550-867 Operating Instructions
Foreword This instruction manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations. The instruction manual contains important information on how to operate the machine securely, properly and economically. Observation of the instructions eliminates danger, reduces costs for repair and down-times, and increases the reliability and life of the machine.
General safety instructions The non-observance of the following safety instructions can cause bodily injuries or damages to the machine. 1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate training. 2. Before putting into service also read the safety rules and instructions of the motor supplier. 3. The machine must be used only for the purpose intended. Use of the machine without the safety devices is not permitted.
Index Page: Preface and General Safety Instructions Part 1: Operating Instructions Class 550-867 – Original Instructions (Edition 12/2011) 1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 Designated Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4 Technical Data . . . . . .
Index Page: 7 7.1 Sewing Seam scanner (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 8 8.1 8.2 Maintenance Cleaning and Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Product Description The DÜRKOPP ADLER class 550-867 is a sewing unit designed for documented airbag tearing seams. Single needle flat bed double lockstitch sewing machine class 867 with bottom feed, needle feed and alternating upper feed. With electromagnetic actuated thread trimmer and sewing foot lifting. Electromotor driven stitch length setting and seam bartacking.
Technical specifications software · · · · · · · · · · · · · · · · · · · · · 6 Intuitive user interface Sewing programs with up to 30 seam segments Switching over via strip detection, stitch counting or manually Different setup masks and endlabel masks can be memorized Teach-in function for ETT (electronically controlled needle thread tension) Test window for the thread tension Display of the thread tension during sewing Recognition of the needle and hook thread via barcode scanning (if the option is av
Data entry · · · · · · · · · · · · · · · · · · · · · · · · · · Date Time Line number Endlabel barcode Entrance barcode 1 - 3 Barcode needle thread Barcode hook thread Additional barcode information (max.
2 Designated Use The class 550-867 is an configured sewing station designed for the sewing of light to medium-heavy material. Such material is generally made of textile fibers, but it may also be leather. These materials are used in the clothing industry and for domestic and motor-vehicle upholstery. It is also possible to produce so-called technical seams with this configured sewing station.
4 Technical data Noise: Lc = dB (A) Workplace-related emission value in accordance with DIN EN ISO 10821 Speed: min -1 Material: Sewing stitch type: 301 / double lock stitch Number of needles: 1 Needle system: 134/35 Needle size : Needle thread size - Cotton: - Synthetic sewing thread: - Core thread Bobbin wind-on capacity with synthetic sewing thread - 60/3: Number of stitches: - with HP equipment: - factory setting: [NM] 90 - 140 [NeB] [Nm] [Nm] 20/3 20/3 20/3 [m] 98 [min ] [min ] 3400 34
5 Operating 5.1 Threading the needle thread Caution: Risk of Injury ! Turn off the main switch! The needle thread may only be threaded with the sewing machine being switched off. 3 2 1 5 4 Before putting in the needle thread cones they need to be scanned with the hand scanner. With thread barcode scanner equipment (optional): – Unscrew the ball 1. – Put the cone 2 on the stand and make sure that the barcode 4 on the thread reel can be read by the optional thread barcode scanner 5.
5.1.1 Machines with electronically controlled needle thread tension (ETT) 1 2 9 8 3 4 7 6 – – – – – – – – 5 Conduct the thread through the threading guide 1 and clockwise around the pretensioner 2. Conduct the thread counter-clockwise around the tensioner 3. Conduct the thread clockwise around the tensioner 4. Conduct the thread through threading guide 5. Pull the thread underneath the thread take-up spring 7 and conduct it through the thread regulator 6 to the thread lever 9.
5.1.2 Machines with mechanically set needle thread tension and with electromagnetic tension release 1 9 2 8 3 4 7 6 – – – – – – – – 10 11 12 13 12 5 Conduct the thread through the threading guide 1 and clockwise around the pretensioner 2. Conduct the thread counter-clockwise around the tensioner 3. Conduct the thread clockwise around the tensioner 4. Conduct the thread through threading guide 5.
5.2 Adjusting the needle-thread tension (mechanically) 1 2 3 4 The tension is to be set according to the values given by the seat cover manufacturers. The cross-over point should lie in the center of the material. – The pretensioner 1 is preset. – Unscrew the locking plate 3. – Set the main tensioner 2 and 4. – Mount the locking plate 3 again. 5.3 Adjusting the needle-thread tension (ETT) The thread tension is set via the machine’s software.
5.4 Adjusting the thread regulator 3 2 1 Caution: Risk of injury! Turn off the main switch. The thread regulator may only be adjusted with the sewing machine switched off. The thread regulator 1 controls the quantity of needle thread required for stitch formation. The thread regulator must be precisely adjusted for an optimum result. With correct setting the needle-thread loop must slide with low tension over the thickest point of the hook. – Loosen screw 2. – Adjust position of the thread regulator 1.
5.5 Winding on the hook thread ATTENTION! Only use bobbins that are specially designed for this machine type! 3 2 – – – – – – – 6 5 4 1 Put the hook thread cone on the thread stand. Conduct the hook thread through the threading guide on the unwinder arm and through the tube 1. Conduct the thread counter-clockwise around the tensioner 3. Conduct the thread through threading guide 2 to the bobbin 4. Pull the thread beginning behind the tear-off knife 6 and tear it off.
5.6 Threading in the hook thread 1 2 3 6 5 4 Caution: Risk of injury! Turn off the main switch! The hook thread may only be threaded with the sewing machine being switched off. – – – – – 16 Raise up the flap 1 and remove the empty bobbin 2. Insert the bobbin 2 in a way that it moves in counter-clockwise direction when unwinding the thread. Conduct the thread through slot 3 and underneath the spring 4. Pull the thread through the slot 6 and continue pulling until it stands out about 3 cm.
5.7 Inserting the hook thread bobbin with machines equipped with residual thread monitor 1 2 ATTENTION! The hook bobbin has to be inserted so that the milling 1 is turned downwards. The area around the bobbin housing and the light barrier has to be cleared of sewing dust ! Winding on the bobbin thread ATTENTION! When winding the thread on, the milling 1 has to be positioned towards the machine so that the thread is first wound into the reserve groove 2.
5.8 Setting the hook thread tension 2 1 Caution: Risk of injury! Turn off the main switch. The hook thread tension may only be adjusted with the sewing machine switched off. Setting the tension spring 2 – Set the tension spring 2 by turning the adjustment screw 1. Increase the hook thread tension = Turn screw 1 clockwise Decrease the pressure = Turn screw 1 counter-clockwise.
5.9 Changing the needle Caution: Risk of injury! Turn off the main switch! The needle may only be threaded in and changed with the sewing machine being switched off. 1 – – – – – Turn the handwheel until the needle bar is in its upper dead center. Loosen screw 1. Remove the needle. Insert the new needle aligning it, so that the needle scarf points to the hook and push it to the top as far as it will go. Tighten screw 1.
5.10 Lifting the sewing feet 1 The sewing feet can be lifted electro-pneumatically by actuating the pedal 1. – Press the pedal 1 half-way back. The sewing feet are lifted with the machine at a halt. – Press the pedal 1 all the way back. The thread trimmer is actuated and the sewing feet are lifted. 5.11 Locking the sewing feet in lifted position 1 1 – – Swivel the lever 1 downwards. The sewing feet are locked in lifted position. Swivel the lever 1 upwards. The sewing feet are unlocked.
5.12 Setting the sewing-foot stroke 1 2 The lift stroke 1 of the sewing foot can be set to eight levels (0 – 7) via the touch screen monitor in the menu item “seam pattern”. The maximum stroke can be switched on during sewing in free seam segments by actuating the knee switch 2. For the documented seam sections this function is disabled. Important note Sewing-foot stroke and number of stitches are interdependent.
5.14 Setting the stitch length The setting of the stitch length is effectuated via touch screen monitor in the menu item “seam pattern”. For each seam section different stitch lengths can be programmed. 5.15 Switch-key on the machine arm 1 Key 2 3 4 6 Function 1 Manually sewing backwards. The machine sews backward stitches as long as the key 1 is being pushed. 2 Setting the needle in high or low position. The function of the key can be defined with the parameter F-140.
11 10 9 8 7 1 LED Function 8 and 9 Display for an empty bobbin with residual thread monitor (left/ right bobbin) 11 LED display “power on” With the screw 7 underneath the keys the respective function can be set as “favorite function” for key 10. – Select a function. Example: 1 = Manually sewing backwards – Turn in the screw underneath the key 1 and turn it 90° to the right (the slot stands vertically). The function can now be called via both keys 1 and 10.
5.
5.17 Residual-thread monitor RFW 20 - 7 The residual thread monitor monitors the quantity of the thread on the bobbin. A signal is issued on the PC announcing that only a small quantity of thread remains. The operator can finish the seam and insert a new bobbin. This way undesirable repairs or damage to the material are avoided.
ATTENTION! The hook bobbin has to be inserted so that the milling 3 is turned downwards. The area around the bobbin housing and the light barrier have to be cleared of sewing dust ! Important note If the empty bobbin is not replaced by a full one, the signal will reappear on the monitor at the end of the next seam. – Wind on the bobbin thread. This process is described in this manual.
5.18 Electro-pneumatic rapid stroke adjustment 5 1 Sewing-foot stroke and speed are interdependent. Through the potentiometer the control unit recognizes the set sewing-foot stroke and limits the sewing speed. The values are predetermined by the control unit. The preset sewing-foot stroke can be switched on during free seam sequences by actuating the knee lever 1 or the switch 5.
5.19 Uninterruptible power supply (UPS) 1 The uninterruptible power supply is connected just before the main switch. It must not be switched off separately so that the accumulator is loaded permanently. Switching on the UPS – Press the button 1. The UPS is switched on. For more details consult the instructions of the manufacturer. 5.20 Sewing lamp 1 5 4 3 2 Switching on the sewing lamp 1. – Set the switch 5 to “1”. – Press the switch 3. The sewing lamp is switched on.
6 Operating the tearing seam visualization The program is operated by pressing the appropriate buttons on the touch panel PC 1. The access to the program is partly protected through three security levels. (Depending on the security level some buttons on the basic screen cannot be selected). 1 6.1 Accessing the system 6.1.1 Logging in with scanner and barcode 2 3 – – Press the switch 2 underneath the table top. The integrated lamp lights up.
6.1.2 Logging in via the menu The operator can also log in manually as follows: “Access” – Press the button “Access”. The following screen will appear: – Press the button “Log in”. The following screen will appear: – – Enter operator and password. Press the “OK” button. The operator is logged in.
6.1.3 Logging out of the system “Access” – Press the button “Access”. The following screen will appear: – Press the button “Log out”. The following screen will appear: “Log out” Note: Operators with security level 0 are automatically logged off after two minutes without action.
6.2 Exiting the program – Press the button “End”. The following screen will appear: – Press the button “PC off”. The program will shut down and the computer will be switched off. Note: If the program is exited with “Yes”, the windows level will be entered (only possible with security level 2).
7 Sewing CAUTION ! Sewing may only be carried out with a fully-assembled sewing unit on which all protective devices have been fitted! 1 2 Switching on the engineered sewing station – Switch on the UPS 2. – Turn on the main switch 1. Windows will be loaded and the program “Soll.exe” will be started. The machine will be tested and initialized. – Scan needle thread cone if necessary. – Scan hook thread cone if necessary. – Insert a bobbin.
Logging in to the system – The log-in takes place by scanning the operator barcode. – The operator can also log in manually as follows: – Press “Access”. – Press “Log in”. – Enter operator name and password. Sewing can only begin if the system start and the scanning of needle thread cone, hook thread cone and bobbin have been accomplished faultlessly. Otherwise the system is not ready for sewing and instead an error message will be displayed Sewing – Press “Sewing”.
– – – green, in the red seam sections (monitored segments) the diode glows red. If an error occurs in a monitored seam section an error message will be displayed. For operators with the security level 0 sewing is blocked Operators with the security level 1 or 2 can unlock the sewing process by logging in to the system (via barcode card) and pressing the field “Continue”.
7.1 Seam scanner (optional) A seam scanner 1 can be optionally fixed onto the machine head. 1 At the end of the seam the scanner checks whether the correct barcode label has been sewn in. If the label is not recognized, first a reminder appears and then the following warning: Operators with the security level 1 or 2 can scan the label after the end of sewing manually or print out a new label.
8 Maintenance 8.1 Cleaning and Checking Caution: Risk of injury! Turn off the main switch. The maintenance of the sewing machine must only be done when the machine is switched off. Maintenance work must be carried out no less frequently than at the intervals given in the tables (see ”operating hours” column) Maintenance intervals may need to be shorter when processing heavy-shedding materials. A clean sewing machine is a trouble-free sewing machine.
3 4 5 Maintenance work to be carried out Explanation Operating hours Sewing drive Clean ventilation filter (e.g. with an air blow gun). Remove lint and pieces of thread from air-intake openings. 8 Check condition and tension of V-belt 1 It must be possible to depress the V-belt by about 10 mm by pressing it with a finger at its mid-point. 160 Check water level in pressure regulator. The water level must not rise to the level of the filter cartridge 3.
8.2 Repair When the machine is damaged or parts are worn please contact: DÜRKOPP ADLER AG Potsdamer Str. 190 D-33719 Bielefeld Phone: +49 (0) 180 5 383 756 Fax: +49 (0) 521 925 2594 E-mail: service@duerkopp-adler.com Internet: www.duerkopp-adler.
Index Page: Part 2: Installation Instructions Class 550-867 – Original Instructions 1 Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3.1 3.2 3.3 3.4 Installing the sewing unit Shipping braces . . . . . . . . . Transport within the factory hall Setting the working height . . . Pedal position . . . . . . . . . . . . .
1 Scope of Delivery The items that are supplied depend on your order. Prior to setting up, please check that all the required parts are present.
2 General ATTENTION! The engineered sewing station must be set up by trained specialist personnel only. All work on the electrical equipment of this special sewing unit may only be carried out by qualified electricians or other appropriately trained persons. The mains plug has to be unplugged. The adjoined manuals of the step motors’ manufacturer have to be headed in any case. 3 Installing the sewing unit 3.1 Shipping braces Before installing the sewing unit the securing devices have to be removed.
3.3 Setting the working height 1 The working height is adjustable between 685 and 1085 mm (measured to the upper edge of the table plate). The working height’s factory setting is 790 mm. – Set the working height as desired by pressing the key 1.
3.4 Pedal position 3 2 The pedal 3 should be set in a way that it can be moved unimpededly forwards and backwards by the operating personnel. – Loosen screw 2. – Set the pedal 3 accordingly. – Tighten screw 2 again.
1 2 The pedal 1 can either be used freestanding or fixed onto the cross brace 2. 3 If you opt for freestanding use: – Fix the rubber feet 3. – Make sure that all four rubber feet are in direct contact with the ground.
4 Attaching the machine parts removed for shipping 4.1 Mounting the thread stand 3 1 2 1 The mounting of the thread stand and its position are shown on the picture. – Insert the thread stand into the bore of the table plate and fix it with the adjoined lock nuts 1 and the washers 2. – Connect the cables for the switch and the scanner.
4.2 Mounting and connecting the monitor 5 4 3 2 – – – – – 1 8 6 Fit the touch panel PC 4 onto the post 3 and fix it with four screws 5. Plug in the mains plug 1 and secure it with the locking brace 2. Connect the USB plug 7 to the middle bushing 8. Pull down cover 6.
5 Electrical connection ATTENTION! All work on the electrical equipment of this special sewing unit may only be carried out by qualified electricians or other appropriately trained persons! The mains plug has to be unplugged! 5.
6 Pneumatic connection 5 6 4 8 2 10 4 3 The pneumatic system of the sewing unit and its optional equipment have to be supplied with anhydrous compressed air. The supply pressure has to be 8 to 10 bar. Connecting the compressed-air maintenance unit – Connect the connection hose 3 (Order no. 0797 003031) to the compressed air supply by using hose fixture R1/4". Adjusting the operating pressure The operating pressure is 6 bar. It can be read off at the manometer 4.
7 Oil lubrication 1 2 3 Caution: Risk of injury! Oil can cause skin rashes. Avoid longer skin contact. After contact wash yourself thoroughly. ATTENTION! The handling and disposal of mineral oils is subject to legal regulations. Deliver used oil to an authorized collecting station. Protect your environment. Be careful not to spill any oil.
8 Sewing test A sewing test should be carried out when the setting-up has been completed. – Plug the mains cable into the socket. Caution: Risk of injury! Turn off the main switch. The needle and hook threads may only be threaded with the sewing machine switched off. – – – – – – 12 Wind up and thread in the bobbin-winder thread (see operating instructions). Thread in the needle and hook thread (see operating instructions). Select the material to be processed.
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Original Instructions - 0791 550102 - 02.0 - EN - 12/2011 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.
