806N Operating Manual
Operating manual 806N Version 00.
Table of contents Table of contents 1 About this operating manual ......................................................5 1.1 Scope of application of the operating manual ..........................5 1.2 For whom is this operating manual?.........................................5 1.3 Representational conventions – Symbols and characters........5 1.4 Other documents ......................................................................6 1.5 Liability..................................................
Table of contents 5.5 Sewing in two-pocket mode....................................................58 5.6 Setting options in User interface 1..........................................61 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 Resetting piece counter ..........................................................61 Setting the bobbin counter......................................................62 Enabling bundle removal ........................................................
Table of contents 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 Setting up ...............................................................................97 Installing the thread reel holder ..............................................98 Electrical connection...............................................................99 Pneumatic connection ............................................................99 Topping up the oil .................................................................100 6.6 Commissioning ........
Table of contents 4 Operating manual 806N Version 00.
About this operating manual 1 About this operating manual The operating manual for the 806N sewing unit was compiled with the utmost care. It contains information and notes in order to make long-term and reliable operation possible. Should you notice any discrepancies or if you have improvement requests, then we would be glad to receive your feedback, Section 5.11.3 Customer service. Please regard the operating manual as part of the product and keep it in a safe place where it can be easily accessed.
About this operating manual Symbol/character The result will be a correct seam. Highlighting Meaning After you have performed the step, the result is written in italics. Designations of surfaces, selection windows, or buttons used in the software and keys on the machine are highlighted in bold type. References to further information in this operating manual or other documents are identified by this symbol.
About this operating manual • The deployment of untrained personnel • Using spare parts not approved 1.5.1 Transportation Dürkopp Adler cannot be held liable for any damage during transport. Check the delivered product immediately after receiving it. Report any damage to the last transport manager. This also applies if the packaging is not damaged. Keep the machines, devices and packaging material in the condition they were at the time when the damage was identified.
Performance description 2 Performance description The Dürkopp Adler 806N is a CNC-controlled sewing unit for automatically sewing pockets onto shirts, blouses, and similar material. It is a flatbed sewing machine for a double lockstitch. The material to be sewn is constantly moved by means of bottom feed. 2.
Performance description 2.3 Technical data Technical data Stitch type 301 (double lockstitch) Sewing head Horizontal hook / vertical hook 806N-121 270 Horizontal hook Needle stroke [mm] 38 Needle system 134 Needle size, according to sewing equipment [Nm] Number of stitches, max. Stitch length, programmable [mm] Thread size, according to sewing equipment; e. g. core spun thread 70 - 100 4,000 min-1 0.1 - 3.
Performance description 2.
Performance description Additional equipment Order number Parts set: Controlled 2-way needle thread tension For especially flexible stitches in the bar area Parts set: Pressure foot for underwear For critical materials The following conditions must be satisfied in order to use the pressure foot: – Transfer plate without inner slider – For double seams, a minimum clearance of 2.
Safety instructions 3 Safety instructions This section contains basic instructions for your safety. Read the instructions carefully before setting up or operating the machine. Make sure to follow the information included in the safety instructions. Failure to do this can result in serious injury and damage to the machine. 3.1 Basic safety instructions The machine may only be used as described in this operating manual. The operating manual must be available at the machine's location at all times.
Safety instructions Work on electrical equipment may only be carried out by qualified specialists. Only authorized persons may work on the machine. Every person who works on the machine must have read the operating manual first. Operation Inspect the machine while in use for any externally visible damage. Interrupt your work if you notice any changes to the machine. Report any changes to your supervisor. A damaged machine may not be used any more.
Safety instructions The following safety devices are mounted on the machine: Figure 14 Designation Purpose EMERGENCY STOP button The machine is immediately placed in the EMERGENCY STOP state: – The motors are braked and then disconnected from the power. – The cylinders are depressurized. – The sewing head moves to the upper position and is locked in place. Integrated EMERGENCY STOP The machine is immediately placed in the EMERGENCY STOP state: – The motors are disconnected from the power.
Safety instructions 3.2 Signal words and symbols used in warnings Warnings in the text are distinguished by color bars. The color scheme is oriented towards the severity of the danger. Signal words specify the severity of a danger: Signal words Signal words and the endangerment that they describe: Signal word DANGER Resulting in death or serious injury. WARNING Death or serious injury possible. CAUTION Moderate to minor injuries possible. ATTENTION Symbols Endangerment Damage possible.
Safety instructions WARNING Type and source of the danger Consequences in the event of noncompliance Measures for avoiding the danger This is what a warning looks like for a hazard that could result in serious injury or even death if not complied with. CAUTION Type and source of the danger Consequences in the event of noncompliance Measures for avoiding the danger This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is not complied with.
806N device description 4 806N device description The 806N sewing unit is system for automatically sewing on pockets. The correct operating principle involves a sequence of different steps and requires precise knowledge of all operating controls. 4.1 806N sewing unit The 806N sewing unit is illustrated in the figure below. The location of its individual components and its operating principle are described here.
806N device description Components of the 806N An illustration with a detailed description can be found for each component of the 806N further on. These illustrations cover the main terms and elements of the components required for work on the 806N. 4.1.1 Operating terminal You can use the operating software to set the sewing unit on the touch screen (1) of the operating terminal. You can import new pocket seam programs or other software via the USB port (2) or network interface in the housing.
806N device description 4.1.2 Edge folding station Place the fabric parts to be sewn on the edge folding station: The base part on the sewn material support (6) with integrated hose insert for the 806N-121 (4) and the pocket blank on the middle slide (3). The edge folding frame (2) is used to fold the (edge) of the pocket blanks. Furthermore, two manual keys (5, 7) and the foot switch (8) used to start the sewing cycle can be found here.
806N device description Detailed description of the key panel The individual elements of the key panel always have two components: The button and a label field. A description of the function can be found in the table below in addition to the illustration and designation of the keys. Key 20 Designation Function Stop key The stop key does not light up. If you press the stop key, the machine ends the current work step and comes to a safe stop. The activities described in Section 5.
806N device description Detailed description of the keys The manual keys and the foot switch are used to operate the machine. A description of the function can be found in the table below in addition to the illustration and designation of the keys.
806N device description 4.1.4 Stacker After sewing the fabric parts together, the machine stacks the product cleanly and tidily away. This is done by means of the outfeed roller (1), the clamp brackets (2, 4) and the support (3). You can select between two stacking variants, Section 5.7.4, Selecting/deselecting stacker variants. Figure 5: Overview of the stacker (1) - Outfeed roller (2) - Inner clamp bracket (3) - Support (4) - Outer clamp bracket 4.1.
806N device description 4.2 Software description The operating terminal is used to control the machine. You can operate the operating software on the touch screen of the operating terminal. The following is described below: • Structure of the operating software • Operating software functions 4.2.1 Structure of the operating software The operating software is set up on different user interfaces. The structure ranges from the start screen to the technician's user interface.
806N device description 4.2.2 Operating software functions The functions of the individual user interfaces are described in this section. The technician's user interface is not included, since a password is required for access. The technician's user interface is described in the Service manual for the 806N. Initial screen When you switch on the machine, Section 5.1, Switching on the machine, the Start screen appears.
806N device description Pocket mode selection window On the Start screen, you use the Reference machine button , to access this selection window after performing a successful reference run. You can select the pocket mode here – to specify whether only the right or left pocket is to be sewn or whether the right and left pocket are to be sewn alternately.
806N device description User interface 1 You go to this user interface by selecting the seam program. You can view here the seam shape and how the pocket is to be sewed on and make various settings.
806N device description Button Function Enable bundle removal, Section 5.6.3 Allows the finished sewn parts to be removed from the stacker. Automatically activate slide at front, Section 5.6.4 The middle slide immediately moves to the front position. It does not have to be brought to the front by manual key 1. Activate strip alignment, Section 5.6.5 After the edge folding process, the machine stops in order to check the alignment of the pocket blank. Initiate shape change, Section 5.6.
806N device description Setting options on user interface 2 The respective section of the operating manual, where you can find further information on the buttons, is also specified. Button Function Work step by step, Section 5.7.1 The machine advances only step by step, which is useful for sewing-in operations or a test run. Activate sewing without edge folding, Section 5.7.2 Useful for testing the sewing head settings. Switch on/off stroke position, Section 5.7.
806N device description Button Function Set sewing motor speed, Section 5.7.10 The speed of the sewing motor can be set between 100 and 4000 rpm. Exit selection window From the Start screen, you use the Exit button selection window.
806N device description 4.2.3 Operating software version The operating software version is important for the technicians. It must be easy to find when requested. User interface 1, Section 5.2.1 Making basic settings, specifies the designation of the machine, Section 4.2.2 Operating software functions.
Operating instructions 5 Operating instructions The 806N sewing unit is system for automatically sewing on pockets. The operating sequence on the 806N consists of several different steps. Faultfree operation is necessary in order to achieve a good sewing result. In the following, the steps are listed in chronological order. The structure of the section is oriented towards this sequence.
Operating instructions 5.1 Switching on the machine The machine is switched on through the compressed air shut-off valve and the main switch, which are both located centrally under the material support. This is how you switch on the machine: CAUTION Risk of crushing due to pneumatic parts. The use of compressed air produces strong forces on the moving parts. If your fingers or hands get in between the parts, this could result in minor to moderate injuries. NEVER reach into the area of moving parts. 1.
Operating instructions 2. Turn the main switch from the "O" position (1) to the right into the "I" position (2). Figure 16: Switching on the main switch (1) - Off (2) - On (3) - Rotary switch The controller for the machine starts up and clicks once. You hear the air being released onto the moving parts. The secure stop light lights up. The operation display starts up and the initial screen appears.
Operating instructions 5.2.1 Making the basic settings Without making the basic settings via the software, the prerequisite conditions for smooth operation cannot be created. When the machine is switched on, Section 5.1 Switching on the machine, the operation display also starts up. The operating program starts automatically and you will see the initial screen: Figure 17: Initial screen To be able to sew pockets on using the machine, you first have to select the pocket mode and the pocket seam program.
Operating instructions This is how you access menu 1: 1. At the bottom left of the initial screen, press the Reference machine button . The button changes and indicates that the machine is operating; the Start key is flashing in green. The machine scans the numeric code on the transfer plate in order to identify it. It then moves to the basic position. The selection window for the pocket mode appears on the touchscreen. Figure 18: Selecting the pocket mode 1-pocket mode 2-pocket mode 2.
Operating instructions Seam program cannot be selected If no pocket seam program can be selected in the selection window for the seam program, then this could be due to several reasons. Remedial action: • Clean the light sensor on the machine. In the event of contamination, the code cannot be read correctly. • Check the code on the rear side of the transfer plate. Are the reflector strips still complete and in good order? • Replace the transfer plate or the entire shaping assembly Section 5.2.
Operating instructions Figure 21: Menu 1 The Start key lights up green. 5.2.2 Inserting the thread reel The thread reel contains the thread for sewing. The thread reel can be used for winding thread onto the bobbin and is also used for threading the sewing thread into the machine - the needle thread. Figure 22: Alignment of the thread reel holder Fit the thread reel as follows: 1. Unpack the thread reel. 2. Fit the thread reel on the thread reel holder.
Operating instructions 3. Pull the thread to the machine through the thread reel holder thread guides. 4. Position the thread reel holder thread guide vertically above the thread reel. 5. Proceed as described in Section 5.2.4 Threading the needle thread.. 5.2.3 Checking the needle A needle is usually already fitted in the machine during the set-up procedure. Despite this, always check that the needle is correctly fitted and aligned to ensure correct sewing.
Operating instructions 5.2.4 Threading in the needle thread After a thread reel and needle have been fitted the needle thread can be threaded as illustrated on the sticker attached to the machine. Thread the needle thread as follows: WARNING Risk of being stabbed by moving machine parts. Serious injuries to any part of the body may occur if you come into contact with needle or other sharpedged and pointed objects. ONLY work on the machine if the secure stop light is lit up.
Operating instructions 6. Guide the thread clockwise around the main tensioner (9). 7. Feed the thread around the guide (10) from below. 8. Feed the thread from below through the thread guide (2) and then to the right to the thread regulator (8). 9. Feed the thread through the thread regulator (8) from below. 10. Feed the thread from the right to the left through the thread lever (1). 11. Feed the thread through the thread guide (2) from above. 12.
Operating instructions Figure 25: Bobbin and bobbin capsule (1) - Spring Removing the bobbin (2) - Lever (3) - Slot Remove the bobbin as follows: 1. Ensure that the machine is in the Safe stop mode - if not: Press the Stop button. 2. Grasp the bobbin capsule, located far to the rear and centrally under the sewing material support, with your left hand. 3. Lift the lever (2) on the bobbin capsule. The bobbin capsule is no longer locked in place and can be removed. 4.
Operating instructions Running the bobbin empty If too many stitches have been entered it is possible for the bobbin to run empty before the machine generates a warning. If this occurs, the normal result is that the needle thread no longer has opposing tension from the hook thread and the thread monitor then provides an indirect indication of this problem. If the thread monitor indicates a thread breakage but the thread is not broken then check if the bobbin is empty.
Operating instructions Component Name and purpose Hose insert – only for 806N-121, so that the pocket fold remains in the shape when the middle slide is withdrawn Front view Rear view Transfer plate – holds the material to be sewn on the table plate and feeds it to the sewing unit – a numeric code is applied to the rear of the metal lug, which the machine uses to detect which seam program is suitable for the transfer plate Front view Rear view Operating manual 806N Version 00.
Operating instructions Initiating a change of shape This is how you initiate a change of shape: WARNING Risk of crushing due to pneumatic parts. The use of compressed air produces strong forces on the moving parts. If your fingers or hands get in between the parts, this could result in minor to moderate injuries. NEVER reach into the area of moving parts. 1. Navigate to Menu 1, Section 4.2.1 Structure of the operating software and Section 5.2.1 Making the basic settings.
Operating instructions The transfer plate moves into the basic position. Middle slide and edge folding frame are lowered towards the front at the bottom and become unpressurized; at the same time, the locking mechanisms are automatically released. The secure stop light lights up. You have now initiated the change of shape. You can now: • Change the shaping assembly; continue with step 1, removing the shaping assembly. • Insert the shaping assembly; continue with step 2, inserting the shaping assembly.
Operating instructions 1. Pull off the hose from the hose connecting piece (5) in an upwards direction. 2. Unscrew the screw handle (2) to the left until the coupling strip (4) can be released from the edge folding frame. The coupling strip (4) can be lifted from the edge folding frame. 3. Raise the rear carriage (1) on the right and left side such that the pins (3) on the edge folding frame stand free. 4. Pull out the edge folding frame towards you. The edge folding frame has now been removed. 5.
Operating instructions Hose insert Remove the hose insert (806N-121 only) as follows: ATTENTION Material damage due to incorrect decoupling. The compressed air connection could become damaged through improper decoupling. Release the compressed air connection according to the manual. NEVER remove the compressed air connection by force. Figure 29: Removing the hose insert (1) - Hand valve (2) - Hose coupling 1. Remove the edge folding frame and middle slide.
Operating instructions Transfer plate This is how you remove the transfer plate: Figure 30: Removing the transfer plate (1) - Right side of the transfer plate (2) - Left side of the transfer plate 1. Briefly and firmly press the right side of the transfer plate (1) until the connection is released. On the right side (1), the transfer plate is no longer connected to the transfer frame. 2. Proceed in exactly the same way on the left side (2).
Operating instructions Step 2: Inserting the shaping assembly Insert the shaping assembly components in the order specified here. This is how you achieve a correctly inserted shaping assembly. ATTENTION Material damage due to incorrect installation. If the shaping assembly components are not inserted correctly, there is a danger that the parts or the machine could get damaged. Check that all components in the shaping assembly are securely fixed. If needed, rectify any incorrect seating of the parts.
Operating instructions Figure 33: Peg and plastic holder (1) - Peg on the transfer plate (2) - Forked plastic holder 4. Firmly press the connecting piece (1) on the left side of the transfer plate and the connecting piece (2) on the left side of the transfer frame into one another. They click into place and the transfer plate is connected to the transfer frame on both sides. 5. Move the transfer plate up and down.
Operating instructions Hose insert Fit the hose insert (806N-121 only) as follows: Figure 34: Fitting the hose insert (1) - Hand valve (2) - Hose coupling 1. Align the hose insert such that the hole line is open and facing upwards. 2. Push the compressed air hose into the port for the quick coupling until it engages. The hose insert is now connected to the compressed air. 3. Insert the hose insert into the table plate so that it is flush with it. The hose insert is now inserted. 4.
Operating instructions Middle slide This is how you insert the middle slide: Figure 35: Inserting the middle slide (1) - Carriage for the middle slide (2) - Middle slide pins 1. Lift the carriage (1). 2. Position the middle slide underneath the carriage (1). 3. Insert the pins (2) on the middle slide into the front locating holes in the center of the carriage (1). 4. Firmly press the carriage (1) once onto the middle slide to ensure a proper connection. The middle slide is now inserted. 5.
Operating instructions Edge folding frame This is how you insert the edge folding frame: ATTENTION Material damage due to crushing. The air hoses could get crushed between the parts when changing the shape. This could impair their correct functioning completely. Remove hoses out of the area of the pins and the coupling strip.
Operating instructions 8. Turn the screw handle (2) to the right until the coupling strip (4) is securely connected to the edge folding frame. The edge folding frame is now inserted. Step 3: To menu 1 This is how you get to menu 1 again: WARNING Risk of crushing due to pneumatic parts. The use of compressed air produces strong forces on the moving parts. If your fingers or hands get in between the parts, this could result in minor to moderate injuries. NEVER reach into the area of moving parts. 1.
Operating instructions 5.4 Sewing with default settings If all aspects in the checklist from section 5.2 Preparing the machine for operation are met, then you can begin sewing with the 806N without making any further settings.
Operating instructions This is how you sew using the default settings: CAUTION Risk of being cut by sharp edges. Injuries to any part of the body may occur if you come into contact with the middle slide or other sharp-edged objects. DO NOT reach into the middle slide's range of motion. DO NOT reach into the area of sharp-edged parts.
Operating instructions WARNING Risk of crushing due to pneumatic parts. The use of compressed air produces strong forces on the moving parts. If your fingers or hands get in between the parts, this could result in minor to moderate injuries. NEVER reach into the area of moving parts. WARNING Risk of being stabbed by moving machine parts. Serious injuries to any part of the body may occur if you come into contact with needle or other sharpedged and pointed objects.
Operating instructions Stacker inactive Additional equipment If the machine is not stacking the material to be sewn, then a stacker is probably not activated. You can activate a stacker in menu 2, Section 5.7.4 Selecting/deselecting stacker variants. Laser positioning aid A laser positioning aid for the 806N is available as an optional extra. It facilitates exact alignment on the material support when the basic part is being applied. 5.
Operating instructions 2. Press the 2-pocket mode button . The selection window for the seam program appears on the touchscreen. Figure 39: Selecting the seam program The available pocket seam programs are listed on the left side. The code for identifying the transfer plate is shown on the right side. The Start key is flashing. Seam program cannot be selected If no pocket seam program can be selected in the selection window for the seam program, then this could be due to several reasons.
Operating instructions 3. Select a pocket seam program for the left pocket. Figure 40: Seam program selected The selected seam program is highlighted in blue and appears in the option field. 4. Press the Confirm button to confirm the choice of seam program. After confirmation, the seam program under the selection field is displayed in green text. Figure 41: Seam program confirmed 5. Select a second pocket seam program for the right pocket. 6.
Operating instructions Figure 42: Menu 1 in 2-pocket mode The Start key lights up green. You are asked to specify the first pocket to be sewn in the next sewing cycle. 7. Select the first pocket to be sewn by pressing the desired pocket. The pocket is highlighted or framed. 8. Start the sewing process by pressing the Start button. The machine starts a normal sewing cycle. It automatically alternates between the two pockets while sewing. 9.
Operating instructions 5.6.2 Setting the bobbin counter The bobbin counter indicates the amount of thread remaining on the bobbin. The menu for changing the bobbin is also displayed here. You access the bobbin counter and bobbin change menu as follows: 1. Press the Set bobbin counter button . The machine enters the Safe stop mode, the inner stacker bar opens and the following dialog is displayed: Figure 43: Bobbin menu dialog This dialog opens automatically when the stitch counter reaches "0".
Operating instructions Bobbin counter You set the bobbin counter in the Bobbin menu screen as follows: 1. Press the Number of stitches button . The following window appears: Figure 44: Selection window for number of stitches 2. Press the buttons to enter the (estimated) number of stitches available on the bobbin. The entered value appears in the input field above. Bobbin capacity The capacity of the bobbin varies depending on the type of thread and material to be sewn.
Operating instructions 7. Press the Exit button to exit the Bobbin menu. You are returned to Menu 1. Changing the bobbin You change the bobbin as follows: You can change the bobbin from the Bobbin menu screen. This procedure is described in Section 5.2.5 Inserting/changing the bobbin. 5.6.3 Enabling bundle removal You must enable the bundle removal when you want to remove the sewn parts. The stacker opens and allows the parts to be removed. You enable bundle removal as follows: 1.
Operating instructions Operating You operate the Slide automatically forward mode as follows: The Start button lights up green and the middle slide is forward. Be careful to avoid being cut by the sharp edges of the middle slide. 1. Place the pocket blank on the middle slide. 2. Place and align the basic part on the edge folding station. 3. Fasten the basic part by pressing Manual button 1 or the Foot switch. The air suction is now switched on. 4.
Operating instructions 5.6.6 Initiating a change of shape Different shaping assemblies are required for each seam program. A shaping assembly consists of: • Edge folding frame • Middle slide • Hose insert (806N-121 only) • Transfer plate The procedure for fitting or replacing the individual parts is described in Section 5.2.6 Fitting/changing the shaping assembly. 5.7 Setting options on user interface 2 Settings in Menu 2 can only be performed between two sewing cycles.
Operating instructions The operation of the Work step-by-step mode is described in detail in Section 5.3 Carrying out a test run. This setting is deleted after switching off the machine, after loading a different seam program or after an EMERGENCY STOP. 5.7.2 Activating Sewing without edge folding In the Sewing without edge folding mode the machine only sews – the folding procedure is not performed. This mode can be used for (e.g.) testing a new seam program or performing a seam quality check.
Operating instructions 3. Press the Stroke position button again to deactivate this mode. The button is no longer highlighted in green. The stroke position is no longer adjusted when sewing and remains unchanged. This setting remains stored after switching off the machine, after loading a different seam program or after an EMERGENCY STOP. 5.7.4 Activating needle cooling The needle is cooled with air to prevent it from becoming too hot from the friction with the material.
Operating instructions The button is now highlighted in green. The following message is displayed if the thread breaks while sewing: Figure 45: Thread breakage error message If the machine displays this error message then pleas proceed as described in Section 5.8.7 Sewing after thread breakage. 3. Press the Thread monitor button again to deactivate this mode. The button is no longer highlighted in green. A thread breakage while sewing is NOT displayed.
Operating instructions 2. Press the Automatic air suction button . The button is now highlighted in green. The air suction is now automatically activated by interruption of the light barrier when the basic part is laid in position. 3. Press the Automatic air suction button mode. again to deactivate this The button is no longer highlighted in green. The air suction is no longer automatically activated, even when a light barrier is installed.
Operating instructions No stacking Note that sewn products can only be stacked when a stacker is actually present. If you have only deactivated a stacker this does not automatically activate the other stacker. This setting remains stored after switching off the machine, after loading a different seam program or after an EMERGENCY STOP. 5.7.8 Setting the outfeed roller path This allows you to set the path over which the finished sewn product is to be rolled before being ejected from the sewing area.
Operating instructions 4. Press the Confirm button to confirm the entered value. The selection window closes and the entered value is displayed in the field above the Outfeed roller path button. 5. Press the Exit button to correct the entered value. The entered value is deleted. 6. Press the Exit button again to exit the selection window. The selection window closes and you are returned to the Menu 2 screen.
Operating instructions 5.7.10 Setting the motor speed The speed of the sewing motor can be set between 100 and 4000 rpm. A speed reduction is useful when (e.g.) you want to sew stepwise or without folding. You set the motor speed as follows: 1. Navigate to Menu 2. 2. Press the Motor speed button . The following window appears: Figure 47: Speed selection window 3. Press the buttons to set the sewing motor speed (value between 100 and 4000). The entered value appears in the input field above. 4.
Operating instructions 5.8 Activities on the machine This section describes activities that do not relate to the operating software. These are mechanical settings performed at specific places in the machine. 5.8.1 Winding the hook thread Winding the hook thread is performed during the normal sewing process. The winding process stops automatically when the bobbin is full. Figure 48: Winding the hook thread (1) - Bobbin lever (2) - Cutting clamp You wind the hook thread as follows: 1.
Operating instructions The number of stitches you can make with the hook thread depends on the type of thread and the material to be sewn. The procedure for estimating the approximate capacity is described in Section 5.6.2 Setting the bobbin counter. 5.8.2 Adjusting the needle thread tension Together with the hook thread tension, the needle thread tension influences the final appearance of the seam. It should be set so that the desired seam appearance is achieved with the lowest possible tension.
Operating instructions 5.8.3 Adjusting the hook thread tension Together with the needle thread tension, the hook thread tension influences the final appearance of the seam. Test runs must be performed to determine the correct setting for a high quality seam appearance. Figure 50: Bobbin with bobbin capsule (1) - Tension spring (2) - Screw You set the hook thread tension as follows: 1. Press the Stop button to place the machine in the Secure hold status. The secure stop light lights up. 2.
Operating instructions 5.8.4 Inserting/changing the needle A needle must be present for sewing. The needle must be correctly inserted to avoid damage to the machine and the seam appearance. A needle strength of 70 - 100 NM is recommended. WARNING Risk of being cut and stabbed by moving machine parts. Serious injuries to any part of the body may occur if you come into contact with the middle slide, needle, or other sharp-edged and pointed objects.
Operating instructions 3. If necessary, release the screw (1) on the needle bar using an SW 1.5 hex key. 4. Slide the new needle into the guide as far as it will go, with the groove facing to the right of the operator as illustrated above. 5. Tighten the screw (1) on the needle bar. Proceed in the reverse sequence to remove a needle. The procedure for threading the needle thread is described in Section 5.2.4 Threading the needle thread. 5.8.
Operating instructions • The machine enters the Safe stop mode. • The sewing head is raised. Proceed as follows to continue sewing after a thread breakage: 1. Thread the needle thread again, Section 5.2.4 Threading the needle thread.. 2. Press the Start button. The Start button flashes green and the Safe stop mode is switched off. The machine automatically moves somewhat before the position of the thread breakage. The sewing head lowers in this position.
Operating instructions 5.9 Switching off the machine Switching off the machine needs two steps: • Shutting down the operation display • Switching off the machine ATTENTION Material damage due to incorrect sequence If the operation display is not shut down first, this could result in the malfunctioning or even the destruction of the operation display. ALWAYS shut down the operation display first. Do not flip the main switch on the machine until you have done this.
Operating instructions Figure 55: Switching off the main switch (1) - Off (2) - On (3) - Rotary switch 3. Turn the shut-off valve to the right into the horizontal position. Figure 56: Closing the shut-off valve Shut-off valve open Shut-off valve closed After the shut-off valve is closed, the residual air may be emptied using the compressed air gun (figure below). This is located under the table plate. Figure 57: Compressed air gun Operating manual 806N Version 00.
Operating instructions 5.10 How to act in the case of an emergency (EMERGENCY STOP) In emergency situations presenting a danger to persons or the machine, the 806N can be brought to a standstill via two EMERGENCY STOP devices. The EMERGENCY STOP devices are located on the edge folding station (button) and the transfer frame (integrated).
Operating instructions When the danger situation has passed and you can continue working the safety devices must first be deactivated. The machine can only be operated normally after this has been performed. Button The red EMERGENCY STOP button is located in the upper part of the edge folding station, Section 4.1.2 Edge folding station. In an emergency it can be triggered by pressing it. You deactivate the EMERGENCY STOP button as follows: 1. Correct any fault or danger that may be present. 2.
Operating instructions 5.11 Maintenance (daily) The machine must be thoroughly cleaned after each shift. If this is not done then faults caused by soiling can occur during operation. Oiling must also be performed at regular intervals to maintain the service life of the machine and achieve the desired seam quality. WARNING Risk of being cut and stabbed by moving machine parts.
Operating instructions ATTENTION Material damage due to incorrect cleaning. If the throat plate is not lifted carefully the equipotential bonding connected to the plate can be damaged or ripped off. ALWAYS lift the throat plate carefully. Pay attention to the equipotential bonding when lifting. Clean the machine as follows: 1. Shut down the machine by shutting down the operating terminal and then switching off the main power switch, Section 5.9 Switching off the machine. 2.
Operating instructions Use only DA10 sewing machine oil or an equivalent oil conforming to the following specifications: • Viscosity at 40°C: 10 mm2/s • Flash point: >160°C DA10 sewing machine oil can be obtained from Dürkopp Adler sales offices under the following part numbers: • 9047 000013 - 2 liters • 9047 000014 - 5 liters WARNING Risk of injuries due to contact with oil. Contact with oil can cause irritation, rashes, allergies or skin injuries. ALWAYS avoid long-term contact with oil.
Operating instructions Check the oil levels WEEKLY: Checking the oil levels Topping up with oil 1. Perform at least 20 sewing cycles to evenly distribute the oil in the machine. 2. Check the oil level in oil reservoir 1. 3. If the oil level lies between MIN and MAX then no further action must be taken. 4. If the oil level is at MIN or lower: Check the oil level in oil reservoir 2. 5.
Operating instructions Possible malfunctions: Fault 88 Removal/remedial action Broken thread Thread the needle thread, Section 5.2.4, then continue sewing, Section 5.8.7 Bobbin is empty Insert a new bobbin, Section 5.2.5, wind thread onto a bobbin, Section 5.8.1 A sewing program cannot be selected - Are the reflector strips on the rear side of the transfer plate all present and intact? Re-attach if necessary - Code code on the transfer plate is incompatible, see Section 5.2.
Operating instructions Fault Removal/remedial action Error 9225 Error text: Pushbutton pressed too long; Operator information Error 9226 Error text: Pushbutton pressed too long; Operator information A technician must be consulted for correcting errors that are not listed here. Operating manual 806N Version 00.
Set-up instructions 6 Set-up instructions The aspects relating to set-up are explained below. Keep to the procedure described here to ensure fault-free operation of the machine. WARNING Risk of injury due to a lack of specialist knowledge Inadequate specialist knowledge can result in serious injuries when setting up the machine. Allow ONLY trained personnel to set up the machine. 6.1 Unpacking the machine WARNING Risk of injury due to own weight and packaging materials.
Set-up instructions 6.3 Removing/mounting covers The covers are divided into covers above and below the table level. The covers above the table level must be removed in order to remove the transport locks. 6.3.1 Removing the covers ATTENTION Material damage due to incorrect sequence. The covers above the table level can be damaged when removed/ installed in the incorrect sequence. ALWAYS remove/mount the covers above the table level in the specified sequence.
Set-up instructions Figure 63: Covers on the rear side of the machine (9) - Right side cover Above the table level (10) - Left and right rear covers The correct sequence for removing the covers above the table level is as follows: Cover (6) - Sewing head 1. Unlock the cover lock using the associated key. 2. Release the clamping lever on the thread reel holder by reaching under the cover. 3. Pull out the thread reel holder upwards. 4. Slide the thread regulator clockwise. 5. Lift the cover upwards.
Set-up instructions Cover (7) - Front right 1. Release the screw using a hey key through the hole. 2. Pull the cover upwards. 3. Remove the cover forwards. Cover (2) - Left side This cover does not normally need to be removed. Everything inside the machine is accessible when the rear covers below the table level are removed. 1. 2. 3. 4. Release the screws on the retaining bar. Pull put the retaining bar. Pull the cover upwards. Remove the cover forwards. Cover (9) - Right side 1. Release the screws. 2.
Set-up instructions Above the table level The correct sequence for removing the covers above the table level is as follows: Cover (1) - Edge folding station 1. Remove the cover upwards while paying attention to the key panel guide. Cover (5) - Carriage 1. Place the cover on the carriage from above. 2. Fit the cover so that it lies on the edge folding station cover (1). Cover (6) - Sewing head 1. Fit the cover into the guide at the upper right of the carriage (5) cover. 2.
Set-up instructions Cover (4) - Front left 1. Simply hang the cover in place. Cover (7) - Front right 1. Fit the cover downwards into the guide hooks. 2. Pull the cover upwards. 3. Fit the cover upwards into the guide hooks. 1. Release the screw using a hex key through the front middle hole. Cover (8) - Stacker 1. Pivot the stacker away from the machine. 2. Fit the cover from above. 3. Tighten the hex screw at the outer left of the cover. 4. Tighten the hex screw at the outer right of the cover. 5.
Set-up instructions Figure 64: Sewing head transport lock (1) - Metal ring Edge folding station (2) - Screw The edge folding station is delivered in shape changing mode, even when no shapes are supplied with the machine. 4. Remove the polystyrene foam from between the protective bar and edge folding frame at the front of the edge folding station. 5. Remove any fastening tape or cable ties from the carriage of the middle slide and edge folding frame.
Set-up instructions 6.5 Setting up/connecting the sewing unit Follow the steps described here for setting up and connecting the unit. Damage to the machine and personal injury can only be avoided by following the correct set-up procedure. WARNING Risk of injury due to a lack of specialist knowledge Inadequate specialist knowledge can result in serious injuries when setting up the machine. Allow ONLY trained personnel to set up the machine. 6.5.
Set-up instructions 6.5.2 Installing the thread reel holder Due to the height the thread reel holder is not installed when the machine is delivered. The thread reel holder must be installed with the covers in place because the covers can no longer be fitted when the thread reel holder is installed. Install the thread reel holder as follows: Figure 66: Installing the thread reel holder (1) - Thread reel holder (2) - Clamping lever (3) - Thread reel holder bracket 1.
Set-up instructions 6.5.3 Electrical connection DANGER Risk of injury from electricity. Unprotected contact with electricity can result in serious injuries or death. Work on the electrical system must ONLY be performed by qualified electricians or appropriately trained and authorized personnel. ALWAYS unplug the power plug before working on the electrical equipment. The power cable is already installed on the machine. On delivery it lies inside the machine.
Set-up instructions Figure 68: Connection to the pneumatic system (1) - Pressure gage (2) - Twist grip Connect the compressed air as follows: 1. Connect the connection hose with the hose coupling to the compressed air supply. 2. Plug the connection hose onto the hose neck of the pressure gage and fasten with a hose clamp. 3. Open the shut-off valve by turning it to the right into the horizontal position. Setting the operating pressure The operating pressure is 6 bar.
Set-up instructions • 9047 000013 - 2 liters • 9047 000014 - 5 liters WARNING Risk of injuries due to contact with oil. Contact with oil can cause irritation, rashes, allergies or skin injuries. ALWAYS avoid long-term contact with oil. ALWAYS thoroughly wash the affected areas if contact with oil occurs. ATTENTION Risk of environmental damage from old oil. Incorrect handling of old oil can result in severe environmental damage.
Set-up instructions 1. Release the screws on the head cover. 2. Remove the head cover. 3. Oil the wick and felt at positions (1) and (2) by applying a small amount of oil directly from the oil can to the marked positions. 4. Fit the head cover. 5. Tighten the screws on the head cover. 6.6 Commissioning The machine is delivered almost completely ready for operation. A test run can be performed after performing the listed steps for set-up and connection of the machine.
Decommissioning 7 Decommissioning A number of activities must be performed if the machine is to be shut down for a longer period of time or completely decommissioned. WARNING Risk of injury due to a lack of care. A lack of care or a lack of sufficient technical knowledge when decommissioning the machine can result in serious injuries. ONLY clean the machine when it is switched off. Avoid contact with oil residues. Allow ONLY trained personnel to disconnect the machine.
Packing, transportation 8 Packing, transportation The aspects relating to packing and transportation are described below. Keep to the procedure described here to ensure fault-free operation of the machine. 8.1 Fitting the transport locks Transport locks must be fitted to the following places in order to protect the machine from damage during transport: • Sewing head • Edge folding station • Stacker • Transfer carriage Fit the transport locks as follows: 1.
Packing, transportation 11. Fasten the polystyrene foam between the protective bar and edge folding frame. 12. If necessary, use tape or cable ties to fasten the middle slide carriage and edge folding frame. The edge folding station components are now fastened for transport. Stacker 13. Use tape or cable ties to fasten the stacker bar to the stacker. 14. Fold the stacker to the machine and tape it to the frame. The stacker is now fastened to the machine. Transfer carriage 15.
Packing, transportation 8.3 Transporting the machine Fit the transport locks before transporting the machine. WARNING Danger of crushing due to unstable transport. Incorrect transport of the machine can result in severe crushing injuries. ALWAYS use a sturdy lifting carriage. ALWAYS wear safety shoes and gloves Lift the machine a MAXIMUM of 20 mm. ALWAYS securely fasten the machine. Ensure the highest possible degree of safety when transporting the machine.
Disposal 9 Disposal The machine must not be disposed of in the normal household waste. The machine must be disposed of in an appropriate and correct manner according to the national regulations. ATTENTION Risk of environmental damage due to incorrect oil disposal. Incorrect disposal of old oil can result in severe environmental damage. ALWAYS observe the legally prescribed regulations for disposal of oil.
Glossary 10 Glossary Term 108 Explanation Air suction The air suction is located in the sewing material support in the edge folding area. The air suction fastens the basic part to the sewing material support. Basic part The basic part is the material product onto which the pocket is to be sewn. Basic position In the basic position the middle slide is at the rear and the transfer plate is at the right. Bobbin The hook thread is wound on the bobbin.
Glossary Term Explanation Sewing material support The sewing material support extends from the edge folding station to the sewing unit. The sewing material support supports the basic part and transports the material to the sewing unit. Shaping assembly The shaping assembly is important for the seam program. A shaping assembly consists of: Edge folding frame, middle slide, transfer plate and hose insert. Snapper The snapper functions like a spring.
Glossary 110 Operating manual 806N Version 00.
Operating manual 806N Version 00.
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Original Instructions - 0791 806011 - EN - 12/2012 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.
