906 Operating instructions
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Table of contents 1 About this operating instructions ............................................. 5 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Scope ........................................................................................... 5 For whom is this operating instructions? ...................................... 5 Representation conventions – symbols and characters ............... 6 Other documents .......................................................................... 7 Liability........................
Table of contents 2 6.3.4 6.3.5 6.4 6.5 6.6 6.6.1 6.7 Attaching the thread reel holders................................................ 54 Setting up the pedal.................................................................... 54 Electrical connection................................................................... 55 Pneumatic connection ................................................................ 56 Oil lubrication ..............................................................................
Table of contents 10 Decommissioning................................................................... 127 10.1 10.2 Decommissioning the machine................................................. 127 Dismantling the automatic stacker............................................ 128 11 Packaging, transportation ..................................................... 131 11.1 11.2 11.3 11.4 Fitting the transport locks .........................................................
Table of contents 4 Operating instructions 906 - Version 00.
About this operating instructions 1 About this operating instructions This operating instructions for the 906 CNC sewing unit has been compiled with the utmost care. It contains information and notes in order to ensure long-term and reliable operation. Please contact us if you find any discrepancies or have any suggestions, 5.14 Customer Service, page 47. Consider this operating instructions part of the product and keep it on hand at all times.
About this operating instructions 1.3 Representation conventions – symbols and characters Proper setting Indicates proper setting. Malfunctions Specifies the faults that can occur due to an incorrect setting. Steps to be performed when operating the machine (sewing and equipping) Steps to be performed for servicing, maintenance, and installation Steps to be performed via the software control panel The individual steps are numbered: 1. 1. First step 2. 2. Second step ...
About this operating instructions 1.4 Other documents This equipment includes components from other manufacturers. Each manufacturer has performed a hazard assessment for these purchased parts and confirmed their design compliance with applicable European and national regulations. The proper use of these components is described in each manufacturer's manual. 1.
About this operating instructions 1.7 Proper use The Dürkopp Adler 906 CNC sewing unit is used for sewing pre-bound or other pockets onto jeans. The material requires a needle strength of 120 - 140. The machine is only intended for use with dry material. The material cannot contain any hard objects. The seam is created with thread made of textile fibers (cotton threads, synthetic threads/core-spun threads). The CNC sewing unit is intended for industrial use.
Performance description 2 Performance description The Dürkopp Adler 906 CNC sewing unit is used for automatically sewing pre-bound or other pockets onto jeans. Depending on the working method, various optional equipment is used. 2.1 Characteristics Base type CNC-controlled, double lockstitch sewing unit based on class 867, with a DAC III controller and specific software. Use Sewing pre-bound pockets, mainly back pockets up to a size of 210 x 210 mm, onto jeans.
Performance description Programming • Operated via the graphic control panel OP 7000 • 99 program storage locations, each with a maximum of 16000 stitches • Programs can be sewn individually or in sequences • Storage of up to 20 sequences, with up to 30 programs in each sequence • Setting of individual stitch parameters per stitch for controlling stroke position of pressure foot, thread cutter, thread clamp, speed, thread tension etc.
Performance description Thread handling • Electronic upper thread monitor • Programmable upper thread tension: Tension values for different thread extraction directions stored in seam program. This creates a clean seam. • Threading device: Pulls the needle thread under the sewing material on the 1st stitch.
Performance description 2.
Performance description 2.4 Technical data Characteristic 906-01 Stitch type 301 Hook type Vertical hook Needle system Needle strength [Nm] Number of needles Stitch length (programmable) [mm] 134/35 120 - 140 1 Maximum 12.
Performance description 14 Operating instructions 906 - Version 00.
Safety Information 3 Safety Information This section contains basic information for your safety. Read the instructions carefully before setting up or operating the machine. Make sure to follow the information included in this section. Failure to do so 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 instructions. The operating instructions should be available at the machine's location at all times.
Safety Information Operator's Observe the country specific safety and accident prevention regulations obligations and the legal regulations concerning industrial safety and the protection of the environment. All warnings and safety signs on the machine must always be in legible condition and may not be removed. Missing or damaged labels should be replaced immediately. Requirements The machine should only be set up by qualified technicians.
Safety Information 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 indicate the degree of risk: Signal words Signal words and the hazard that they describe: Signal word Hazard DANGER Will result in serious injury or death. WARNING Can result in serious injury or death. CAUTION Can result in minor or moderate injury. ATTENTION Can result in property damage.
Safety Information WARNING Type and source of risk Consequences of non-observance Measures for avoiding the risk This is what a warning looks like for a hazard that could result in serious injury or even death if ignored. CAUTION Type and source of risk Consequences of non-observance Measures for avoiding the risk This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored.
Operating instructions 906 - Version 00.0 - 05/2014Machine Description 4 Operating instructions 906 - Version 00.
Operating instructions 906 - Version 00.0 - 05/2014Machine Description 20 Operating instructions 906 - Version 00.
Operation 5 Operation 5.1 Switching the sewing unit on and off Figure 3: Switching the sewing unit on and off ① (1) - Main switch Switching on the sewing unit 1. Turn the main switch (1) to the right into the "I" position. The sewing unit is referenced. After referencing, the startup screen is displayed on the operating terminal for a few seconds. On the start screen, you can set the language for the user interface in the Language menu or open the Service menu ( 7.3 Starting the software, page 64).
Operation 5.2 Switching on Safe Stop WARNING Risk of injury from sharp or moving parts. The sewing unit must first be switched off or switched to a Safe Stop before performing any maintenance or setup work. When the Safe Stop is active, do not reach into the hook area until this is lit up. Figure 4: Switching on Safe Stop ③ ① (1) - Drive carriage (2) - Hook cover ② (3) - Safe Stop switch Switching on Safe Stop 1. Press in the switch button (3). Important: The switch button must latch into place.
Operation 5.3 Switching on the Quick-stop The Quick-stop switch (1) can be used to immediately stop all working steps on the machine, e.g. after an operating error. WARNING Risk of injury from sharp or moving parts. After a Quick Stop, power is still present in the sewing unit and the clamps can move. You must always switch the machine off at the main switch (2) before performing any maintenance or cleaning work.
Operation 5.4 Sewing on pre-bound pockets After using the two-hand control, the sewing process is carried out step-by-step: • The transfer plate transfers the sewing material to the clamp and moves back into its starting position. • The sews the pre-bound pocket onto the sewing material. • The automatic stacker places the sewn product onto the bundle mount. WARNING Risk of injury from moving parts. During the sewing process, machine parts move quickly.
Operation Preparation Figure 6: Insert the sewing material and pre-bound pocket ③ ① ② (1) - Sewing material (2) - Transfer plate (3) - Pre-bound pocket 1. Place a bundle of sewing material onto the material tray of the two-hand control. 2. Place the sewing material under the transfer plate and align it with the marks. 3. Use foot pedal. The transfer plate is closed. 4. Place the pre-bound pocket to fit into the shape cut-out of the transfer plate. Start sewing 1. Use two-hand control.
Operation Remove the bundle from the tray on the automatic stacker The machine will stop when the tray on the automatic stacker is full. A message on the screen indicates that you should remove the bundle. Figure 7: Removing the bundle 1. Remove bundle from automatic stacker 2. Tap the OK button on the screen. The machine is ready for the next sewing process. 26 Operating instructions 906 - Version 00.
Operation 5.5 Pivoting the machine upper section The machine upper section can be raised for maintenance work. WARNING Risk of injury from sharp or moving parts. Switch off the sewing unit at the main power switch before raising the machine upper section and performing maintenance work. 5.5.1 Raising the machine upper section Important: The drive carriage (2) must be moved to the left stop position.
Operation Figure 9: Raising the machine upper section ④ ⑤ (4) - Locking lever (5) - Latch 1. Release the locking lever (4) under the table top. 2. Lift the machine upper section in the head cover region (1) and raise carefully. The latch (5) latches into place. The space under the machine table is now accessible. 5.5.2 Lowering the machine upper section ATTENTION Danger of machine damage from falling machine upper section.
Operation 5.6 Changing needle WARNING Serious injuries can be caused by the machine suddenly starting up. Turn off the sewing machine on the main switch before replacing the needle. Do not touch the tip of the needle. Figure 11: Changing needle ① ② ③ ④ (1) - Crank (2) - Needle bar (3) - Inner hexagon screw (4) - Groove Steps 1. Push the crank 1) down and rotate it to the left until the needle bar (2) reaches the highest position. 2. Loosen hexagon screw (3) (screwdriver width 2 mm) 3.
Operation Faults caused by an incorrect hook clearance • After inserting a thinner needle: • Missing stitches • Thread damage • After inserting a thicker needle: • Damage to the hook tip • Damage to the needle 5.7 Threading the needle WARNING Serious injuries can be caused by the machine suddenly starting up. Turn off the machine before threading. Do not touch the tip of the needle.
Operation 4. Feed the thread clockwise around the tensioner (9). 5. Insert the thread through the thread guides (7) and (8). 6. Feed the thread clockwise around the diverter (6). 7. Feed the thread under the thread tensioning spring (5), through the guide (3) and through the thread regulator (2) to the thread lever (1). 8. Feed the thread through the thread lever (1) and thread guide (4).
Operation 5.8 Setting the thread regulator The thread regulator determines the needle thread quantity to be guided around the hook. The required thread quantity depends on the thickness of the material to be sewn, thread strength, and stitch length.
Operation 5.9 Winding the hook thread The separate winder allows the hook thread to be wound while sewing or independently of sewing. Figure 15: Winding the hook thread ⑤ ④ ③ ② ① ⑥ (1) - Thread winding tension (2) - Thread guide plate (3) - Thread guide plate (4) - Winder shaft (5) - Winder flap (6) - Cutter Steps 1. Place the thread reel on the thread reel holder and guide the needle thread through the hole in the guide on the unwinding bracket.
Operation 5.10 Replacing the hook thread bobbin WARNING Risk of injury by the needle point or moving parts. Switch the sewing unit to the Safe Stop mode before changing hook thread bobbin. Figure 16: Replacing the hook thread bobbin – Part 1 ① ② ③ (1) - Safe Stop switch (2) - Cover plate (3) - Lighting 1. Press the Safe Stop switch (1). The drive carriage moves to the bobbin change position. The cover plate (2) pivots to the side. The sewing feet are moved to the lower position.
Operation Figure 17: Replacing the hook thread bobbin – Part 2 ④ ⑤ ⑥ ⑦ ⑧ (4) - Bobbin (5) - Bobbin housing flap (6) - Guide (7) - Tension spring (8) - Slot 2. Fold up the bobbin housing flap (5). 3. Remove the empty bobbin. 4. Insert a full bobbin (4). Important: Insert the bobbin (4) so that it moves in the opposite direction of the hook when the thread is pulled out. 5. Feed the hook thread through the slot (8) in the bobbin housing. 6. Pull the hook thread under the tensioning spring (8). 7.
Operation 5.11 Setting hook thread tension WARNING Risk of injury by the needle point or moving parts. Switch the sewing unit to the Safe Stop mode before changing hook thread bobbin. Figure 18: Replacing the hook thread bobbin - Part 1 ① ② ③ (1) - Safe Stop switch (2) - Cover plate (3) - Lighting 1. Press the Safe Stop switch (1). The drive carriage moves to the bobbin change position. The cover plate (2) pivots to the side. The sewing feet are moved to the lower position.
Operation Figure 19: Setting hook thread tension ④ ⑤ (4) - Tension spring (5) - Adjusting screw The hook thread tension is generated by the tension spring (4) and adjusted via the adjustment screw (5). To increase tension: 1. Turn the adjusting screw (5) clockwise. To reduce tension: 1. Turn the adjustment screw (5) counterclockwise. Order 1. Release the Safe Stop button (1). The cover plate (2) pivots back to the original position. Operating instructions 906 - Version 00.
Operation 5.12 Changing the configuration set For pockets with a different shape, you must change the configuration set. A configuration set is comprised of an inner slider, the outer frame and the transfer plate. To change the configuration set, you must activate the clamp change mode. Figure 20: Configuration set ① ③ ② (1) - Inner slider (2) - Outer frame (3) - Transfer plate 5.12.
Operation 5.12.2 Changing the outer frame and inner slider You must first remove the outer frame and then the inner slider. The installation takes place in reverse order. Removing the outer frame and inner slider Figure 22: Removing the outer frame and inner slider ① ② (1) - Outer frame (2) - Inner slider 1. Hold the outer frame (1) with your left hand. 2. Tap the 2 button on the screen. The locking device opens. 3.
Operation Installing the inner slider Figure 23: Installing the inner slider ③ ② ① (1) - Inner slider (2) - Driver pin (3) - Stopper bracket 1. Spread the inner slider (1), slide as far as the stopper (3) into the bracket and hold it in this position. Important: The guide drill hole of the slider must be positioned in the pin of the driver (2) 2. Tap the 1 button on the screen. The transfer plate is closed. 40 Operating instructions 906 - Version 00.
Operation Installing the outer frame Figure 24: Installing the outer frame ② ① (1) - Inner slider (2) - Driver pin (3) - Stopper bracket 1. Slide the outer frame (1) as far as the stopper (2) into the bracket and hold it in this position. 2. Tap the 2 button on the screen. The locking device is closed. 5.12.3 Changing the transfer plate Removing the transfer plate Figure 25: Removing the transfer plate ① (1) - Transfer plate 1. Hold the transfer plate (1) with your left hand. 2.
Operation Installing the transfer plate Figure 26: Installing the transfer plate ② ① (1) - Transfer plate (2) - Stopper bracket 1. Slide the transfer plate (1) as far as the stopper (2) into the bracket and hold it in this position. 2. Press the 3 button on the screen. The locking device is closed. 5.12.4 Ending clamp change mode The clamp change mode can only be ended once all locking devices are closed on the configuration set. 1. Tap the OK button on the screen.
Operation 5.13 Maintenance This section describes simple maintenance work that needs to be carried out on a regular basis. The maintenance work can be carried out by the operating personnel. Advanced maintenance work should only be carried out by qualified technicians. Further maintenance work is described in the Service Manual. 5.13.1 Cleaning ATTENTION Malfunctions due to machine contamination. Lint and thread remnants can impair the operation of the machine.
Operation Figure 27: Cleaning the sewing unit ① ② (1) - Area around the needle (2) - Area around the hook Areas requiring special cleaning • Area around the needle (1) • Area around the hook (2) • Ventilation sieve on the control box (not illustrated) 5.13.2 Oil lubrication WARNING Skin damage due to contact with oil. Oil can cause a rash if it comes into contact with skin. Avoid any skin contact with the oil. If oil gets on your skin, wash the affected areas thoroughly.
Operation ATTENTION Machine damage possible due to incorrect oil. An incorrect oil type can cause damage to the machine. Only use oil that complies with the data in the manual.
Operation The sewing unit is equipped with a central oil-wick lubrication system. The bearings are supplied from the oil reservoir (1). Figure 28: Oil lubrication ① ② ③ ④ (1) - Oil reservoir (2) - Refill opening (3) - Maximum level marking (4) - Minimum level marking Warning messages for oil level that is too low • The lamp in the oil reservoir (1) lights up red. • A warning message is displayed on the screen.
Operation 5.14 Customer Service Contact for repairs if machine is damaged: Dürkopp Adler AG Potsdamer Str. 190 33719 Bielefeld, Germany Tel. +49 (0) 180 5 383 756 Fax +49 (0) 521 925 2594 E-mail: service@duerkopp-adler.com Internet: www.duerkopp-adler.com Operating instructions 906 - Version 00.
Operation 48 Operating instructions 906 - Version 00.
Setting up 6 Setting up WARNING The machine may only be set up by trained specialists. Wear safety gloves and safety shoes when unpacking and setting up. 6.1 Checking the scope of delivery Important: The scope of delivery depends on your specific order. 1. Check that all parts are present before setup. Figure 29: Scope of delivery 1 ① ② ③ ④ ⑤ (1) - Thread reel holder (2) - CNC sewing unit (3) - Automatic stacker Operating instructions 906 - Version 00.
Setting up Figure 30: Scope of delivery 2 ⑥ ⑦ (6) - Compressed air pistol (7) - Compressed air maintenance unit Scope of delivery: • CNC-controlled double lockstitch machine (2), equipped with: • Automatic sewing foot and clamp ventilation • Stroke position adjustment • Thread cutter • Needle thread monitoring • Threading device • Multiple thread tensioning • • • • • • 50 Automatic stacker (3) Compressed air maintenance unit (7) with compressed air pistol (6) Height-adjustable frame (4) Thread reel h
Setting up 6.2 Transporting the sewing unit 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. Fitting the transport locks ATTENTION Possible machine damage through unsecured transport. Never transport the machine without the transport locks.
Setting up 6.3 Setting up the sewing unit Ensure sufficient free space for operation and maintenance of the sewing unit. 6.3.1 Positioning the sewing unit WARNING Danger of injuries from unsafe positioning of the machine. Prior to starting up the sewing unit, ensure that it is in a safe position. If necessary, adjust the frame feet for this purpose. 1. Insert the lifting carriage or forklift under the frame and relieve the frame feet. 2. Release the nuts (1) on the frame feet (2). 3.
Setting up 6.3.3 Installing the automatic stacker WARNING Risk of injury. The automatic stacker is heavy and has bulky dimensions. Carry out the installation with two people in order to avoid back injuries or crushing injuries if the machine falls down. Figure 32: Installing the automatic stacker ⑦ ① ⑥ ② ③ ④ ⑤ ② (1) - Setscrews (2) - Threaded screws (3) - Cover plate (4) - Support pipe (5) - Pneumatic connection (6) - Plug for valve control lines (7) - Equipotential bonding 1.
Setting up 6.3.4 Attaching the thread reel holders Figure 33: Attaching the thread reel holders ① ② ① ③ ⑤ ④ (1) - Thread reel holder (2) - Unwinding bracket (3) - Thread plate (4) - Hole (5) - Nut 1. Insert the thread reel holder (1) into the drill hole (4) screw together with the nut (5) 2. Screw the thread plate (3) and the unwinding bracket (2) onto the thread reel holder in such a way that they are exactly parallel above each other. 6.3.
Setting up 6.4 Electrical connection DANGER Danger of life-threatening electric shock The machine may only be connected by trained electricians. Disconnect the power plug before carrying out work on the electrical equipment. Make sure the power plug cannot be accidentally plugged back in. Observe the information in the operating instructions of the stepper motor manufacturer provided with the unit.
Setting up 6.5 Pneumatic connection ATTENTION Machine damage possible due to incorrect operating pressure. Incorrect pressure can result in damage to the machine. The operating pressure for the pneumatic unit is 6 bar. A minimum operating pressure of at least 6 bar must be maintained, even under maximum air consumption. Make sure the operating pressure is set correctly before starting the machine. ATTENTION Machine damage possible due to oily compressed air.
Setting up Figure 35: Connecting the compressed air maintenance unit ① ② ③ (1) - Adjustment knob (2) - Pressure indicator (3) - Connecting hose Connecting the compressed air maintenance unit 1. Attach the connecting hose (3) (order number 0797 003031) to the compressed air supply using a ¼" hose coupling. Setting operating pressure The operating pressure is 6 bar and is shown on the pressure indicator (2). 1. Pull the adjustment knob (1) up. 2.
Setting up 6.6 Oil lubrication 6.6.1 Oil lubrication WARNING Skin damage due to contact with oil. Oil can cause a rash if it comes into contact with skin. Avoid any skin contact with the oil. If oil gets on your skin, wash the affected areas thoroughly. CAUTION Risk of environmental damage from oil. Oil is a pollutant and must not enter the sewage system or the soil. Carefully collect waste oil and dispose of the waste oil and oil-contaminated machine parts in the legally prescribed manner.
Setting up DA 10 can be obtained from DÜRKOPP ADLER AG sales offices using the following part number: • 250 ml container: 9047 000011 • 1 liter container: 9047 000012 • 2 liter container: 9047 000013 • 5 liter container: 9047 000014 The sewing unit is equipped with a central oil-wick lubrication system. The bearings are supplied from the oil reservoir (1).
Setting up 6.7 Commissioning Conduct a sewing test before starting up the machine. Adjust the machine to the requirements of the material to be sewn. To do this, read the corresponding sections in the Operating instructions. Read the corresponding sections in the Service manual in order to make adjustments to the machine if the sewing results do not conform to the requirements. WARNING Risk of injury by the needle point or moving parts.
Settings via the software 7 Settings via the software The controller is operated via the operating terminal (1) at the automatic material feeder. Figure 37: Operating terminal ① (1) - Operating terminal The operating terminal contains a touch-sensitive screen (touchscreen). Buttons and elements are displayed on the touchscreen. A command is executed by touching a button or an element. Activating a button/selecting an element • Touch the corresponding button or element.
Settings via the software 7.1 Structure of the software The software allows the creation and management of seam programs and sequences. During sewing, these programs are called up and processed stitch for stitch. The software is also used to define general settings that apply to all programs. The software also includes technical menu items for testing and maintaining the machine. Seam program A seam program consists of a seam contour with parameters defining the individual contour sections.
Settings via the software 7.2 Overview of the menu structure The following table provides an overview of the menu structure and the function buttons on the main screen. Different colors indicate which functions are mainly used for normal sewing operations, which items are used for creating and maintaining seam programs and the menu items that are used for making technical settings.
Settings via the software Buttons on the main screen Button Function Submenu items Described on Continue sewing the contour from a particular point Repair mode page 78 Define announcement of the bobbin change. The thread consumption is set in meters for this. Bobbin change page 77 Reset counter to a particular value Reset counter page 78 7.
Settings via the software The main screen The main screen is displayed during sewing. When the machine is started the main screen is opened with the settings of the last sewing program used.
Settings via the software Arrow keys (5) for navigating within the bar With the arrow keys (5) on the right, you can move additional seam programs into the visible bar area. Button for resetting the counter (6) This button can be used for resetting the counter for the sewn programs or sequences. The current counter value is displayed in this button. Button for bobbin change (7) This button is used to inform the system that a new bobbin has been inserted (e.g. after a color change).
Settings via the software 7.4 Basic functions for using the software 7.4.1 Entering a password Depending on the settings, a password is only required for accessing the technical menus or is required every time the machine is started. Figure 40: Entering a password ① ② (1) - Data entry field (2) - Numeric buttons Entering a password 1. Use the numeric buttons (2) to enter the password. Password settings can be carried out in the Extras menu ( page 105).
Settings via the software 7.4.3 Display principles Figure 41: Activated and deactivated elements ② ① (1) - Grayed-out: Deactivated element (2) - Dark background: Activated element The currently activated or selected element is highlighted with a dark background (2). Buttons that are not used in the current context are grayed-out (1). 7.4.
Settings via the software 7.4.5 Selecting options from a list When selecting options, a distinction is made between round option buttons and square checkboxes Selection with option buttons Figure 43: Selection with option buttons ① (1) - Option buttons: Selected element With round option buttons you can only select one of the displayed options. • Tap the desired option. The selected option (1) is marked with a dot.
Settings via the software 7.4.6 Using file filters When opening, copying or deleting seam programs or sequences, a list of all available files is displayed. You can use the filter functions to make the list more manageable: 1. Tap the File Filter button under the list. The file filter screen opens. Figure 45: File filter 2. Tap the desired filter criterion: • .fnp911: Seam programs only • .seq911: Sequences only • All Files: Seam programs and sequences 3. Tap the Open button.
Settings via the software 7.4.7 Entering text A text entry window is displayed when you need to enter text, e.g. for the name of a program. Figure 46: Text entry window ① ⑤ ② ④ ③ (1) - Data entry field (2) - Keyboard (3) - OK button: Adopt the entered text (4) - Del: Delete a character (5) - Aa: Switch between uppercase/lowercase Write text • Use the keyboard (2) to enter the text. Switch between uppercase/lowercase • Tap the Aa (5) button. Delete the last character • Tap the DEL (4) button.
Settings via the software 7.4.8 Entering parameter values A numeric entry window opens when you need to enter numeric values for program or machine parameters. Figure 47: Numeric entry window ① ② ③ ④ ⑤ ⑥ (1) - Title bar (2) - Status bar (3) - Symbol (4) - Value range (5) - Data entry field (6) - Numeric buttons The title bar (1) shows the parameter group. The status bar (2) shows the name of the parameter currently being edited. The symbol (3) of the parameter is displayed below.
Settings via the software 7.4.9 Switching the full-screen display on and off In order to see the seam contour in more detail you can switch the main window to occupy the full screen and hide the buttons at the right side of the main screen. Figure 48: Switching the full-screen display on and off ① ② (1) - Full-screen switched off (2) - Full-screen switched on 1. Tap the menu items Extras > Full-screen on/off. The display switches to the respective other mode. 7.4.
Settings via the software 7.5 Opening a seam program or sequence for sewing The stored seam programs or sequences frequently need to be opened for sewing. 1. Tap the menu items File > Open in the main window. The selection window appears. All seam programs and sequences are displayed. Using File filter, you can limit the selection and make the list more manageable ( 7.4.6 Using file filters, page 70). Figure 50: Opening a file 2. Tap the desired file. 3. Tap the Open button.
Settings via the software 7.6 Briefly sewing with modified values If you must briefly sew a special material, or use a particular thread strength with different values, without changing the seam program you can use the Correction menu item to temporarily change the values for thread tension and sewing speed. The values then apply to all subsequently executed seams. The values are deleted when the machine is switched off.
Settings via the software 7.6.2 Sewing with a modified sewing speed 1. Tap the menu items Correction > Sewing Speed. The window for changing the thread tension appears: Figure 52: Sewing with a modified sewing speed 2. Enter the desired speed. 3. Tap the OK button. The value is adopted and used for all seams until the machine is switched off. 76 Operating instructions 906 - Version 00.
Settings via the software 7.7 Replacing the hook thread bobbin The machine automatically detects when the hook thread has been used up and a new bobbin needs to be inserted. In this case, or when a thread breakage occurs, the Manage Thread Breakage window is automatically displayed. Figure 53: Managing a thread breakage 1. Tap the Change Bobbin button. 2. Changing the bobbin ( 5.10 Replacing the hook thread bobbin, page 34). WARNING Risk of injury by the needle point or moving parts.
Settings via the software 7.8 Continuing a seam in Repair mode after an error In Repair mode, you can move to any desired point on the contour. E.g. in order to continue the seam program from this position after an error has occurred. 1. Tap the Repair mode button on the main screen. The Repair mode window is displayed. Figure 54: Repair mode 2. Use the Forwards and Back buttons to move to the point where sewing is to continue. 3. Tap the Continue Sewing button.
Settings via the software 7.10 Creating a new seam program ATTENTION The machine can be damaged by sewing without material. Place the material under the inner slider and outer frame prior to creating the seam program. A new seam program is created using a teach-In procedure. Individual seam paths with specific seam parameters are defined via the operating terminal in order to do this. 1. Tap the menu items File New Seam Program. The teach-In window is displayed.
Settings via the software Selecting the line type 4. Use the line selection buttons (7) to select the type of line to be defined. • Seamless path The clamp moves over this path to the next position without sewing. • Straight seam A straight seam is sewn. • Curved seam A curved seam is sewn. After tapping the button for a straight or curved seam the corresponding window for entering the seam parameters for this path opens.
Settings via the software Seam parameters for teach-In Button Meaning Speed Stitch length Thread tension Stroke height Cut thread Drawing a path 7. Use the arrow buttons to move the cursor to the end point of the desired path. Alternatively, you can tap an arrow button once in order to define the direction and then continue moving in this direction by pressing the pedal. Important: Take care to ensure that the contour remains within the permissible sewing field of your particular sewing unit.
Settings via the software Saving the program After you have defined all the seam paths, you can save the program and specify a name. 9. Tap the Save... button. The window for entering the program name opens. 10.Enter the desired name and adopt the change by pressing OK. 7.4.7 Entering text, page 71 The program is now available under this name for sewing, editing or copying. Important: After creating or changing a program, perform a contour test ( 7.11 Performing a contour test, page 83).
Settings via the software 7.11 Performing a contour test After creating or changing a program or changing a seam contour, perform a contour test. Ensure that the contour lies within the limits of your particular unit by performing a contour test. Checking a contour 1. Lay the material under the transfer plate and lower the transfer plate by using the foot pedal. 2. Tap the menu items Edit > Seam program > Contour test. The Contour test window opens. Figure 57: Contour Test 3. Use two-hand control. 4.
Settings via the software 7.12 Create a sequence You can combine up to 30 seam programs to form a sequence. You can create up to 20 sequences. Select the seam program 1. Tap the menu items File New Sequence. The window for selecting the seam programs appears. Figure 58: Select the seam programs for the sequence All existing seam programs are listed in the Seam programs field. The Sequence field shows the seam programs that are allocated to the sequence. 2.
Settings via the software 7.13 Edit an existing sequence You can edit an existing sequence by adding or removing seam programs. Figure 59: Editing an existing sequence 1. Tap the menu items File > Open in the main window ( page 74). The sequence is opened in the main screen. 2. Tap the menu items Edit > Sequence. The window for editing the sequence appears. 3. Add programs to the sequence using the Insert button or remove from the sequence using the Delete button.
Settings via the software 7.14 Saving a seam program or sequence under a different name You can save a seam program or sequence under a different name. To create a new program, you can use a similar, already-existing program as a template. You can save the existing program under a new name and change the respective details. 1. Tap the menu items File > Save As. A selection window allowing you to select a seam program or sequence is displayed. You can limit the selection with File filter.
Settings via the software 7.15 Copying a seam program or sequence You can also copy seam programs or sequences from a USB stick to the controller or from the controller to a USB stick. Not all commonly available USB sticks are suitable for the copying process. You can obtain a suitable USB stick from Dürkopp Adler using the order number 9805 791113. Select the file 1. Tap the menu items File > Copy. The window for selecting the file to be copied appears.
Settings via the software 7.16 Deleting a seam program or sequence Seam programs or sequences that are no longer required can be deleted from the controller. Figure 61: Deleting a seam program or sequence 1. Tap the menu items File > Delete. The window for selecting the file to be deleted appears. You can limit the selection with File filter. This makes the list more manageable ( 7.4.6 Using file filters, page 70). 2. Tap the desired file. The selected file is highlighted with a dark background. 3.
Settings via the software 7.17 Editing an existing seam program You can change the contour and parameters of existing seam programs. The changes are applied to the seam program that is currently open on the main screen. Selecting the program to be edited 1. Open the sequence you wish to modify via the menu items File > Open ( page 74). The program is opened in the main screen. 7.17.1 Adjusting a contour 1. Tap the menu items Edit > Seam program > Adjust Contour.
Settings via the software Figure 63: Contour adjustment – Part 2 ① (1) - Stitching point to be changed 4. Use the arrow keys to select the stitching point (1) to be changed. 5. Tap the Go To button. The window for changing the seam path is displayed. Figure 64: Contour adjustment – Part 3 ② ① (1) - Green: New stitching point (2) - Red: Old stitching point 6. Use the arrow buttons to move the stitching point to the new position (1). The modified seam path is displayed in green. 7.
Settings via the software Figure 65: Contour adjustment – Part 4 Define technology operations for the new seam path (optional): • Tap the New button: Open the Technology operations window. • OK button: Save and exit contour adjustment (continue with step 10). Select technology operations Figure 66: Technology operations 8. Select the desired technology operations for the new seam path ( 7.4.5 Selecting options from a list, page 69). 9. Confirm the selection with OK.
Settings via the software 10.Tap the OK button. A query appears to accept the changes. When you confirm, the modified contour will be saved. Important: After creating or changing a program, perform a contour test ( 7.11 Performing a contour test, page 83). Ensure that the contour lies within the limits of your particular unit.
Settings via the software 7.17.2 Changing the parameters You can also change the general settings that apply to the entire seam program. 1. Tap the menu items Edit > Seam program > Parameters. The window for selecting the program parameter group is opened. Figure 67: Selecting the program parameter group 2. Tap the desired parameter group. The individual parameters of this group are displayed. 3. Tap the desired parameter. The window for modifying the parameter opens. 4.
Settings via the software There are 8 program parameter groups: Symbol Parameter group PP1 - Configuration General settings PP2 - Insertion mode Insertion mode and position PP3 - Removal mode Removal mode and position PP4 - Softstart Number of stitches and speed PP5 - Needle thread monitor Sensitivity value for the needle thread monitor PP6 - Thread consumption Values for determining thread consumption PP7 - Offset Contour is offset in a particular direction PP8 - Scaling: The size of the contour is chang
Settings via the software Symbol Meaning Needle reversing mode The following options can be set: Not active: The needle remains at the Stop position. After the entire contour: After completing all seams in the contour the needle is reversed to the value specified in the machine parameters. After every seam (Def.): The needle is reversed after every seam. Needle cooling (On/Off) Activates/deactivates the needle cooling. Adjust sewing speed (min. = 10 .. max. = 200; Def.
Settings via the software PP2 - Insertion mode Symbol Meaning Insertion mode The following options can be set: Mode 1 (Def.) Standard sewing mode with transfer of the material. In the insertion position, the outer frame, inner slider and transfer plate are open. The sewing procedure runs in the following sequence: • Use foot pedal: The transfer plate is closed. • Use two-hand control: The material is transferred to the outer frame/inner slider and the sewing starts.
Settings via the software PP3 - Removal mode Symbol Meaning Removal mode The following options can be set: Mode 1 (Def.) Stacker active. Mode 2 Reserved (function as with Mode 1) Mode 3 Reserved (function as with Mode 1) Mode 4 Reserved (function as with Mode 1) Mode 5 Stacker inactive. Removal position (On/Off) With the removal position activated the clamps move to the desired position for convenient removal of the sewing material after the sewing procedure.
Settings via the software PP5 - Needle thread monitor (min. = 0 .. max. = 99; Def. = 5) Is only active if activated in the machine parameters. (A higher value makes the needle monitor less sensitive. 99 = Needle thread monitor switched off in this program only.) PP6 - Thread consumption Symbol Meaning Material thickness (min. = 0 .. max. = 20.0; Def. = 0) The thickness of the sewing material when pressed together. Material consumption adjustment (min. = -10.0 .. max. 10.0; Def. 0.
Settings via the software PP8 - Scaling. Symbol Meaning X scaling (min. = 80 .. max. = 120; Def. = 100 %) 100% corresponds to the original size. Y scaling (min. = 80 .. max. = 120; Def. = 100 %) X scaling origin (min. = -150.0 .. max. = 150.0; Def. = 0.0 mm ) Y scaling origin (min. = -150.0 .. max. = 150.0; Def. = 0.0 mm ) Operating instructions 906 - Version 00.
Settings via the software 7.18 Editing machine parameters You use the machine parameters to define the basic machine settings that apply to all programs. 1. Tap the menu items Edit > Machine parameters. The window for selecting the machine parameter group is displayed. Figure 68: Select the machine parameter group 2. Tap the desired parameter group. The individual parameters of this group are displayed. 3. Tap the desired parameter. The window for modifying the parameter value opens. 4.
Settings via the software Overview of the individual machine parameters MP1 - Configuration Symbol Meaning Needle cooling The following options can be set: None: No type of needle cooling is active. Air cooling (Def.): The needle is cooled with air while sewing the seam. Ice cooling: Optional equipment. Foot mode The foot can be operated in the following modes: Hopper (standard mode): The foot only presses on the sewing material while the needle is in the sewing material.
Settings via the software MP2 - Limit values Symbol Meaning Max. speed (min. = 500 .. max. = 3000; Def. =2700 rpm) All sewing programs are limited to this maximum speed. Max. run-empty speed (min. = 10 .. max. = 100; Def. = 100 %) Limits all clamp movements of the outer frame/inner slider between the seams to this value. Transport start angle (min. = 30 .. max. = 350; Def. = 210 °) The movement of the outer frame/inner slider during the stitch starts at this angle of needle motion. Transport phase (min.
Settings via the software Symbol Meaning Bobbin change Y position The value range varies depending on the subclass and sewing field size. MP4 - Thread cutting Symbol Meaning Cutting speed (min. = 70 .. max. = 500; Def. =180 rpm) Speed of the cutting stitch. Cutting position on (min. = 0 .. max. = 359; Def. = 180 °) Angular position of the needle at which the thread cutting knife is switched on. Cutting position off (min. = 0 .. max. = 359; Def.
Settings via the software MP6 - Counters Symbol Meaning Counter type The following options are available: Piece counter increments (Def.) The counter is incremented after each sewn program. Piece counter decrements The counter is decremented after each sewn program. Sequence counter increments The counter is incremented after each sewn sequence. Sequence counter decrements The counter is decremented after each sewn sequence. Reset value for the counters (min. = 0 .. max. 9999; Def.
Settings via the software 7.19 Checking and changing the technical settings The technical settings are made via the menu item Extras > Service. Figure 69: Technical menu items A password must always be entered in order to access the menu items in Extras > Service ( 7.4.1 Entering a password, page 67). 7.19.1 Adjust the contour data Password options Certain areas are protected from direct access and can only be reached through a password.
Settings via the software Defining the operating password protected areas 1. Tap the menu items Extras > Service > Settings. The Settings window opens. 2. Tap the Operator Password option in this window.
Settings via the software Testing the touchscreen You can use the Extras > Service > Settings menu item to check that the touchscreen is functioning correctly over all areas of the screen. 1. In the menu item Extras > Service > Settings tap the Control panel settings option. 2. In the following window tap the Touch Test option. An empty window is opened. 3. Use your finger to tap various different points or draw lines.
Settings via the software 2. Tap the desired symbol. Symbol Meaning Controller events List of the latest errors Log settings Only for Dürkopp Adler Service personnel Log display List of the last log settings Only for Dürkopp Adler Service personnel Control panel status Status appears in the log display Only for Dürkopp Adler Service personnel 7.19.
Settings via the software Testing inputs and outputs This manual only provides an overview of the test possibilities. The tests may only be performed by qualified personnel that have received training from Dürkopp Adler. WARNING Risk of injury from sharp or moving parts. Do reach into the machine during function testing of the input or output elements. 1. In the Extras > Service > Multitest menu item, tap the test Inputs/outputs option. The IO Test Page window is displayed.
Settings via the software Input elements No.
Settings via the software Output elements No.
Settings via the software Testing the sewing motor WARNING Risk of injury from sharp or moving parts. Do reach into the machine during function testing of the input or output elements. 1. In the menu item Extras > Service > Multitest tap the Test sewing motor option. The sewing motor test screen is displayed: Figure 73: Testing the sewing motor Important: Remove the thread from the needle and needle lever before starting the test. 2. Tap the button. The window for entering the sewing speed opens.
Settings via the software 8. Tap the button. The sewing motor runs at the entered sewing speed. 9. Tap the button. The sewing motor stops and the thread cutter is actuated. Setting stroke position WARNING Risk of injury from sharp or moving parts. Do not reach into the machine when setting the stroke position. Switch off the power to the drive when you wish to test the freedom of motion of the sewing foot rod. 1. In the menu item Extras > Service > Multitest tap the Set stroke position option.
Settings via the software Calibrate thread tension 1. In the menu item Extras > Service > Multitest tap the Thread tension option. Figure 74: Calibrating thread tension The Calibrate thread tension function is only intended for use by Dürkopp Adler Service personnel. Detailed information can be found in the 906 servicing instructions. 114 Operating instructions 906 - Version 00.
Settings via the software 7.19.4 Initializing the controller, performing updates You can use Extras > Service > Initialization and Update to reset the controller and control panel to the factory defaults and to update the controller with a new software version. 1. Tap the menu items Extras > Service > Initialization and Update. The screen for initialization and update appears.
Settings via the software Updating the controller The latest software version is available in the download area at www.duerkopp-adler.com. You can easily transfer a new software version from a USB stick to the controller. Not all commonly available USB sticks are suitable for the copying process. You can obtain a suitable USB stick from Dürkopp Adler using the order number 9805 791113. 1. Switch off the machine. 2. Insert the USB stick into the USB connector (1) on the operating terminal.
Settings via the software Displaying software version information The menu item ? displays information on the software currently installed on the machine. Figure 77: Software version ① (1) Menu info 1. Tap menu items ? > Info (1). The following information is displayed: • Class • Subclass • Date of creation of this software version Operating instructions 906 - Version 00.
Settings via the software 118 Operating instructions 906 - Version 00.
Error and information messages 8 Error and information messages 8.
Error and information messages Error code 2153 120 Description Remedy X-axis stepper motor overvoltage • Mains voltage too high • Checking the mains voltage 2155 X-axis stepper motor overload • Correct the cause of not moving • Transport system not moving freely freely • Obstacle to transport motion • Remove obstacles/adjust the motion 2156 X-axis stepper motor overtemperature • Stepper motor not moving freely • Remove the cause of the lack of • Stepper motor defective freedom of motion • Controll
Error and information messages Error code Description Remedy 2353 Stroke position stepper motor overvoltage • Mains voltage too high • Checking the mains voltage 2355 Stroke position stepper motor overload • Transport system not moving freely • Correct the cause of not moving • Obstacles to the transport motion freely • Remove obstacles/adjust the motion 2356 Stroke position stepper motor overtemperature • Transport system not moving freely • Correct the cause of not moving • Stepper motor defectiv
Error and information messages Error code Description Remedy 4201 Internal CF card defective • Switch the machine off and on again • Retrofit/replace controller 5301 Program cannot be sewn Copy program to DAC 6551 Error in upper part position/AD converter/process error • Switch the machine off and on again • Software update Internal error • Notify DA Service Stepper motor driver error Internal error • Switch the machine off and on again • Software update • Notify DA Service 6554 6651 6653 6
Error and information messages 8.2 Information messages Informati Description on code Remedy 8400 Control panel has no valid program for the DAC Load the current program into the control panel from a USB stick. 8401 8402 Control panel has no valid program for the DAC Load the current program into the control panel from a USB stick. 8403 Program in DAC is no longer cur- Load the current program into the rent. DAC. 8404 DAC update failed.
Error and information messages 124 Operating instructions 906 - Version 00.
Creating programs with DA CAD 5000 9 Creating programs with DA CAD 5000 You can use the DA CAD 5000 program to create seam programs on a PC. The DA CAD 5000 program is available as additional equipment 2.3 Additional equipment, page 12. This manual only provides an overview of the program steps. A detailed description is provided in the Operating instructions for the DA CAD 5000 program. Selecting the machine class The first step is to select the machine class.
Creating programs with DA CAD 5000 Saving the seam contour Figure 80: Saving the seam contour The final step is to save the finished seam program and copy it to a USB stick. Not all commonly available USB sticks are suitable for the copying process. You can obtain a suitable USB stick from Dürkopp Adler using the order number 9805 791113. 1. Select the menu items Data transfer > USB memory stick > Save (PC->>USB).
Decommissioning 10 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. 10.1 Decommissioning the machine 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.
Decommissioning 10.2 Dismantling the automatic stacker The dismantling of the automatic stacker is optional. However, it could be necessary to dismantle it for transport or space-saving storage. WARNING Risk of injury. The automatic stacker is heavy and has bulky dimensions. Carry out the dismantling with two people in order to avoid back injuries or crushing injuries if the machine falls down.
Decommissioning 6. Loosen both setscrews (1) but do not remove them (screwdriver width 5 mm). 7. Remove six threaded screws (2) (screwdriver width 10 mm) and cover plate (3). 8. Remove the automatic stacker from the bracket, rotate 180° (the protective bar is at the bottom) and carefully put aside. Operating instructions 906 - Version 00.
Decommissioning 130 Operating instructions 906 - Version 00.
Packaging, transportation 11 Packaging, 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. 11.1 Fitting the transport locks ATTENTION Possible machine damage through unsecured transport. Never transport the machine without the transport locks. Transport locks must be fitted in order to protect the machine from damage during transport. 11.
Packaging, transportation 11.3 Packing the machine WARNING Risk of injury due to own weight and packaging materials. Contact with the packaging materials without wearing appropriate protective clothing can result in serious injuries. ALWAYS wear gloves and safety shoes when packing the machine. ALWAYS watch out for sharp edges on clamps, paper and packing straps. Pack the machine so that it cannot slip or fall over. Use a stable base and fasten the machine to this.
Disposal 12 Disposal The customer is responsible for disposal of the machine and packaging materials. The machine must not be disposed of via the normal household waste. The machine must be disposed of in an appropriate and proper manner according to national regulations. CAUTION Risk of environmental damage due to incorrect oil disposal. Improper disposal of the machine can result in serious environmental damage. Follow the statutory rules in regard of disposal.
Disposal 134 Operating instructions 906 - Version 00.
Appendix 13 Appendix Operating instructions 906 - Version 00.
Appendix 136 Operating instructions 906 - Version 00.
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Original Instructions - 0791 906740 EN - 00.0 - 05/2014 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.
