Manual Durkopp Adler 550-767 (page 3 of 66) (English)

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550-767

Gestalteter Arbeitsplatz für

Seitenairbag - Sollreißnaht

Engineered work station for

side airbag tearing seam

Bedienanleitung / Operating instructions

Aufstellanleitung / Installation instructions

Postfach 17 03 51, D-33703 Bielefeld  Potsdamer Straße 190, D-33719 Bielefeld Sprache: D/ GB

Telefon +49 (0) 5 21/ 9 25-00  Telefax+49(0)521/9252435 www.duerkopp-adler.com

Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:

10/2007 Rev. index: 01.0 Printed in Federal Republic of Germany 0791 550034

Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise

Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG

verboten.

Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner,

even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.

Dürkopp Adler AG - 2007

Übersicht Summary

Bedienanleitung

Aufstellanleitung

Serviceanleitung (0791 767651)

Bauschaltplan

9890 550004 B

Operating Instructions

Installation Instructions

Service Instructions (0791 767651)

Interconnection-diagram

9890 550004 B

Foreword

This instruction manual is intended to help the user to become familiar

with the machine and take advantage of its application possibilities in

accordance with the recommendations.

The instruction manual contains important information on how to

operate the machine securely, properly and economically. Observation

of the instructions eliminates danger, reduces costs for repair and

down-times, and increases the reliability and life of the machine.

The instruction manual is intended to complement existing national

accident prevention and environment protection regulations.

The instruction manual must always be available at the machine/sewing

unit.

The instruction manual must be read and applied by any person that is

authorized to work on the machine/sewing unit. This means:

– Operation, including equipping, troubleshooting during the work

cycle, removing of fabric waste,

– Service (maintenance, inspection, repair) and/or

– Transport.

The user also has to assure that only authorized personnel work on the

machine.

The user is obliged to check the machine at least once per shift for

apparent damages and to immediatly report any changes (including the

performance in service), which impair the safety.

The user company must ensure that the machine is only operated in

perfect working order.

Never remove or disable any safety devices.

If safety devices need to be removed for equipping, repairing or

maintaining, the safety devices must be remounted directly after

completion of the maintenance and repair work.

Unauthorized modification of the machine rules out liability of the

manufacturer for damage resulting from this.

Observe all safety and danger recommendations on the machine/unit!

The yellow-and-black striped surfaces designate permanend danger

areas, eg danger of squashing, cutting, shearing or collision.

Besides the recommendations in this instruction manual also observe

the general safety and accident prevention regulations!

General safety instructions

The non-observance of the following safety instructions can cause

bodily injuries or damages to the machine.

1. The machine must only be commissioned in full knowledge of the

instruction book and operated by persons with appropriate training.

2. Before putting into service also read the safety rules and

instructions of the motor supplier.

3. The machine must be used only for the purpose intended. Use of

the machine without the safety devices is not permitted. Observe all

the relevant safety regulations.

4. When gauge parts are exchanged (e.g. needle, presser foot, needle

plate, feed dog and bobbin) when threading, when the workplace is

left, and during service work, the machine must be disconnected

from the mains by switching off the master switch or disconnecting

the mains plug.

5. Daily servicing work must be carried out only by appropriately

trained persons.

6. Repairs, conversion and special maintenance work must only be

carried out by technicians or persons with appropriate training.

7. For service or repair work on pneumatic systems, disconnect the

machine from the compressed air supply system (max. 7-10 bar).

Before disconnecting, reduce the pressure of the maintenance unit.

Exceptions to this are only adjustments and functions checks made

by appropriately trained technicians.

8. Work on the electrical equipment must be carried out only by

electricians or appropriately trained persons.

9. Work on parts and systems under electric current is not permitted,

except as specified in regulations DIN VDE 0105.

10. Conversion or changes to the machine must be authorized by us

and made only in adherence to all safety regulations.

11. For repairs, only replacement parts approved by us must be used.

12. Commissioning of the sewing head is prohibited until such time as

the entire sewing unit is found to comply with EC directives.

13. The line cord should be equipped with a country-specific mains

plug. This work must be carried out by appropriately trained

technicians (see paragraph 8).

It is absolutely necessary to respect the safety

instructions marked by these signs.

Danger of bodily injuries !

Please note also the general safety instructions.

Contents Page:

Preface and general safety instructions

Part 1: Operating Instructions, Class 550-767

(Edition: 10.2007)

1. Items delivered .............................................. 5

2- Designated use .............................................. 5

3. Equipment

3.1 Basic equipment .............................................. 6

3.2 Additional equipment ........................................... 6

4. Technical data ............................................... 7

5. Operation

5.1 Threading the needle thread ....................................... 8

5.2 Adjusting the needle thread tension .................................. 10

5.3 Opening the needle-thread tension ................................... 11

5.4 Winding on the hook thread ....................................... 12

5.5 Threading the bobbin thread ....................................... 13

5.6 Adjusting the bobbin thread tension .................................. 13

5.7 Replacing the needle ........................................... 14

5.8 Liftingandlockingthesewingfeet ................................... 15

5.9 Adjustingthesewing-footstroke..................................... 16

5.10 Sewing-footpressure........................................... 16

5.11 Adjusting the stitch length ........................................ 17

5.12 Buttonsonsewingarm .......................................... 17

5.13 RFW 13–3 bobbin thread monitor .................................... 18

5.14 HP 13–10 electro-pneumatic rapid stroke adjustment ........................ 20

6. Operating the rupture-seam visualisation facility

6.1 Accesstothesystem ........................................... 21

6.1.1 Advice for the production begin ..................................... 24

6.2 Seam-typefunction ............................................ 25

6.2.1 Createanewseamtype ......................................... 25

6.2.2 Editseamtype ............................................... 30

6.2.3 Copyseamtype .............................................. 31

6.2.4 Deleteseamtype.............................................. 32

6.3 Database function ............................................. 33

6.4 Checkfunction............................................... 35

6.5 Needle-thread tension tolerance range ................................. 48

6.6 Error codes ................................................. 50

6.7 Setting the end-label barcodes ..................................... 51

6.8 Setting the end-label layouts ....................................... 54

6.9 Adjustingbarcodedefinitions ...................................... 55

7. Sew ing

7.1 Label scanner (optional) ......................................... 62

8. Maintenance

8.1 Cleaning ................................................... 63

8.2 Oiling..................................................... 64

1. Product description

The DÜRKOPP ADLER class 550-767 is an engineered sewing station

with the following features:

flat-bed double-lockstitch sewing machine with underfeed, needle

feed and alternating-foot overfeed.

single-needle machine with thread cutter under the throat plate.

apparatus slide in the base plate for the rapid change of different

apparatus.

maximum clearance of 16 mm under the sewing feet when raised.

stroke of alternating sewing feet adjustable to a

maximum of 7mm by programming function.

automatic, unpressurised oil-recirculating lubrication with sight

glasses for oil level and circulation inspection,

hook lubrication integral to the circulation.

large two-piece vertical hook with bobbin-housing lift.

safety coupling to avoid displacing or damaging the hook if the

thread gets jammed in the hook track.

2. Designated use

The class 550—767 machine is an engineered sewing station designed

for sewing light to medium-heavy material. Such material is generally

made of textile fibres, but it may also be leather. It is used in the

clothing industry and for domestic and motor-vehicle upholstery.

This sewing machine can also be used to produce so-called technical

seams. In this case, however, the operator must assess the possible

dangers which may arise (with which DÜRKOPP ADLER AG would be

happy to assist), since such applications are on the one hand relatively

unusual and, on the other, they are so varied that no single set of

criteria can cover them all. The outcome of this assessment may

require appropriate safety measures to be taken.

Generally only dry material may be sewn with this sewing unit. The

material may be no thicker than 10 mm when compressed by the

lowered sewing feet. The material may not contain any hard objects,

since if it does the machine may not be operated without an

eye-protection device. No such device is currently available.

The seam is generally produced with textile-fibre sewing thread of up

to gauge 11/3 NeB (cotton), 11/3 Nm (synthetic) or 11/4 N m (covered

yarn). Before using any other thread the possible dangers arising must

be assessed and appropriate safety measures taken if necessary.

This sewing unit may be set up and operated only in dry,

well-maintained premises. If the sewing machine is used in other

premises which are not dry and well-maintained it may be necessary to

take further precautions (which should be agreed in advance

– see EN 60204-31: 1999).

As manufacturers of industrial sewing machines we proceed on the

assumption that personnel who work on our products will have

received training at least sufficient to acquaint them with all normal

operations and with any hazards which these may involve.

3. Equipment

3.1 Basic equipment

The class 550—767 sewing unit is supplied w ith the following basic

equipment:

RAP 13-2 Electro-pneumatic bar tack and sewing-foot lift,

foot-operated.

HP 13-10 Electro-pneumatic rapid stroke adjustment by

knee switch (switch and touch operation) to maximum

stroke height with simultaneous stitch-rate limit.

Automatic infinitely-variable stitch-rate limit as a

function of the stroke height set.

RFW 13-3 residual-thread monitor

798 500088 Sewing light transformer

907 487519 Mounting kit for sewing light

9822 510001 Sewing lamp (halogen)

3.2 Additional equipment

The following additional equipment can be supplied for the ?class

550-767 sewing unit:

0467 367959 pneumatic needle-cooling unit NK 13-1

0767 590129 Uninterruptible power supply 230 V/1000 A

0767 100134 DS 2200-1100 5 V barcode scanner for end-label

recognition

0767 490214 DS 2200-1100 5 V barcode scanner for

hook thread recognition

0767 490224 DS 2200-1100 5 V barcode scanner for

needle thread recognition

9800 330010 Operating panel EFKA V820

4. Technical data

Stitch type: 301 / double lockstitch

Number of needles: 1

Needle system: 134-35

Needle size

: 110-170 Nm

Thread thicknesses

- Cotton: 12/3 NeB

- Synthetic sewing thread: 11/3 Nm?

- Covering thread: 11/3 Nm

Bobbin capacity

with synthetic sewing thread

- 30/3 max. 35 m

- 11/3 max. 12 m

Stitch rate

- equipment with HP: max. 3500 min-1

- on delivery: 3200 min-1

Stitch length

:0-9mm

Stroke height of sewing feet: max. 7 mm

(on delivery): 6 mm

Clearance under sewing feet

- Sewing: 7 mm

- Raised: 16 mm

Handwheel groove (average diameter): 80 mm

Operating pressure: 6 bar

Air consumption: approx. 0.7 Nl per

working cycle

Nominal voltage: 1~ 190-240 V, 50/60 Hz

Input power: 1 kVA

Dimensions (including PC table): 2100 x 1150 x 1500 mm

Working height : 685-1085 mm

(to upper edge of table plate)

Weight (head only): approx. 60 kg

Workplace-related emission value to D IN 45635-48-A-1-KL2:

Lc = 83 dB (A)

Stitch length: 5.0 mm, sewing-foot stroke: 1.6 mm, stitch rate: 2 500 min

-1

material G1 DIN 23328 4-ply

Lc = 80 dB (A)

Stitch length: 7.2 mm, sewing-foot stroke: 5.6 mm, stitch rate: 1.500 min

-1

material 2-ply Skai 1.6 mm 900 g/m2 DIN 53352

accordingtoENo.

depends on stitch length and stroke height of the sewing feet

5. Operation

5.1 Threading the needle thread

CAUTION: DANGER OF INJURY!

Turn off the main switch!

The needle thread may only be threaded with the machine turned off.

Versions with switch 2:

Before placing the needle-thread cones on the s tand they must be

scanned by the manual scanner. If a needle-thread bobbin is removed,

this is recognised by the control via switch 2 and the scanning process

is to be repeated.

Version w ith optional thread-barcode scanner:

–

Place the thread bobbin on the stand while ensuring that the

barcode of the thread bobbin can be read by the optional

thread-barcode scanner.

If the barcode is not recognised by the scanner, an error message

will be displayed on the monitor.

–

Open and fold back cover 1.

–

Pass the thread through guide 7 and anti-clockwise around

prethread-tensioning spring-tensioner 8. Pass the thread through

guide 7 again.

–

Pass the thread around guide 10 and then anti-clockwise around

the main tensioner 9. Pass the thread clockwise around main

tensioner 11.

–

Pass the thread clockwise around the thread tensioning unit 4, past

the check spring 3 and through the guide 2.

–

Pass the thread through take up lever 1 and through guides 2, 5

and 6.

–

Pass the thread through the needle; pull out several c entimetres of

thread and cut.

–

Pass the needle thread through the needle from the right, pull out a

few centimetres of thread and cut.

HINT

The needle thread can be threaded without opening cover 1 by tying

the new needle thread to the residual needle thread and pulling it

through the thread tensioner.

5.2 Adjusting the needle thread tension

The tension must be set according to the requirements of the

manufacturer of seat-covers. The cross-over point should be in the

centre of the material.

–

Adjust the pre-tension 1. The pre-tensioning should be set lower

than at the main tensioners 2 and 3.

–

Adjust the main tension 2 and 3.

–

Adjust the tolerance range 4 (window) for seam monitoring via the

Touch Screen Monitor.

–

0 = monitoring deactivated.

Hint

The required thread tension is set via the “ELTEX” menu. See section

6.5: Needle-thread tension tolerance range.

5.3 Opening the needle-thread tension

The needle-thread tension is automatically opened when the thread is

cut.

–

Press button 2 manually or press down the upper right-hand corner

of cover 1. The needle-thread tension remains opened for as long

as the button or c over is held down.

5.4 Winding on the hoo thread

CAUTION:

Only special bobbins suitable for this type of machine may be used!

The matt side of the bobbin

–

Place the needle-thread cone onto the thread stand.

–

Pass the needle thread through the thread guide on the take-up

arm and through pre-tensions 1 and 2 as shown in the illustration.

–

Carefully wind a few turns of thread anti-clockwise onto the reserve

groove 6 of the bobbin by hand and place the bobbin on the thread

stand with the ring 3 and the matt surface towards the operator.

–

Swivel the bobbin-winder lever 5 against the empty bobbin.

–

Enter the bobbin number via the Touch Screen Monitor.

When the bobbin is full, winding is automatically stopped by the

bobbin-winder lever 5.

Caution!

Before you press the ENTER key, please ensure that the number

entered does in fact correspond to the number engraved on the

bobbin.

–

Adjust pre-tensions 1 and 2.?

The thread should be wound on at as low a tension as possible.

5.5 Threading the bobbin thread

CAUTION: danger of injury!

Turn off the main switch!

The bobbin thread may only be threaded when the sewing machine is

switched off.

–

Raise flap 1 and remove the e mpty bobbin using a magnet.

–

Insert bobbin 2 so that it turns anti-clockwise when the thread is

drawn off.

–

Pass the thread through slit 4 and pull beneath spring 5.

–

Pass the thread through slit 6 and pull out approx. 3 cm of thread.

–

Close flap 1 and pull the thread through the guide 6 of flap 1.

–

Enter the bobbin number engraved on the bobbin 7.

CAUTION!

Before you press the ENTER key, please ensure that the number

entered does in fact correspond to the number engraved on the

bobbin.

5.6 Adjusting the bobbin thread tension

The bobbin thread tension must be adjusted in accordance with the

required seam type.

–

Adjust the tension with screw 3.

6543

5.7 Replacing the needle

CAUTION: danger of injury!

Turn off the main switch!

The needle may only be threaded and replaced when the sewing

machine is switched off.

–

Turn the handwheel until the needle bar has reached its top dead

centre.

–

Undo screw 1.

–

Remove needle.

–

Insert the new needle with its channel towards the hook and push it

up as far as it w ill go.

–

Tighten screw 1.

CAUTION:

If a needle of a different thickness is fitted the settings must ?be

altered as specified in the servicing instructions.

A thinner needle may cause faulty stitches or damage to the thread.

A thicker needle may damage the hook point itself.

5.8 Lifting and locking the sewing feet

The sewing feet can be raised mechanically or pneumatically.

Mechanical operation

–

Swivel lever 2 downwards.

Pneumatic operation

–

Push pedal 3 half-way back (first position back).

Once raised mechanically or pneumatically, the sewing feet can be

secured in raised position using lever 2.

–

Swivel lever 2 downwards.

The sewing feet are secured in the r aised position.

–

Swivel lever 2 downwards.

The sewing feet are released.

5.9 Adjusting the sewing-foot stroke

The stroke height 1 of the sewing-foot can be adjusted via the Touch

Screen Monitor in the “seam types” menu in four steps (0, 1, 2, 3).

The maximum stroke can be activated during s ewing in free seam

sections with the knee switch 2.

This function is not available in documented seam sections.

HINT!

The sewing-foot stroke and stitch rate are interdependent. The control

unit detects what foot-stroke has been set by means of a potentiometer

and restricts the stitch rate accordingly. The values are pre-set in the

control unit.

5.10 Sewing-foot pressure

The required sewing-foot pressure is set using rotary knob 3.

–

To increase the sewing-foot pressure

:turnknob3clockwise

–

To reduce the sewing-foot pressure

:turnknob3clockwise

HINT!

The sewing-foot pressure can only be altered when knob 3

(clamping block) is released: see the Servicing instructions.

5.11 Adjusting the stitch length

The stitch length is adjusted in the ”Seam types” menu on the Touch

Screen Monitor.

5.12 Buttons on sewing arm

Button 5 = intermediate lock-stitches during sewing

Button 6 = needle in high or low position

Button 7 = suppresses starting or finishing lock-stitches

Button 8 = authorises thread-cutting in the monitored region

–

Press and hold down button 5.

An intermediate lock-stitch is sewn. The machine sews backwards

for as long as the button is held down.

–

Press button 6.

The needle is raised or lowered.

–

Press button 7.

The next starting or finishing lock-stitch will not be sewn.

–

Press button 8.

The thread can now be severed in the monitored region using the

pedal. This enables the material to be removed in the event of a

fault. The program issues an error message.

56 7 8

5.13 RFW 13–3 bobbin thread monitor

The bobbin thread monitor monitors the quantity of thread on the

bobbin. A signal is issued on the PC when only a small quantity of

thread remains.

The operator can finish the seam and fit a new bobbin, thus avoiding

damage to the material and the need for repairs.

Function and operation of the bobbin thread monitor

If the light beam from the light barrier is reflected b y surface 1 on the

bobbin core during sewing, a signal is displayed on the PC and sewing

is interrupted.

–

Acknowledge the message on the PC screen.

–

Release the pedal, then push it forwards again. The seam will be

continued. The quantity of thread in reserve groove 2 of the bobbin

is normally sufficient to finish it.

–

At the end of the seam push the pedal back. The thread is cut.

–

Terminate sewing mode on the PC with “Back”.

CAUTION: danger of injury!

Turn off the main switch!

The bobbin may only be replaced with the machine turned off!

–

Replace the bobbin.

–

Reactivate sewing mode on the PC with “Sew”.

A new seam can be sewn.

CAUTION:

The bobbin must be placed in position with ring 3 downwards. The area

around the bobbin housing and light barrier must be cleaned of any

fluff!

Hint

If the empty bobbin is not replaced by a full one, the s ignal reappears

on the monitor at the end of the next s eam.

–

Wind on the bobbin thread.

The process is described in this Operating manual.

CAUTION:

When winding-on ring 3 must be at the front. Only wind the thread

around the bobbin core by hand in the area of reserve groove 2.

5.14 HP 13–10 electro-pneumatic rapid stroke adjustment

The sewing-foot stroke and stitch rate are interdependent. The control

unit detects what foot-stroke has been set by means of a potentiometer

and restricts the speed of rotation accordingly. The values are pre-set

in the control unit.

In free seam sections the maximum stroke can be activated while

sewing with knee switch 1.

CAUTION: DANGER OF INJURY!

Turn off the main switch!

The sewing-foot stroke and rocker switch may only be adjusted with

the machine turned off.

Setting the function of the knee sw itch

The function of the knee switch is activated o n the motor with the

parameter 138.

Activate the maximum stroke w hile sew ing

–

Press knee switch 1.

Once knee switch 1 is pressed (switch mode) the maximum

sewing-foot stroke remains effective until it is switched off by

pressing knee switch 1 again (stop mode).

6. Operation of the rupture-seam visualisation facility

The program is operated by touching the appropriate field on the Touch

Screen Monitor 1.

Access to the program is protected by three security levels (depending

on the security level, not all the fields in the basic screen are

available).

6.1 Access to the system

–

The operator is identified by a magnetic bar code card 4. This

allows all the operator ’s data, including his security level, to be

stored and directly communicated to the system.

–

The manual scanner 3 is used to scan in – i.e. read into the system

– the yarns that are to be used and the pieces that are to be sewn.

Logging onto the system

–

The operator logs on by wiping his bar code card 4 through the

magnetic-card reader 2.

32 1

Logging on w ithout a bar code card

–

The operator can also log on manually as follows:

–

Press the “Access” field.

–

Press the “Access” field.

–

Enter name and password.

Logging off

–

To log off from the system, press the “Log off” field.

Hint

Users with security level “0” are automatically logged off after two

minutes of inactivity.

Registering a new operator or a new bar code card

Before a new operator can work on the sewing unit he must be

registered with the system. The registering person must have at least

security level 2.

–

Log on to the s ystem.

–

Press the “Access” field.

–

Press the “Access” field.

–

Enter the name of the new operator and state his security level.

–

Enter a personnel number if appropriate.

–

Enter password

–

Confirm password.

–

Wipe the bar code card through the magnetic card reader.

–

Press the “OK” field.

–

Press the “Save” field.

HINT

Each operator can be allocated only one bar code card.

If a bar code card is re-registered, the old entries of the corresponding

operator are erased.

Deleting an operator

In order to carry out this operation the user must have security level 2.

–

Log on to the s ystem.

–

Press the “Access” field.

–

Press the “Delete” field.

–

Select the operator concerned.

–

Press the “Delete operator” field.

The operator ’s details will be deleted.

6.1.1 Advice for the production begin

Check imperatively the system date (see Part 2, chapter 2.2.1).

ATTENTION !

Never change neither the date nor the time when the machine is in

operation.

A corresponding warning notice will be displayed on the monitor.

A non-observance of the above will lead to the following

consequences:

–

Any reversing of the date setting will generate a duplicate in the

database.

HINT

In this way it is no longer possible to identify clearly any completed

seams.

–

Any reversing of the time setting will generate a duplicate in the

database.

HINT

In this way it is no longer possible to identify clearly any completed

seams.

6.2 Seam-type function

–

The “Seam types” field enables new seam types to be created and

existing seam types to be edited or deleted.

6.2.1 Creating a new seam type

–

Press the “New seam type” field.

A list of available seam types with their alteration status is

displayed.

–

Enter a two-digit or three-digit seam-type code.

Three-digit seam-types may be created with the software version

550-767A07 and later.

–

Touch “Seam-type code” field 2.

The following entry mask is displayed.

–

Enter the seam-type code.

–

Press the “Return” button.

–

Touch “Seam-type name” field 1 .

The following entry mask is displayed.

–

Enter a seam-type name.

–

Press the “Return” button.

A list of available seam types with their alteration status is

displayed.

–

Press the “OK” field.

The screen containing the seam sections box is displayed.

–

Select number of seam sections, e.g. 3.

–

Press the “OK” field.

The new seam type screen is displayed.

–

Select the individual seam sections by clicking on them and enter

the appropriate seam parameters.

Monitored (red) Not monitored

(green)

Selected

seam section

–

When the seam parameters for all seam sections have been set,

press the “Save seam-types” field.

Inserting a seam section

–

Selectaseamsectioninfrontofwhichanewsectionistobe

inserted.

–

Press the “Insert” field.

The following screen is displayed.

–

Press the “OK” field.

The screen containing the inserted seam type 1 is displayed.

–

Click the new seam section field to select and enter the appropriate

seam parameters.

–

When the seam parameters have been set, press the “Save

seam-types” field.

Deleting a seam section

–

Touch the seam section to be deleted.

For example: Seam section 1.

–

Press the “Delete” field.

The following screen is displayed.

–

Press the “OK” field.

The new seam type screen is displayed.

6.2.2 Edit seam type

–

Press the “Edit seam type” field.

A list of available seam types with their alteration status is

displayed.

–

From the list of seam types select the one that is to be edited by

clicking on the “Seam-type code” field.

–

Press the “OK” field.

The new seam type screen is displayed.

–

Call the individual seam sections and make the necessary

changes.

–

Press the “Save” field.

6.2.3 Copy seam type

–

Press the “Copy seam type” field.

A list of available seam types with their alteration status is

displayed.

–

From the list of seam types select the one that is to be copied by

clicking on the “Seam-type code” field.

For example: Seam type 04.

The following screen is displayed:

–

Touch the “Seam-type code” field.

–

Enter the new seam-type code.

For example: 05

–

Press the “Return” button.

–

Touch the “Seam-type name” field and type the new name.

–

Press the “OK” field.

The following window is displayed:

–

Press the “OK” field.

Seam-type 4 was copied and saved as the new seam type 5.

6.2.4 Delete seam type

–

Press the “Delete seam types” field.

A list of available seam types with their alteration status is

displayed.

–

From the list of seam types select the one that is to be deleted by

clicking on the “Seam-type code” field.

For example: 05 for seam type 5.

–

Press the “OK” field.

A confirmation prompt is displayed.

–

Click “Yes” to confirm the prompt.

The seam type 05 will be deleted.

6.3 Database function

Completed seams are recorded and the data filed in a database.

The “database” field enables these recorded files to be displayed,

printed and copied.

–

The required files are selected using the fields 1.

“File” field

A record file is filed every day. It is possible to r etrieve and display

these files via the “file” field

–

Press the “File” field.

The following dialog box is displayed:

–

Select the required record file and click “Open”.

“Print” field

If a printer is connected the selected record file can be printed out

using the “Print” field.

“Copy” field

The selected day file is copied into a designated directory.

“Help” field

A list of error codes is displayed ( see 6.6).

“Thread tension” field

File for displaying thread-tension values of each stitch of documented

seam sections.

6.4 Check function

Functions relating to preserving and restoring data, to information

about sewing materials and to the testing, adjustment and setting-up

of the integrated sewing unit are available through the “Check” field.

“Backup system” field

When this function is activated all system-relevant settings are saved

to diskette.

“Restore system” field

System-relevant data are read into the system from diskette.

The required parameters can be pre-set.

“Print BC Label” field

When this function is activated a barcode label is printed out by the

label printer.

“Backup record database” field

When this function is activated all database records of the work-station

are stored under the appropriate machine number.

The data are transferred to the ZIP drive.

“Load data” field

Back-up files are loaded loaded from diskette.

“Copy dump files” field

When this function is activated all dump are saved to diskette.

“Connections” field

When this function is activated the computer ’s connections are listed.

“Setup” field

When this function is activated system settings can be entered.

“General settings”

When this function is activated the language is selected, code numbers

for manufacturers and sewing unit are attributed, relevant barcode

digits determined and the employed EFKA software is selected.

“Components”

Here the used working materials or functions are activated or

deactivated.

“Values”

When this function is activated the scanners are selected, the barcode

type for the card-reader is defined and the desired number of barcode

digits adjusted.

When the function “Sew label separately” is activated in the field

“Components”, the number of stitches for the additional seam can be

set via the function “Number of stitches of label sewing”.

In order to avoid that each thread passing through the light barrier

simulates a nick mark <M>[2 or 3 stitches], the response behaviour of

the light barrier can be manipulated via the function “Nick-mark

identification filter stitches”. When setting the value 2, the s ize of the

nick mark must comprise two stitches in order to be identified as such.

Authorization for access to the system c an be influenced by changing

the user level. The set values indicate the s afety levels w hich are at

the very least required for executing the programme function.

In the field “Lot size” the number of sewing procedures, which should

be released by a one-time scanning-in of the input barcodes, can be

set.

“Barcode” field

Barcode definitions can be modified, saved or loaded via the “Barcode”

field.

Masks are placed to determine the relevant barcode digits.

Changing a barcode definition

–

Touch the corresponding barcode line 1.

The following entry mask is displayed.

–

Type the barcode definition.

–

Press the “OK” field".

The new definition is accepted.

–

Press the “Save” field.

“Label” field

The layout of the end label can be defined via the “Layout” field. W hich

barcode information is to be printed is determined here.

Additional information to be printed on the end label can be defined via

the “Define additional label information” field.

1 Setting the end-label barcode type

See section 6.7.

2 Setting the end-label layout

See section 6.8.

3 Determining the text to be printed out

“Path+Net” field

The function of the “Path+Net” field is to specify the paths to be used

when saving the record database and system databases, as well as the

interval between automatic saves.

“Yarns” field

When this function is activated a database containing the yarns

designated for use with the system is displayed.

New yarns can be entered, and existing yarns edited or deleted.

HINT

When a new yarn is entered its identity no. must be entered. This

number, w hich consists of predetermined digits of the thread barcode,

enables the system to recognise the yarn.

Registering new yarn

–

Touch the “New yarn” field.

The ‘yarn database editor ’ opens.

–

Type the yarn barcode.

–

scan-in the yarn barcode.

–

Touch the “Scan” field.

The following screen is displayed:

–

Scan-in the yarn barcode using the hand-held scanner.

–

Press the “OK” field".

The new yarn barcode is accepted.

–

Enter further yarn data and press the “OK” field to confirm entries.

“Change yarn” field

The selected yarn can be changed once this function has been

activated.

“Delete yarn” field

The selected yarn can be deleted once this function has been

activated.

“Print DB” field

When this function is activated the seam database is printed out (only

if a printer is connected and activated in the setup).

“Display DB” field

When this function is activated the seam database is opened and all

seam parameters are displayed.

“Bobbins” field

All registered bobbins are displayed when this function is activated.

Selected bobbins can be deleted using the “Delete” field.

“DB needle” field

If the component “Needle-check” is activated in the set-up, the user will

be asked at certain times to check the needle and, if necessary,

replace it.

These activities will be recorded in the needle-change database.

“SM-Kali” and “ELTEX-Kali” fields

If the component “Calibration check” is activated in the set-up, the user

will be asked at certain times to check and possibly calibrate the

settings for the step motor and the ELTEX-thread-tension measuring

device.

Both activities will be recorded in the ELTEX and the step-motor

calibration database.

See section 6.5: Needle-thread tension tolerance range.

“SM” field

After activating the function, the adjustment of the stitch length can be

calibrated and verified.

–

Press the “Min.” field.

The step motor moves to the shortest stitch length.

–

Press “Enter 100 stitches+length” field.

The following window is displayed.

–

Sew test seam.

100 stitches will be sewn.

–

Measure stretch.

–

Enter the value for the measured stretch, then press the field “8" to

confirm.

–

Press the “Ref.” field.

The step motor will move to an average stitch length.

–

Press “Enter 100 stitches+length” field.

The following window is displayed.

–

Sew test seam.

100 stitches will be sewn.

–

Measure stretch.

–

Enter the value for the measured stretch, then press the field “8" to

confirm.

–

Press the “Save” field.

Calibration will be terminated.

Calibration of the step motor is carried out on thin paper. Since the

actual stitch length shortens in relation to an increasing thickness of

the material, a correction factor can be set in the seam display, which

will take into account the thickness of the sewing material.

“E/A” field

When this function is activated system inputs and outputs can be

tested.

“Scanner” field

When this function is activated the barcode-scanner can be tested.

“EFKA” field

This function allows all of the functions of the EFKA d.c. motor to be

checked.

The settings made, e.g. initial lock-stitches, final lock-stitches, speed,

stitch length, etc., will be transmitted to the control unit by pressing the

“Transmit” key and one seam will be released.

HINT

Entries can only be made via an external operating panel of the type

V810 or V820.

“ELTEX” field

This function is for setting the thread tension in considering pre-set

tolerance limits, sewing speed, lifting height and stitch length.

See section 6.5: Needle-thread tension tolerance range.

Uninterruptible pow er supply function

The emergency power supply enables the integrated sewing unit to

continue in operation for up to 30 minutes even in the event of a power

failure.

–

If the mains supply fails, a warning message is displayed on the

monitor.

–

Once this message has been acknowledged, an indication of how

long operation can continue with the buffered energy is displayed.

–

Shortly before the buffered energy runs out the operator is

prompted to shutdown the PC. If this is not done manually, it is

carried out automatically in order to avoid the loss of stored data.

“Abort” function

The “Back” function enables the user to return to the “Rupture-seam

visualisation” menu.

6.5 Needle-thread tension tolerance range

In monitored seam ranges, the needle-thread tension values are

compared during operations with a pre-set tolerance range. If these

values deviate from the tolerance range more often than they should,

the seam is designated as a bad seam.

Adjusting the thread tension to w ithin the tolerance range

The needle-thread tension value is affected by many factors such as

sewing speed, material, sewing yarn, seam range etc. The upper and

lower needle-thread tension limits can be set via the “ELTEX” function.

–

Press the “Check” field in the “Thread-tension measuring device”

window.

–

Press the “ELTEX” field.

–

Enter the appropriate values of the rupture seam in both the “Lower

limit” and “Upper limit” fields.

The entered tolerance range is indicated in w indow 2 within two

lines.

–

Enter the values for minimum and maximum s peed.

–

Enter stitch length and stroke height.

–

Press the “Sew” field.

–

Carry out a test seam with thread-cutting.

The adjusted upper-thread tension is displayed in window 1.?

It must be within the two lines indicating upper an lower tension.

–

Adjust the upper-thread tension, press the “Sew” field and sew

another test seam.

–

Check the needle-thread tension in window 1.

–

The needle-thread tension values of each individual stitch are

displayedinfield3.

–

The average thread tension value calculated is displayed in the

“Average” field 2.

–

Carry out another test seam.

On completion of the seam, the fields 1 must still be displayed in

green, otherwise the entries must be adjusted once more.

HINT

It is recommended that the ELTEX device be recalibrated regularly

once a year by the manufacturer.

Eltex of Sw eden AB

Box 608

SE-343 24 ELMHULT

Sweden

Telephone: +46 (0) 476-488 00

Fax: +46 (0) 476-134 00

E-mail: Info-fax: +46 (0) 476-134 00

E-mail: info@Telefax: +46 (0) 476-134 00

E-mail: info@eltex.se

Internet: www.eltex.se

6.6 Error codes

EC10000 fault clearance by supervisor

EC20000 check thread tensioner (not in use at present)

EC21000 forced thread-cutting in a rupture seam

EC21500 Received wrong error message from Efka motor

EC21600 Received hook thread message from Efka motor

EC22000 forced bar-tacks in a rupture seam

EC22500 wrong bar-tacking in the seam

EC22600 wrong stitch count, motor and PC

EC23000 thread break in a rupture seam

EC23500 thread tension too low in a rupture seam

EC23600 thread tension too high in a rupture seam

EC25000 thread break in a free seam

EC25500 thread tension too low in a free seam

EC25600 thread tension too high in a free seam

EC26000 unknown barcode label (supplementary barcode)

not read

EC27000 hardware fault, DA82 sewing motor not responding

properly

EC27500 hardware fault, ELTEX thread-tension measuring device

not responding properly

EC28000 below permitted stitch range

EC28000 above permitted stitch range

EC31000 end-label barcode misread by supervisor using

manual scanner

EC31500 wrong end label sewn into piece

EC32000 a bobbin containing a prohibited thread was inserted

during sewing

EC33000 barcode printer not ready

ECxxxxxACK error “xxxxx” confirmed by supervisor

ECxxxxxCNT Supervisor has released the piece for further processing

despite error ‘xxxxx’

6.7 Setting the end-label barcodes

The operator must have security level 2 in order to carry out changes

in the barcode labelling system.

–

Log on to the s ystem.

–

Activate “Check” func tion

–

Activate “Setup” function

–

Activate “Label” function

The structure of the end-label barcode is displayed in field 1.

?The significance of the predefined codes is as follows:

D2 current day (two-digit); e.g.: 9. 9 June = 09

M2 current month (two-digit); e.g.: 9. 9 June = 06

Y2 current year (two-digit); e.g.: 1999 = 99

Y4 current year (four-digit); e.g.: 1999 = 1999

J3 number of days in year (three-digit); e.g.: 20 February = 051

H2 current hour (two-digit); e.g.: 8:52:13 = 08

U2 current minute (two-digit); e.g.: 8:52:13 = 52

S2 current second (two-digit); e.g.: 8:52:13 = 13

P1 current personnel number (one-digit); e.g.: 1234 = 1

P2 current personnel number (two-digit); e.g.: 1234 = 12

P3 current personnel number (three-digit); e.g.: 1234 = 123

P4 current personnel number (four-digit); e.g.: 1234 = 1234

E1 current machine number (one-digit); e.g.: 567 = 5

E2 current machine number (two-digit); e.g.: 567 = 56

E3 current machine number (three-digit); e.g.: 567 = 567

F1 manufacturer code (one-digit); e.g.: 1357 = 1

F2 manufacturer code (two-digit); e.g.: 1357 = 13

F3 manufacturer code (three-digit); e.g.: 1357 = 135

F4 manufacturer code (four-digit); e.g.: 1357 = 1357

N2 daily number of pieces (two-digit); e.g.: 1234 = 34

N3 daily number of pieces (three-digit); e.g.: 1234 = 234

N4 daily number of pieces (four-digit); e.g.: 1234 = 1234

N5 daily number of pieces (five-digit); e.g.: 12345 = 12345

N6 daily number of pieces (six-digit); e.g.: 123456 = 123456

CP the number of digits and the coding are defined by the

mask specified under “Prim. barcode mask label”.

1 = digit is accepted; 0 = digit is ignored.

TU the number of digits and the coding are defined by the

mask specified under “Needle-thread mask label”.

1 = digit is accepted; 0 = digit is ignored.

TU the number of digits and the coding are defined by the

mask specified under “hook-thread mask label”.

1 = digit is accepted; 0 = digit is ignored.

WE calendar week (1 – 53)

WD weekday from 1 = Sunday to 7 = Saturday

MB element of multi-barcode

KX constant sign

LR Identifier left/right/L/R/U

LN Identifier left/right 0/1/2

SN Screen type number

Y1 Year 1-digit

CQ Part I primary barcode

CR Part II primary barcode

R2..R8 Resident counter

In accordance with the end-label barcode structure in field 1 the

following information is displayed in the endlabel barcode:

number of days in year (J3)

current year in two-digit display(Y2)

Three-digit part number (N3)

three-digit display of personnel number (P3)

Three-digit machine number (E3)

Three-digit manufacturer code (F3)

Extended label printing (EXTLabel.txt)

This option allows the information compiled on the list to be printed

additionally on the end label.

The desired information is placed on the end label by means of a

defined programme line.

When the extended label-print is activated, the information will always

be printed on the specified places, independent of the loaded barcode

set-up file.

***********************************************************************

* 550-767

* This is the extended label printing set-up file

* for customer specific printing.

* Format of the control lines:

* ————————————————————————-

* POSX, POSY, FONT, DESCRIBING TEXT, INFO-CODE

* Each line, which has a “*” as first character is

* ignored.

* Avaible Info-Codes:

* ————————————————-

* MB1 - MB9 : scanned multi barcodes 1 - 9

* ONM : operator name

* OPN : operator personel number

* FAB : manufacturer code

* MAC : machine number

* TRN : needle thread barcode

* TRB : bobbin thread barcode

* DPC : daily piece number

* ERC : actual error code

* SNM : seam record name

* SRN : seam record number 00-99

* D AT : date

*TIM : time

* BON : bobbin number

* PB1,PB2,PB3: parts barcode 1,2,3

* SRT : text from the seam record

* C YN : cycle number

* J DY : Julean day with three digits

* YR2 : actual year with last two digits

* YR4 : actual year with lastfour digits

* DAY : actual day with two digits

* MON : actual month with two digits

* DNF : daily piece count formatted four digits

**************************************************************************

54,14,2, ,DNF

61,14,2, , MAC

65,14,2, , YR2

69,14,2, , JDY

6.8 Setting the end-label layout

The operator must have security level 2 in order to carry out changes

in the barcode labelling system.

–

Log on to the s ystem.

–

Activate “Check” func tion

–

Activate “Setup” function

–

Activate “Label” function

–

Enter the required height of the label in the “ Label length” field.

e.g.: 25 mm

–

Enter the gap between labels in the “Gap” field.

e.g.: 3 mm

–

Enter the required label texts in fields 1,

e.g.:

end-label text 1 = manufacturer

end-label text 2 = model

end-label text left = left-hand seat

end-label text right = right-hand seat

–

Set the origin for the text coordinates in fields 2.

–

Set the position of end-label text 1 in the “Pos. text 1 X” and “Pos.

text 1 Y” fields.

–

Set the position of end-label text 2 in the “Pos. text 2 X” and “Pos.

text 2 Y” fields.

–

Set the position of the barcode in the “Pos. BC X” and “Pos. BC Y”

fields.

–

The required font can be set in field 3.

–

To print the label, press button 4 prints out the label.

6.9 Adjusting barcode definitions

The operator must have security level 2 in order to carry out changes

in the barcode labelling system.

–

Log on to the s ystem.

–

Activate “Check” func tion

–

Activate “Setup” function

–

Activate the “Extended” function.

–

Select the required type in the “Primary barcode type” field.

This barcode is read into the system by the manual scanner.

–

Select the required type in the “Thread-barcode type” field.

The selection applies to both the upper and hook threads.

–

Select the required type in the “End-label barcode type” field.

–

Masks can be set in the “Primary-barcode identifier A” (material

and colour barcode), “Primary-barcode identifier B” (upper and

lower piece barcode), “Primary-barcode identifier C” (stitch type

barcode) and ”Primary-barcode mask L/R" (left and right-piece

barcode) fields to pass on system-relevant information (entry: “1")

or ignore unimportant information (entry: ”0").

E.g.:

Primary barcode:

(scanned in by manual scanner)

11112233001234567890

Primary-barcode identifier in the “Primary- barcode identifier A”

field (material and colour barcode):

11110000000000000000

ID number:

1111

If only pieces with the ID number “1111" are to be processed, this

number can be entered in the ”Identifier A set value" field. If pieces

with various different ID numbers are to be processed, the “Identifier A

set value” field must remain blank.

–

The “Primary-barcode identifier B” field determines the piece type,

i.e. whether it is an upper, middle or lower piece.

E.g.:

Primary barcode:

(scanned in by manual scanner)

11112233001234567890

Primary-barcode identifier in the “Primary- barcode identifier B”:

00001100000000000000

ID number:

The ID number must be defined in one of the “ID part 1", ID part 2"

and ”ID part 3" fields. It is impossible to enter the same ID number

in more than one field.

Sewing parameters are set with the “Primary-barcode identifier C”

field.

E.g.:

Primary barcode:

(scanned in by manual scanner)

11112233001234567890

Primary-barcode identifier in the “Primary- barcode identifier C”:

00000011000000000000

ID number:

The ID number is used to retrieve the parameters from the database

(here: stitch type with ID number 33).

HINT

From the software version 550-767A07 onwards, 3-digit seam displays

can be generated. It should be remembered that with identifier C three

digits have to be occupied and that the 2-digit seam displays are no

longer available.

Three-digit seam displays shall be provided with a seam-display

identification between 100 and 999 (identifications between 001 and

099 are not permitted).

–

The “Prim. barcode mask L/R” field determines whether it is a right

or left-hand seat.

E.g.:

Primary barcode:

(scanned in by manual scanner)

11112233001234567890

Primary-barcode identifier in the “Primary- barcode mask L/R” field:

00000000110000000000

ID number:

–

The ID number must be defined in the “ID left” or “ID right” fields.

Example w ith tw o pieces:

11112233001234567890 11112333001234567890

“Primary -barcode identifier A”:

11110000000000000000 11110000000000000000

ID number:

1111 1111

The ID numbers are the same = OK.

11112233001234567890 11112333001234567890

“Primary -barcode identifier B”:

00001100000000000000 00001100000000000000

ID number:

22 23

The ID numbers are different = OK.

The piece with ID number 22 is the upper layer, ID number 23 is the

lower layer.

11112233001234567890 11112333001234567890

“Primary -barcode identifier C”:

00000011000000000000 00000011000000000000

ID number:

33 33

The ID numbers are the same = OK.

The sewing parameters no. 33 are read from the database.

11112233001234567890 11112333001234567890

“Primary barcode mask L/R” field:

00000000110000000000 00000000110000000000

ID number:

00 00

The ID numbers are the same = OK

A right-hand seat is sewn.

The text for a right-hand seat is printed on the end label.

–

Via the “Primary-barcode mask label” field, information from the

initial barcode can be printed on the end label.

–

How many additional barcodes (multi-barcode) shall be scanned in

and stored is determined via the “Multi-barcode mask number”

field.

The desired number will be realized by selecting the appropriate

digits of the primary barcode.

–

Information from the multi-barcode can be printed on the end-label

via the “Multi-BC Print Mask” field

(refer to “MB” information code, section 6.7).

7. Sewing

CAUTION:

Sewing may only be carried out on a fully-assembled sewing ?unit with

all protective devices fitted!

Sw itching on the sew ing unit

–

Press button 3 (lamp 4 flashes )

–

= Wait until lamp 4 lights up.

–

Turn on main switches 1 and 2.

Windows is loaded and the program “Soll.exe” activated.

The sewing unit is tested and initialised.

–

Scan in the needle-thread cone if appropriate.

–

Scan in the hook-thread cone if appropriate.

–

Enter the bobbin number (engraved on the bobbin).

Logging onto the system

–

The operator logs on by wiping his bar code card through the

magnetic-card reader.

–

The operator can also log on manually as follows:

–

Press the “Access” field.

–

Press the “Log on” field.

–

Enter name and password.

Sewing can only begin if the system start and scanning of the

needle-thread cone, hook-thread cone and bobbin were faultless.

Failing this the system is not ready for sewing, and an error message

will be displayed.

Sew ing

–

Press the “Sewing” field.

–

Scaninthepiecestobesewn.

Up to nine (9) more barcodes can be defined in advance.

All previously defined barcodes must be read in.

–

The seam ranges can be sewn.

Odd-numbered seam ranges are unmonitored, the diode on the

stop lights up green. In the even-numbered (monitored) seam

ranges the diode lights up red.

–

If an error occurs in a monitored seam section an error message is

displayed.

–

Sewing is blocked to operators with s ecurity level 0.

–

Users with security level 1 or 2 can remove the block by logging

onto the system by means of the magnetic card and then pressing

the “Continue” field.

7.1 Label scanner (optional)

A label scanner 1 can be fitted to the head of the sewing unit as an

optional extra.

–

At the end of the seam the scanner checks whether the correct

barcode label has been sewn on.

–

If the label is not recognised a reminder appears, followed by this

warning:

–

Users with security level 1 or 2 can scan-in the label manually after

the seam end or print out a new label.

8. Maintenance

CAUTION: DANGER OF INJURY!

Turn off the main switch.

Maintenance of the sewing unit may only be undertaken with the

machine turned off!

8.1 Cleaning

HINT

A clean sewing unit is a trouble-free sewing unit!

–

Clean the hook area, thread cutter, needle plate, feeder and

sewing head every day to remove fluff, fragments of yarn and other

cutting waste!

–

Clean the oil collector daily!

Check the water level in the pressure regulator every day. The water

level must not rise as far as filter insert 2. After screwing in drain screw

3 blow out the water from the water separator 1 under pressure.

8.2 Oiling

CAUTION: DANGER OF INJURY!

Oil can cause skin eruptions.

Avoid protracted contact with the skin.

In the event of contact, thoroughly wash the affected area!

CAUTION:

The handling and disposal of mineral oils is subject to legal regulation.

Deliver used oil to an authorised collection point!

Protect your environment: take c are not to spill oil!

Top up the oil reservoir using DA-10 lubricating oil or an equivalent oil

with the following specification only:

–

Viscosity at 40°C: 10 mm/s

–

Flashpoint: 150°C

DA-10This oil is available from DÜRKOPP ADLER AG retail outlets

under the following part numbers:

250-ml container: 9047 000011

1-litre container: 9047 000012

2-litre container: 9047 000013

5-litre container: 9047 000014

–

Unscrew the oil-filler cap 2 and top up with oil.

–

Check the oil level at sight glass 1.

The oil level must be between “ EMPTY ” und “ FULL”.

–

Replace oil-filler cap 2.

–

Remove any oil which has overflowed into the oil collector.

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