobbin thread. The process is described in this Operating manual. CAUTION: When winding-on ring 3 must be at the front. Only wind the thread around the bobbin core by hand in the area of reserve groove 2.
5.14 HP 13–10 electro-pneumatic rapid stroke adjustment 1 The sewing-foot stroke and stitch rate are interdependent. The control unit detects what foot-stroke has been set by means of a potentiometer and restricts the speed of rotation accordingly. The values are pre-set in the control unit. In free seam sections the maximum stroke can be activated while sewing with knee switch 1.
6. Operation of the rupture-seam visualisation facility The program is operated by touching the appropriate field on the Touch Screen Monitor 1. Access to the program is protected by three security levels (depending on the security level, not all the fields in the basic screen are available). 1 6.1 Access to the system 3 2 1 – – 4 The operator is identified by a magnetic bar code card 4.
Logging on without a bar code card – The operator can also log on manually as follows: – Press the “Access” field. – – – Press the “Access” field. Enter name and password. Logging off – To log off from the system, press the “Log off” field. Hint Users with security level “0” are automatically logged off after two minutes of inactivity.
Registering a new operator or a new bar code card Before a new operator can work on the sewing unit he must be registered with the system. The registering person must have at least security level 2. – Log on to the system. – Press the “Access” field. – Press the “Access” field. 1 – – – – – – – Enter the name of the new operator and state his security level. Enter a personnel number if appropriate. Enter password Confirm password. Wipe the bar code card through the magnetic card reader.
Deleting an operator In order to carry out this operation the user must have security level 2. – Log on to the system. – Press the “Access” field. – Press the “Delete” field. – – 6.1.1 Select the operator concerned. Press the “Delete operator” field. The operator’s details will be deleted. Advice for the production begin Check imperatively the system date (see Part 2, chapter 2.2.1). ATTENTION ! Never change neither the date nor the time when the machine is in operation.
6.2 Seam-type function – The “Seam types” field enables new seam types to be created and existing seam types to be edited or deleted. 1 6.2.1 Creating a new seam type – Press the “New seam type” field. A list of available seam types with their alteration status is displayed. – Enter a two-digit or three-digit seam-type code. Three-digit seam-types may be created with the software version 550-767A07 and later.
2 26 1 – Touch “Seam-type code” field 2. The following entry mask is displayed. – – – Enter the seam-type code. Press the “Return” button. Touch “Seam-type name” field 1. The following entry mask is displayed. – – Enter a seam-type name. Press the “Return” button. A list of available seam types with their alteration status is displayed.
– Press the “OK” field. The screen containing the seam sections box is displayed. 1 – – Select number of seam sections, e.g. 3. Press the “OK” field. The new seam type screen is displayed.
– Select the individual seam sections by clicking on them and enter the appropriate seam parameters. Monitored (red) Not monitored (green) Selected seam section – When the seam parameters for all seam sections have been set, press the “Save seam-types” field. Inserting a seam section – Select a seam section in front of which a new section is to be inserted. – Press the “Insert” field. The following screen is displayed. – 1 28 Press the “OK” field.
– – Click the new seam section field to select and enter the appropriate seam parameters. When the seam parameters have been set, press the “Save seam-types” field. Deleting a seam section 1 1 – – – Touch the seam section to be deleted. For example: Seam section 1. Press the “Delete” field. The following screen is displayed. Press the “OK” field. The new seam type screen is displayed.
6.2.2 Edit seam type – Press the “Edit seam type” field. A list of available seam types with their alteration status is displayed. – From the list of seam types select the one that is to be edited by clicking on the “Seam-type code” field. Press the “OK” field. The new seam type screen is displayed. – – – 30 Call the individual seam sections and make the necessary changes. Press the “Save” field.
6.2.3 Copy seam type – Press the “Copy seam type” field. A list of available seam types with their alteration status is displayed. – From the list of seam types select the one that is to be copied by clicking on the “Seam-type code” field. For example: Seam type 04. The following screen is displayed: – – – – – – 1 Touch the “Seam-type code” field. Enter the new seam-type code. For example: 05 Press the “Return” button. Touch the “Seam-type name” field and type the new name. Press the “OK” field.
6.2.4 Delete seam type – Press the “Delete seam types” field. A list of available seam types with their alteration status is displayed. – From the list of seam types select the one that is to be deleted by clicking on the “Seam-type code” field. For example: 05 for seam type 5. Press the “OK” field. A confirmation prompt is displayed. – – 32 Click “Yes” to confirm the prompt. The seam type 05 will be deleted.
6.3 Database function Completed seams are recorded and the data filed in a database. The “database” field enables these recorded files to be displayed, printed and copied. 1 1 – The required files are selected using the fields 1. “File” field A record file is filed every day. It is possible to retrieve and display these files via the “file” field – Press the “File” field. The following dialog box is displayed: – Select the required record file and click “Open”.
“Copy” field The selected day file is copied into a designated directory. “Help” field A list of error codes is displayed (see 6.6). “Thread tension” field File for displaying thread-tension values of each stitch of documented seam sections.
6.4 Check function Functions relating to preserving and restoring data, to information about sewing materials and to the testing, adjustment and setting-up of the integrated sewing unit are available through the “Check” field. 1 “Backup system” field When this function is activated all system-relevant settings are saved to diskette. “Restore system” field System-relevant data are read into the system from diskette. The required parameters can be pre-set.
“Print BC Label” field When this function is activated a barcode label is printed out by the label printer. “Backup record database” field When this function is activated all database records of the work-station are stored under the appropriate machine number. The data are transferred to the ZIP drive. “Load data” field Back-up files are loaded loaded from diskette. “Copy dump files” field When this function is activated all dump are saved to diskette.
“Setup” field When this function is activated system settings can be entered. “General settings” When this function is activated the language is selected, code numbers for manufacturers and sewing unit are attributed, relevant barcode digits determined and the employed EFKA software is selected. “Components” Here the used working materials or functions are activated or deactivated.
“Barcode” field Barcode definitions can be modified, saved or loaded via the “Barcode” field. Masks are placed to determine the relevant barcode digits. 1 Changing a barcode definition – Touch the corresponding barcode line 1. The following entry mask is displayed. 38 – – Type the barcode definition. Press the “OK” field". The new definition is accepted. – Press the “Save” field.
“Label” field The layout of the end label can be defined via the “Layout” field. Which barcode information is to be printed is determined here. Additional information to be printed on the end label can be defined via the “Define additional label information” field. 3 1 2 1 1 Setting the end-label barcode type See section 6.7. 2 Setting the end-label layout See section 6.8.
“Yarns” field When this function is activated a database containing the yarns designated for use with the system is displayed. New yarns can be entered, and existing yarns edited or deleted. HINT When a new yarn is entered its identity no. must be entered. This number, which consists of predetermined digits of the thread barcode, enables the system to recognise the yarn. Registering new yarn – Touch the “New yarn” field. The ‘yarn database editor’ opens. – Type the yarn barcode.
– Touch the “Scan” field. The following screen is displayed: – – Scan-in the yarn barcode using the hand-held scanner. Press the “OK” field". The new yarn barcode is accepted. Enter further yarn data and press the “OK” field to confirm entries. – “Change yarn” field The selected yarn can be changed once this function has been activated. “Delete yarn” field The selected yarn can be deleted once this function has been activated.
“Print DB” field When this function is activated the seam database is printed out (only if a printer is connected and activated in the setup). “Display DB” field When this function is activated the seam database is opened and all seam parameters are displayed. “Bobbins” field All registered bobbins are displayed when this function is activated. Selected bobbins can be deleted using the “Delete” field.
“SM-Kali” and “ELTEX-Kali” fields If the component “Calibration check” is activated in the set-up, the user will be asked at certain times to check and possibly calibrate the settings for the step motor and the ELTEX-thread-tension measuring device. Both activities will be recorded in the ELTEX and the step-motor calibration database. See section 6.5: Needle-thread tension tolerance range. “SM” field After activating the function, the adjustment of the stitch length can be calibrated and verified.
– – – – – – Press the “Ref.” field. The step motor will move to an average stitch length. Press “Enter 100 stitches+length” field. The following window is displayed. Sew test seam. 100 stitches will be sewn. Measure stretch. Enter the value for the measured stretch, then press the field “8" to confirm. Press the “Save” field. Calibration will be terminated. Calibration of the step motor is carried out on thin paper.
“E/A” field When this function is activated system inputs and outputs can be tested. “Scanner” field When this function is activated the barcode-scanner can be tested.
“EFKA” field This function allows all of the functions of the EFKA d.c. motor to be checked. The settings made, e.g. initial lock-stitches, final lock-stitches, speed, stitch length, etc., will be transmitted to the control unit by pressing the “Transmit” key and one seam will be released. HINT Entries can only be made via an external operating panel of the type V810 or V820.
Uninterruptible power supply function The emergency power supply enables the integrated sewing unit to continue in operation for up to 30 minutes even in the event of a power failure. – If the mains supply fails, a warning message is displayed on the monitor. – Once this message has been acknowledged, an indication of how long operation can continue with the buffered energy is displayed. 1 – Shortly before the buffered energy runs out the operator is prompted to shutdown the PC.
6.5 Needle-thread tension tolerance range In monitored seam ranges, the needle-thread tension values are compared during operations with a pre-set tolerance range. If these values deviate from the tolerance range more often than they should, the seam is designated as a bad seam. Adjusting the thread tension to within the tolerance range The needle-thread tension value is affected by many factors such as sewing speed, material, sewing yarn, seam range etc.
– Carry out another test seam. On completion of the seam, the fields 1 must still be displayed in green, otherwise the entries must be adjusted once more. 1 1 HINT It is recommended that the ELTEX device be recalibrated regularly once a year by the manufacturer. Eltex of Sweden AB Box 608 SE-343 24 ELMHULT Sweden Telephone: +46 (0) 476-488 00 Fax: +46 (0) 476-134 00 E-mail: Info-fax: +46 (0) 476-134 00 E-mail: info@Telefax: +46 (0) 476-134 00 E-mail: info@eltex.se Internet: www.eltex.
6.
6.7 Setting the end-label barcodes The operator must have security level 2 in order to carry out changes in the barcode labelling system. – – – – Log on to the system. Activate “Check” function Activate “Setup” function Activate “Label” function 1 1 The structure of the end-label barcode is displayed in field 1. ?The significance of the predefined codes is as follows: D2 current day (two-digit); e.g.: 9. 9 June = 09 M2 current month (two-digit); e.g.: 9.
N5 daily number of pieces (five-digit); e.g.: 12345 = 12345 N6 daily number of pieces (six-digit); e.g.: 123456 = 123456 CP the number of digits and the coding are defined by the mask specified under “Prim. barcode mask label”. 1 = digit is accepted; 0 = digit is ignored. TU the number of digits and the coding are defined by the mask specified under “Needle-thread mask label”. 1 = digit is accepted; 0 = digit is ignored.
Extended label printing (EXTLabel.txt) This option allows the information compiled on the list to be printed additionally on the end label. The desired information is placed on the end label by means of a defined programme line. When the extended label-print is activated, the information will always be printed on the specified places, independent of the loaded barcode set-up file.
6.8 Setting the end-label layout The operator must have security level 2 in order to carry out changes in the barcode labelling system. – – – – Log on to the system. Activate “Check” function Activate “Setup” function Activate “Label” function 1 1 2 3 4 – – – – – – – – – 54 Enter the required height of the label in the “Label length” field. e.g.: 25 mm Enter the gap between labels in the “Gap” field. e.g.: 3 mm Enter the required label texts in fields 1, e.g.
1 6.9 Adjusting barcode definitions The operator must have security level 2 in order to carry out changes in the barcode labelling system. – – – – – – – – Log on to the system. Activate “Check” function Activate “Setup” function Activate the “Extended” function. Select the required type in the “Primary barcode type” field. This barcode is read into the system by the manual scanner. Select the required type in the “Thread-barcode type” field. The selection applies to both the upper and hook threads.
E.g.: · Primary barcode: (scanned in by manual scanner) 11112233001234567890 · Primary-barcode identifier in the “Primary- barcode identifier A” field (material and colour barcode): 11110000000000000000 · ID number: 1111 If only pieces with the ID number “1111" are to be processed, this number can be entered in the ”Identifier A set value" field. If pieces with various different ID numbers are to be processed, the “Identifier A set value” field must remain blank.
The ID number is used to retrieve the parameters from the database (here: stitch type with ID number 33). HINT From the software version 550-767A07 onwards, 3-digit seam displays can be generated. It should be remembered that with identifier C three digits have to be occupied and that the 2-digit seam displays are no longer available. Three-digit seam displays shall be provided with a seam-display identification between 100 and 999 (identifications between 001 and 099 are not permitted). – The “Prim.
11112233001234567890 11112333001234567890 “Primary barcode mask L/R” field: 00000000110000000000 00000000110000000000 ID number: 00 00 The ID numbers are the same = OK A right-hand seat is sewn. The text for a right-hand seat is printed on the end label. 58 – Via the “Primary-barcode mask label” field, information from the initial barcode can be printed on the end label.
7. Sewing CAUTION: Sewing may only be carried out on a fully-assembled sewing ?unit with all protective devices fitted! 1 2 1 4 3 Switching on the sewing unit – Press button 3 (lamp 4 flashes ) – = Wait until lamp 4 lights up. – Turn on main switches 1 and 2. Windows is loaded and the program “Soll.exe” activated. The sewing unit is tested and initialised. – Scan in the needle-thread cone if appropriate. – Scan in the hook-thread cone if appropriate.
– Enter the bobbin number (engraved on the bobbin). Logging onto the system – The operator logs on by wiping his bar code card through the magnetic-card reader. – The operator can also log on manually as follows: – Press the “Access” field. – Press the “Log on” field. – Enter name and password. Sewing can only begin if the system start and scanning of the needle-thread cone, hook-thread cone and bobbin were faultless.
Sewing – Press the “Sewing” field. – Scan in the pieces to be sewn. Up to nine (9) more barcodes can be defined in advance. All previously defined barcodes must be read in. – – – – The seam ranges can be sewn. Odd-numbered seam ranges are unmonitored, the diode on the stop lights up green. In the even-numbered (monitored) seam ranges the diode lights up red. If an error occurs in a monitored seam section an error message is displayed. Sewing is blocked to operators with security level 0.
7.1 Label scanner (optional) A label scanner 1 can be fitted to the head of the sewing unit as an optional extra. 1 – – – 62 At the end of the seam the scanner checks whether the correct barcode label has been sewn on. If the label is not recognised a reminder appears, followed by this warning: Users with security level 1 or 2 can scan-in the label manually after the seam end or print out a new label.
8. Maintenance CAUTION: DANGER OF INJURY! Turn off the main switch. Maintenance of the sewing unit may only be undertaken with the machine turned off! 8.1 Cleaning HINT A clean sewing unit is a trouble-free sewing unit! – – Clean the hook area, thread cutter, needle plate, feeder and sewing head every day to remove fluff, fragments of yarn and other cutting waste! Clean the oil collector daily! 1 2 1 3 Check the water level in the pressure regulator every day.
8.2 Oiling CAUTION: DANGER OF INJURY! Oil can cause skin eruptions. Avoid protracted contact with the skin. In the event of contact, thoroughly wash the affected area! CAUTION: The handling and disposal of mineral oils is subject to legal regulation.
