511 CNC-Automat für Riegel- und Kurznähte CNC automat for bartacking seams and short seams Bedienanleitung / Operating Instructions 1 Aufstellanleitung / Installation Instructions 2 Serviceanleitung / Service Instructions 3 Postfach 17 03 51, D-33703 Bielefeld Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 5 21/ 9 25-00 Telefax +49 (0) 5 21/ 9 25 24 35 www.duerkopp-adler.com Ausgabe / Edition: 08/2009 Änderungsindex Rev. index: 00.0 Printed in Federal Republic of Germany Teile-Nr.
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Foreword This instruction manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations. The instruction manual contains important information on how to operate the machine securely, properly and economically. Observation of the instructions eliminates danger, reduces costs for repair and down-times, and increases the reliability and life of the machine.
General safety instructions The non-observance of the following safety instructions can cause bodily injuries or damages to the machine. 1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate training. 2. Before putting into service also read the safety rules and instructions of the motor supplier. 3. The machine must be used only for the purpose intended. Use of the machine without the safety devices is not permitted.
Contents Page: Preface and General Safety Instructions Part 1: Operating Instructions for Class 511 (Edition 08/2009) 1. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. Proper and Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3. Sub-classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4. Additional Equipment . . . . . . . . . . .
Contents Page: 8.6 8.6.1 8.6.2 8.6.3 8.6.3.1 8.6.3.2 8.6.4 8.7 8.8 8.8.1 8.8.2 8.8.3 Main menu . . . . . . . . . . . . . . . . . . . . . . . . Seam pattern operation . . . . . . . . . . . . . . . . Programming mode . . . . . . . . . . . . . . . . . . . Seam pattern sequences . . . . . . . . . . . . . . . Switching the sequence programming mode on or Programming a sequence . . . . . . . . . . . . . . . Technician mode . . . . . . . . . . . . . . . . . . . . Distributor PCB . . . . . . . . . . . . . . . .
1. Product Description The Dürkopp Adler 511 is a CNC machine for bartacking seams and short seams. The available standard bartacks are size-adjustable and can additionally be saved in this modified shape. Free seam contours can be programmed directly at the control panel without any further devices. Technical features – DAC control unit with control panel. The following functions are available: – 50 standard bartacks. These bartacks can temporarily be modified in respect to length, width and speed.
2. Proper and Intended Use The class 511 machine is a bartacking machine designed for sewing light to medium-heavy material. Such material is generally made of textile fibres, but it may also be leather. Such fabrics are used in the clothing industry and for domestic and motor-vehicle upholstery. Furthermore, this automatic bartacker can also sew “technical” seams. In such a case, the operator must assess the possible dangers which may arise (preferably in conjunction with DÜRKOPP ADLER AG).
3. Sub-classes Class 511-211 Automatic single-needle lockstitch bartacker with thread trimmer and thread wiper. Equipped with special sewing equipment for general bartacking operations in outer garments. With electro-magnetic sewing foot lift. Class 511-212 Automatic single-needle lockstitch bartacker with thread trimmer and thread wiper. Equipped with a contraction clamp specially for bartacking double-chainstitch buttonholes. With electro-magnetic sewing foot lift.
5. Frame The following stand is available for the automatic bartacker 511: MG55 40 029 4 Stand package Table top size 600 x 1060 mm Stand height 1160 to 1305 mm MG53 40 148 4 Stand package (China) Table top size 600 x 1060 mm Stand height 1160 to 1305 mm 6. Technical Specifications Noise level: Lc = 78dB (A) Workplace-related emission value according to DIN 45635-48-A-1-KL-2: Bartack length: Stitch/bartack: Throw width: Speed: Fabric: Sewing cycle: 6 15 mm 28 2.
6.1 Sub-class-specific technical parameters Sub-class: -211 -212 -213 -214 Stitch type: 301 301 301 301 Hook type: oscillating hook Needle system: DPx5 (134) Needle size: [Nm] Needle size standard production: [Nm] Thread size: Stitch length: Max. speed 90 DPx17 (135x17) 90 50/3 - 120/3 [mm] [min -1 ] Clamp stroke Delivery maximum [mm] Sewing field size Max. in X-direction: Max.
7. Operations 7.1 Threading the needle thread Caution – Risk of Injury ! Turn the main switch off! Insert the needle thread only when the automatic bartacker is switched off. – – 8 Put thread reels on the thread reel holder and insert needle thread and bobbin thread through the unwinding arm. The unwind holder must be perpendicular to the reel. Thread the needle thread as shown on the following illustration.
7.2 Adjusting the needle thread tension 1 3 2 1 Pretension 3 With the main tension 2 open, a minor residual stress of the needle thread is required. This residual tension is created by the pre-tensioner 3. The pre-tensioner 3 influences both the length of the cut needle thread and the starter thread for the next seam. – Shorter starter thread: Turn knurled nut 1 in clockwise direction. – Longer starter thread: Turn knurled nut 1 counter-clockwise.
7.4 Adjusting the thread regulator 3 2 1 Caution – Risk of Injury ! Turn the main switch off. Adjust thread regulator only when the automatic bartacker is switched off. The thread regulator 3 is used to control the quantity of needle thread required by the stitch formation. The best sewing results can only be ensured when using a precisely adjusted thread regulator. At the properly adjusted setting, the needle thread loop must be able to slide over the thickest section of the hook. – Loosen screw 1.
7.5 Winding the bobbin thread 5 1 4 3 2 6 – – – – – – Put bobbin on bobbin winder 4. Pull thread through guide 2 and around tension 1. Wind thread counter-clockwise around the core of the bobbin (approx. 5 times). Press the bobbin-winder lever 3 in the bobbin. Sew. The winder lever stops as soon as the bobbin is full. Tear off thread at thread clamp 5 after winding up is finished.
7.6 Replacing the shuttle bobbin 1 7 4 2 5 6 2 3 Caution – Risk of Injury ! Turn the main switch off. Change hook thread bobbin only when automatic bartacker is switched off. Taking off the empty bobbin – Pull down hook cover 3. – Raise up the bobbin enclosure hood 1. – Take out the upper part of the bobbin enclosure 2 with the bobbin 6. – Remove the empty bobbin from the upper part of the bobbin enclosure 2. Inserting a full bobbin – Place full bobbin in the top of bobbin case 2.
7.7 Adjusting the bobbin thread tension 1 2 3 1 Caution – Risk of Injury ! Turn the main switch off. Adjust the bobbin thread tension only when the automatic bartacker is switched off. The required bobbin thread tension should be generated by tension spring 1. The top of bobbin case 3 should drop slowly due to its own weight when being held at the threaded-in bobbin thread. Setting the tension spring – Take off top of bobbin case 3 with the bobbin.
7.8 Replacing the needle 2 1 3 2 1 Caution – Risk of Injury ! Turn the main switch off. Change the needle only when the automatic bartacker is switched off. – – – Loosen screw 1. Push in the new needle until it reaches the limit stop in the hole for the needle bar 2. CAUTION ! The hollow groove 3 of the needle must point to the hook. Tighten screw 1. CAUTION ! After the changeover to another needle size, the distance between hook and needle has to be corrected (see service instructions).
8. Operating the 511 Controller 8.1 The control panel A control panel with an LCD display and function keys is used for input and output of data. 1 8.1.1 The keys Function key Function Cursor keys If no text field is activated: Press the “ï” key to return from a sub-menu to the parent menu. If a text field is activated: Change between the points (this does not refer to the selection of seam patterns or sequences).
Function key Function If no text field is activated: Change between the lines of the menus. The selected line is displayed white on black. If a text field is activated: Increase or reduce the value of the respective point by one, or change between the parameters in the event that there are functions with several choices. OK key If no text field is activated: Activate the text field. The value can be altered with the “ñ” and “ò” keys. If a text field is activated: The set value is applied.
8.2 8.2.1 User interface Structure of menu Turn on main switch F key Service menu Code 1 Sewing mode ESC key ESC key F key Code 1 P key Programming mode Key ESC 1 Technician mode S key S key P key Sequence programming mode Call up the service mode – Press the function key “F” and keep it pressed. – Turn on the main switch. The control unit is initialized. After a short while, the window for entering the code number will appear. – Enter the code number (code 1, refer to chapter 8.5.4).
Call up the technician mode – Turn on the main switch. The control unit is initialized. The sewing mode menu appears on the display. 8.3 8.3.1 – Press the “F” key. – Enter Code 1 (see Chapter 8.5.4). – – Press the “OK” key. The display changes over to the technician mode. Altering numerical values, parameter values and selection of alternatives Alter numerical values – Select the desired line with the “ñ” and “ò” keys. – Press the “OK” key.
8.3.2 Selection of a parameter Some parameters offer a selection of non-modifiable adjustments. – Select the desired line with the parameter to be altered with the “ñ” and “ò” keys. – Press the “OK” key. – Change between the given possibilities with the “ñ” and “ò” keys. For example: Seam pattern number – Press the “OK” key. The currently set parameter is applied. 1 Or – Press the “ESC” key. The original parameter is maintained. 8.3.
8.4 Seam pattern Three different seam pattern types are available for the automatic bartacker 511: · Specified standard seam patterns (Type 1) (see chapter 11): The sewing parameters length, width and sewing speed can be altered in the sewing mode; the laser marking lamps can be switched on and off. The alterations are saved. However, after selection of another seam pattern, the alterations will be lost.
8.6 8.6.1 Main menu Seam pattern operations The parameters for the individual seam patterns are found in the main menu. The seam patterns can be altered using these parameters. – Turn on the main switch. The control unit is initialized. The main menu appears. – Select the desired parameter with the “ñ” and “ò” keys. The symbol of the selected parameter is displayed white on black. Alter selected parameter as described in chapter 8.3.
Thread tension in range 1 (refer to table 1) Input: 0 – 100 0 = lowest thread tension 100 = highest thread tension The thread tension magnet adjusts the thread tension according to the current value so that it can then be checked. The thread tension values for all further ranges in the seam pattern are set as the difference to the previous value. For the standard seam patterns (1 – 50), the thread tension cannot be individually set for the different ranges.
Number of stitches The number of stitches is indicated on this menu line (it cannot be modified). When selecting the line with the “OK” key, the sub-menu “Special functions” is opened. When selecting the line with the “OK” key, the sub-menu “Counter of daily number of pieces/Counter of capacity” is opened. Reset counter for daily number of pieces – Select the menu item by using the “ñ” and “ò” keys. – Press the “OK” key for 3 seconds until the displayed piece count is reset to 0.
Winding thread onto a bobbin: With the pedal: – Step pedal forwards (step 2). The sewing motor starts. – Step pedal backwards. The sewing motor stops. With the control panel – Press the “F” key. The sewing motor starts. – Press the “ESC” key. The sewing motor stops. With push button (optional) – Press button 2. The sewing motor starts. – Press button 1. The sewing motor stops. Soft start The soft start can be switched on or off using this parameter.
Sub-menu for counter of daily number of pieces or counter of capacity S .......Ö (5000) -: S =?: On 5000 Alternative display of counter of daily number of pieces or counter of capacity. Both counters work in parallel. You can select which counter is displayed in the main menu. · · – The counter of the daily number of pieces counts the number of the sewn seam patterns Display: 0 – 65000 The bobbin thread counter counts backwards.
8.6.2 Programming mode Under this menu item, the parameters for programming of seam patterns are arranged. With the help of these parameters, the shape, length, width and speed of the seam pattern are specified. : : : : : : : : 51 1 2700 25 16.0/ 2.0 0.0/ 0.0 42 On – Turn on the main switch. The control unit is initialized. The main menu appears. – Press function key “P” on the main menu. The display changes over to the menu of the programming mode.
Sub-menu for thread tension The thread tension values for the ranges in the current seam pattern are specified here. Sub-menu for thread tension: cross-tack seam pattern. Thread tension in Thread tension in Thread tension in The thread tension sub-menu for the range 1 (linear thread tension) range 2 (zig-zag thread tension) range 5 (thread tension at seam end) 1 Input: 0 100 , 0 = lowest thread tension 100 = highest thread tension All values can be set independently from each other.
Seam pattern Tack type Cross tack Straight-lined cross tack Longitudinal tack Straight-lined longitudinal tack Circular tack, stitched eyelet D tack Imitated button-hole tack Circular tack Tri-tack No.
Sub-menu for seam pattern dimension Select this sub-menu to set the seam pattern length and width. Display: current length/width Sub-menu for seam pattern offset Select this sub-menu to set the seam pattern offset in the X and Y directions. Display: current X/Y offset values Number of stitches Only indicates the number of stitches. Soft start The soft start can be switched on or off using this parameter.
8.6.3 Seam pattern sequences 8.6.3.1 Switching the sequence programming mode on or off Changeover from seam pattern operations to the seam pattern sequence operations – Press the function key “S” while the main menu is being displayed in order to go to the sequence programming mode. 0 – – Start the editing by pressing the “OK” key. Select any sequence by using the “ñ” key (1-25) – Confirm the selection with the “OK” key. The seam pattern sequence operation is switched on.
Switching from seam pattern sequence operation to seam pattern operation – Press the function key “S” while the main menu is being displayed in order to go to the sequence programming mode. – – Start the editing by pressing the “OK” key. Select the sequence number 0 by using the “ò “ key. – Confirm the selection with the “OK” key. The seam pattern sequence operation is switched off. – Press the “ESC” key or the “ï “ key. The main menu for the seam pattern operation will be displayed.
Menu items in the main menu for the seam pattern sequence Sequence Selection of the seam pattern sequence. Input: 1 (2 – 25, if available) Sequence succession Display of the sequence succession. The current seam pattern number is marked with a bar (underlined). If there are more than five numbers, the display is scrolled.
8.6.3.2 Programming a sequence In this menu item, individual seam patterns are combined to form retrievable seam pattern sequences. A total of 25 independent seam pattern sequences are available. Every seam pattern sequence can be combined out of 20 seam patterns in any order. The seam pattern sequence operations can also be turned on in this menu. – Turn on the main switch. The control unit is initialized. The main menu appears. – Press function key “S” in the main menu.
8.6.4 Technician mode The following menus are included in the technician mode: Machine configuration In this menu, machine-specific adjustments are made. User configuration In this menu, operation-specific adjustments are made. Service functions These service functions allow a quick verification of all hardware components. Free contours With the automatic bartacker 510, up to nine freely-defined seam contours can be created and sewn. The coordinates are entered directly at the control panel.
Access technician mode – Turn on the main switch. The control unit is initialized. The main menu appears. – Press function key “F” in the main menu. The screen for the code entry appears. – Enter code number “25483“ (Code 1). After entry of the correct code number, the display changes over to the menu “Technician mode”. – Confirm with the “OK” key. The following menu appears: Machine User settings Service Free contours Memory dongle : ---- – Select the desired sub-menu with the “ñ” and “ò” keys.
8.6.4.1 Machine configuration Parameter Soft start Equipment Times S : 262 Parameters In this sub-menu, different machine parameters can be set. Soft start In this sub-menu, the driving speeds for the soft start slope can be set. Equipment In this sub-menu, settings for the sewing equipment and optional units can be made. Times In this sub-menu, different timing parameters can be set. å 36 Machine cycles The total sewn cycles are displayed here.
Sub-menu for machine parameters Cut.rpm: 250 Max.rpm: 2700 Stop pos.: 0 Sew.st.pt.: A Ref.freq.: 1 Cl.thr.cl.:160 Op.thr.cl.:300 Op.thr.tn.:300 – Select the desired parameter with the “ñ” and “ò” keys. The symbol of the selected parameter / sub-menu is displayed white on black. – Start selected parameter with the “OK” key or change into the sub-menu. 1 Cutting speed Input of the sewing motor speed in the last three stitches.
Referencing The referencing mode of the step motor after the sewing process can be configured in this menu item. Input: 0 = no referencing 1 = referencing each time 2 – 10 = referencing after each second to tenth sewing step Closed thread clamp angle Setting the angle for closing the thread clamp. Input: 100 ° 240° Opened thread clamp angle Setting the angle for opening the thread clamp. Input: Closed thread clamp ...
Sub-menu for soft start In this sub-menu, speed adjustments for the soft start can be made. Speed first stitch Input of the speed in the first stitch. Input: 400 – 900 [rpm] Speed second stitch Input of the speed in the second stitch. Input: 1 400 – 2700 [rpm] Speed third stitch Input of the speed in the third stitch. Input: 400 – 2700 [rpm] Speed fourth stitch Input of the speed in the fourth stitch. Input: 400 – 2700 [rpm] Speed fifth stitch Input of the speed in the fifth stitch.
Sub-menu for sewing equipment In this sub-menu, adjustments for the sewing equipment can be made. W.clamp f....Ö Open dimens. Number: Length: Width: 1 4.5 20.0 Configuration Note The entry of the clamping foot number (also refer to chapter 12) is used to automatically verify whether the seam pattern to be currently sewn is positioned within the inner frame of the clamping foot. If the clamp numbers 9 to 13 and 16 are selected, only certain seam pattern numbers and sequence numbers are allowed.
Clamping foot number Max. Tack size (X,Y) [mm] Size X x Y [mm] Inner frame Inner frame Rectangular Description 1 2 3 4 5 6 7 8 9 10 11 12 13 19.0 x 3.5 20.0 x 4.1 26.0 x 4.0 9.0 x 3.5 4.6 x 20.0 18.0 x 11.0 40.0 x 20.0 8.5 x 3.6 14.0 x 14.0 11.0 x 8.0 8.6 x 11.6 11.6 x 7.5 12.9 x 11.2 20.0 x 4.5 21.0 x 5.1 27.0 x 5.0 10.0 x 4.5 5.6 x 23.0 19.0 x 12.0 44.0 x 24.0 9.5 x 4.5 16.0 x 16.0 12.0 x 14.0 24.6 x 12.6 12.6 x 21.0 34.8 x 12.
Sub-menu Configuration Hand sw.: El.wiper.: Thr.clamp: _/-clamp: Laserl.: Off Off On Off Off Input alloc. Output alloc. Hand switches Activating of optional hand switches. When the option is switched on, a menu item for selecting the operation mode will appear in the menu “User configuration”. Input: ON / OFF Electric thread wiper The optional electrical thread wiper can be turned on or off here. It can only be turned on as an alternative to the thread clamp.
Sewing process with the hand switch (optional) – Press key 1: clamp 1 will be lowered – Press key 2: clamp 2 will be lowered – Press key 2 again: the sewing process will be started – Press key 1: the clamp closed last will be lifted again – Press key 1 and keep it pressed (1.5 sec.): clamp 1 and clamp 2 will be lifted Laser lights Activating the 3 optional laser lights. Input: ON / OFF Assignment of the inputs This menu item gives an overall view of the assignment of the inputs with (optional) units.
Sub-menu Times Delay between pedal level 1 (lowering the clamping foot) and sewing start (t1) This time is only relevant with quick start via pedal or hand switch (optional). The menu is item is only displayed when the monitoring switch for the clamping foot is not connected. Input: 50 255 ms Turn-on delay for the thread wiper magnet (t2) This menu item will only be displayed if the “electric thread wiper” option is activated in the “Configuration” menu.
8.6.4.2 User configuration In this menu, user-specific settings are made. Language Hand switch: B Par.lock.: Off Pattern lock. Sequence lock. – Select the desired parameter or sub-menu with the “ñ” and “ò” keys. The selected parameter or sub-menu is displayed white on black. – Start the selected parameter with the “OK” key or change into the sub-menu. 1 Language In this sub-menu, the language can be chosen. German Selection of the German language for the technician level.
Push button operating mode (optional) Selection of the push button mode. This menu item is only available if the “hand switch” option in the “Configuration” menu is switched on. Input: A = Quick-start B = Normal In the push button mode “NORMAL”, the keys have the following functions: Key 1: Lifting and lowering of the clamping foot. Interruption of the sewing operation. Sewing operations stopped after interruption. Key 2: Sewing start when clamping foot is lowered. Interruption of the sewing operation.
Lock seam pattern In this sub-menu, individual seam patterns can be released or locked, for selection in the sewing mode. Lock all Unlock all 2: 3: 4: 5: 6: 7: On On On On On On The following restrictions apply: 1. Seam pattern operations · · The seam pattern currently selected in the sewing mode cannot be locked. In the sewing mode, locked seam patterns cannot be chosen from the selection list. Locked seam patterns are marked with “#”. 2.
Lock sequences In this sub-menu, individual sequences can be released or locked for selection in the sewing mode. The menu item is only displayed when more than one seam pattern sequence is programmed (refer to chapter 8.5.3, seam pattern sequence) Lock all Unlock all 2: 3: On On The following restrictions apply: 1. Seam pattern operations · The last sequence selected in the sequence operation cannot be locked. 2.
8.6.4.3 Service functions The service functions allow for quick inspection of all hardware components. Multitest 180°-disc Events Init Note The service menu can also be reached directly when switching on the machine (see chapter 8.2.1). 1 Multitest In the “Multitest” menu, all hardware components can be checked. 180° disc This menu item offers a function to correctly adjust the reference position of the sewing motor (180° disc) (refer to the Service Instructions).
Initialization The event memory buffer and the permanent data can be reset to the factory default settings in this menu. Multitest Selection of the Multitest sub-menu Output test PWM output tst Input test Auto input tst Motor test Step.motor tst RAM test EEPROM test 50 – Select the desired test function with the “ñ” and “ò” keys. The selected test function is indicated white on black. – Choose the selected test function using the “OK” key.
Output test With this testing function, the function of the output elements is checked. – – Start testing function with the “OK” key. Select the desired output element by pressing the “ñ” or “ò” keys. – Switch the selected output element on and off by pressing the “OK” key. ==== Output test ==== Output Y1: + – Press the function key “ESC” in order to leave the testing function. Caution – Risk of Injury ! Do not reach into the running machine during the function test of the output elements.
PWM output test This testing function checks the function of the magnets. – – Start test function with the “OK” key. Select the desired output element by pressing the “ñ” or “ò” keys. – Switch the selected output element on and off by pressing the “OK” key. == PWM output test == Output Y31: – 0 – The present electricity, flowing through the clamping foot solenoid will be displayed.
Input test With this testing function, the input element to be tested is selected. CAUTION ! The input elements have been carefully adjusted in the factory. Adjusting and correcting should only be carried out by trained service staff. Caution – Risk of Injury ! Do not reach into the working area of the machine when starting and ending the input tests. – Start the test function with the “OK” key. – Select the desired input element with the “ñ” and “ò” keys.
Auto-Input test With this testing function, the functioning of the input elements is checked. CAUTION ! The input elements have been carefully adjusted in the factory. Adjusting and correcting should only be carried out by trained service staff. Caution – Risk of Injury ! Do not reach into the working area of the machine when starting and ending the input tests. – Start testing function by pressing the “OK” key. – Press desired input element.
Sewing motor test With this testing function, the sewing motor can be checked. – – Start testing function with the “OK” key. Start motor with the “ñ” key. – Adjust the speed with the “ñ” and “ò” keys. The speed is displayed. ==== Motor test ===== 1 – Press the function key “ESC”. The test is finished and the motor stops. The sewing motor control makes a reference run and the clamping foot is lifted. The menu Multitest appears on the display.
Step motor test With this test function the step motors and the related reference switches can be checked. – Start testing function with the “OK” key. – Check transverse motion of the step motor (X axis). Move step motor with the “ï” or “ð” keys. The number of steps made is indicated to the left of the arrow. The status of the reference switch changes in the vicinity of the reference position. – Check longitudinal motion of the step motor (Y axis). Adjust the speed with the “ñ” and “ò” keys.
RAM test With this testing function, the static memory (SRAM and program data memory) is checked. – Start testing function with the “OK” key. The display shows the testing result. ===== RAM test ====== SRAM : Ö NVSRAM: Ö Display SRAM OK SRAM ERROR NV-RAM OK NV-RAM ERROR – 1 Explanation Static Random Access Memory works perfectly Error in the static memory Program data memory is okay Error in the program data memory Press the function key “ESC”. The test is finished.
EEPROM test This testing function checks the read memory (ROM) of the microprocessor. – Start testing function with the “OK” key. The display shows the following test results: - ROM size, - machine class, - software version, - software date, - check sum and status ==== EEPROM test ==== ROM size: 628k Class: 511 Version: A01 Date: 01-07-08 Check sum: 0x1234 Ok Note: The details will vary depending on the software version. – 58 Press the function key “ESC”. The testing is finished.
Events In the event of a malfunction, this menu can give important hints regarding the cause. Event memory Latest events Event memory === Event memory ==== E4304: E8254: 1 3 x 1 x (example) This menu item displays all events which have occurred. – Exit the menu item by pressing the “ESC” key. – Continued display by pressing the “ò” key.
Initialization (Init) This is the selection of the sub-menu for the initialization of the event memory and the permanent data. Event memory Progr./Sequ. Mach./User p. Free Contours Maschine cpl. Event memory Using this menu item, the event memory can be reset. Seam pattern programs (variants) and sequences Using this menu item, seam pattern programs and sequences can be deleted.
8.6.4.4 Free contours With the automatic bartacker 510, up to nine freely-defined seam contours can be created and sewn. The entry of the coordinates is carried out at the control panel. Design Edit: Delete: Copy: 0 0 0 No.st.av.:4900 No.pat.av.: 8 Creating Using this menu item, a new seam contour can be created. 1 Note The number of the seam contour is assigned automatically. Altering After selection of the seam contour to be altered, the sub-menu for altering the seam contour will appear.
Maximum sewing area (grey field) Stitch to be determined Sketched seam contour Machine zero point Coordinate system with X- and Y-axis Note The seam contour should be laid out in such a way that the machine neutral point is as close to the middle of the contour as possible. – – – – – 62 Sketch the maximum sewing field size on the millimetre-scaled graph paper (X = max. 40 mm, Y = max. 20 mm). Draw the coordinate system in the centre of the sewing field. Draw in seam contour.
Create seam pattern In this menu, the X- and Y-coordinates are entered for each individual stitch. X1: 0.0 Y1: 0.0 X2: 0.0 Y2: 0.0 X3: 0.0 Y3: 0.0 Append stitch Parameters Note In order to enter stitch operations (e.g. intermediate cutting), first complete the seam pattern (entering of the coordinates) and then insert the stitch operation through editing in the menu “Changing seam pattern”. 1 X1: Input of the X-coordinate for stitch 1 Input: -20.0 – +20.
Sub-menu parameter Selection of the sub-menu for entering the seam pattern parameters Std.rpm: Orig. X: Orig. Y: 1500 0.0 0.0 Standard speed: Standard speed Input: 100 – 2700 rpm orig. X: Reference point X for change of size Input: -20.0 – +20.0 orig. Y: Reference point Y for change of size Input: -10.0 – +10.0 The reference point for the change of the seam pattern size is individually and internally defined for every seam pattern. Normally it is the machine zero point.
Change seam pattern Design Edit: Delete: Copy: 0 0 0 No.st.av.:4900 No.pat.av.: 8 – Select desired menu item with the “ñ” and “ò” keys. – Press the “OK” key. – Select free seam contour with the “ñ” and “ò” keys. – Confirm by pressing the “OK” key. The menu “Change seam pattern” is displayed. 1 Stitch coordin Del.St.: 0 Ins.St.: 0 Append stitch Parameter No.stich: 100 No.st.av.:4900 Stitch coordinates Selection of the sub-menu for altering the stitch coordinates. Delete stitch: Delete stitch.
Sub-menu stitch coordinates If the seam pattern to be altered has less than 99 stitches, the sub-menu appears immediately. If the seam pattern to be altered has more than 99 stitches, the following menu appears first: – Select the desired range of stitches with the “ñ ” or “ò” keys. – Select the range of stitches with the “OK” key. The sub-menu “Stitch coordinates” appears – Select the desired stitch with the “ñ ” or “ò” keys. – Select stitch with the “OK” key.
Sub-menu “Alter stitch coordinate” This sub-menu appears when selecting a stitch coordinate from the menu “Stitch coordinates” and after adding or altering a stitch. (example) Op1 Altering the movement operation for stitch 10 Input: refer to the table below 1 Op2 Altering the thread-tension operation for stitch 10 Input: refer to the table below Op3 Altering the speed operation for stitch 10 Input: refer to the table below Note: The stitch operation entered will be executed after the stitch.
Type of operation Operation Description Movement operation (Op1) Intermediate thread cutting The intermediate cutting can be programmed up to 10 times within a seam pattern. At least 3 stitches must be sewn between two intermediate cuttings.
Delete seam pattern Design Edit: Delete: Copy: 0 0 0 No.st.av.:4900 No.pat.av.: 8 – Select the menu item “Delete” with the “ñ” and “ò” keys. – Press the “OK” key. – Select desired seam pattern number with the “ñ” and “ò” keys. – Confirm by pressing the “OK” key. The seam pattern will be deleted. 1 CAUTION ! If you delete a free seam contour, the numbering of the seam pattern programs or sequences can also be deleted and thus changed.
Copying a seam pattern Design Edit: Delete: Copy: 0 0 0 No.st.av.:4900 No.pat.av.: 8 – Select the menu item “Copy” with the “ñ” and “ò” keys. – Press the “OK” key. – Select the desired seam pattern number (1-50, 91-99) with the “ñ” and “ò” keys. – Confirm by pressing the “OK” key. The seam pattern will be copied and the “Change seam pattern” menu will be displayed. Stitch coordin Del.St.: 0 Ins.St.: 0 Append stitch Parameter No.stich: 42 No.st.av.
8.6.4.5 Memory dongle With this sub-menu, data can be transferred from the machine to the dongle or vice versa. Dongle index Load Save Format Dongle contents With this menu item, the content of a dongle connected to the control unit can be displayed. 1 Load With this menu item, program data (seam pattern programs and sequences), machine parameters and free seam contours can be uploaded from the dongle to the machine.
Display dongle contents Boot dongle If a boot dongle is inserted, information is sent to the machine program. Class: 511 Subclass: 000 Version: A01 Date: 010708 (example) In order to display the dongle information, a boot dongle with a machine program for any machine class can be inserted. Data dongle: If a data dongle formatted for the machine class 510 is inserted, then the saved seam pattern programs or free seam contours are displayed.
Output of saved free seam contours F01: F02: F03: F04: Data1 Kontur02 Kontur03 cont. 94 (example) Data dongle for a different machine class The following is displayed if a dongle from another machine class is inserted. 1 (example) Upload data from the dongle to the machine Here, program data (seam pattern programs and sequences), machine parameters or all free seam contours can be uploaded from the dongle to the machine. Dongle index Free contours Progr./Sequ. Machine param. Machine cpl.
Contents With this menu item, the content of a memory dongle connected to the control unit can be displayed. Before the following four data types are loaded, a confirmation window is displayed. – Press the “ï” key (no) in order to abort the process. Press the “ð” key (yes) in order to continue with the process. The time needed for the upload depends on the number of seam pattern programs and free seam contours. Free seam contours The loading of all free seam contours can be started with this menu item.
Saving data on the dongle Here, program data (seam pattern programs and sequences), machine parameters or all free seam patterns can be downloaded from the machine to the dongle. Dongle index Free contours Progr./Sequ. Machine param. Machine cpl. Contents With this menu item, the content of a memory dongle connected to the control unit can be displayed. Before the following four data types are saved, a confirmation window is displayed. – Press the “ï” key (no) in order to abort the process.
A confirmation window will be shown for confirming your selection. – Press the “ï” key (no) in order to abort the process. Press the “ð” key (yes) in order to continue with the process. The program data and machine parameters on the dongle will be deleted when saving! Note The time needed for saving the data depends on the number of seam pattern programs on the machine. Format a dongle Before a dongle can be used to save data, it must be formatted as a data dongle.
Error messages Icon Designation Possible cause Action Dongle missing No dongle is inserted Insert the dongle in the control unit Dongle empty No data is saved on the dongle Save data to the dongle Wrong dongle type The dongle is incorrectly formatted for the desired function • Use another dongle • Format dongle Wrong machine class Data dongle is not formatted for Class 511 • Use another dongle • Format dongle Format-ID error • Dongle has been incorrectly formatted • Dongle defective • Refo
8.7 Distributor PCB The distributor PCB is located at the back of the machine below the clamping foot magnet. All control unit inputs and outputs are accessible from here. The rear cover must be removed in order to gain access to the terminals. Description of the outputs Output number Output Assignment Y1 (FW/FK) 24V / 4 A Thread clamp magnet / optional: Thread wiper magnet Y2 24V / 0.5 A - Y3 24V / 3 A - Y4 (FS) 24V / 4 A* Thread tension magnet Y5 24V / 0.
Description of inputs Input number Input Assignment S1 24V Optional: Hand switch 1 S2 24V Optional: Hand switch 2 S3 - S10 24V - S12 (N-Ref.) 24V Reference switch for the sewing motor S14 24V Pedal A S15 24V Pedal B S16 24V Pedal C S17 24V Pedal D S21 - S24 24V - S25 (X-Ref.) TTL Reference switch for the step motor, X axis S26 (Y-Ref.) TTL Reference switch for the step motor, Y axis S27 - S28 TTL - 1 S1 - S17: The lower switching threshold is 7.2V.
8.8 Error messages If an error occurs with the control system or the seam pattern program, the display shows a symbol and an error number. The following table can help in troubleshooting these errors. 8.8.1 No. Error categories Name Description 1 Critical error An emergency shut-off will be carried out. The automatic bartacker must be turned off and then back on. 2 Error The user must confirm the error before continuing work. 3 Caution The user must confirm the error before continuing work.
8.8.2 Icon Application messages Description Category Action Capacity counter is zero Note • The clamping foot can be lowered only after pressing the “OK” key. • The message disappears after the key is pressed. • After pressing the key, the capacity counter is reset to its starting value. Handwheel turned manually Caution After aborting the sewing process: • No further sewing is possible • Abort the sewing process by pressing back on the pedal.
Icon 82 Description Category Action The contour overlaps the clamping-foot inner frame in the X direction Caution • • • • No sewing start is possible Select another clamping foot Select another seam pattern Decrease the seam pattern in the X direction The contour overlaps the clamping-foot inner frame in the Y direction Caution • • • • No sewing start is possible Select another clamping foot Select another seam pattern Decrease the seam pattern in the Y direction The contour overlaps the clampi
8.8.
Error code 3104 Description 24V switching power supply: overload Possible cause - Overload 24V output - Short circuit output distribution board - Cable connection to the distribution board damaged Remedy - Check the output element or the other outputs - Check the connections, fix the short circuit.
Error code 4312 Description Unknown dongle type Possible cause Remedy - Dongle has been incorrectly formatted - Dongle faulty - Reformat dongle - Use a different dongle 4530 4537 4900 Menu system / user message error Internal error Turn machine off and then on again. Software update. Inform DA service 5101 NV-RAM empty Control unit is new, no data available.
Error code Description Possible cause Remedy 7551 7559 Communication control panel interface Internal error - Switch machine off and on again - Software update - Inform DA Service 7556 7557 Communication control panel interface - Line interference - Cable to control panel interface is defective - Switch off source of interference - Check the cable 7700 Protocol: Max.
9. Sewing Sequence of operations and functions during sewing: Sewing process Operation / Explanation Before the start of sewing Starting position - Pedal is in the resting position. The automatic bartacker is at rest. Needle is up, fabric clamps are up. Load the workpiece Sewing - Push the pedal to the front to level 1. The clamps are lowered. - Let up on pedal. The clamps raise up again. The workpiece can be re-positioned. - Step forward on the pedal fully.
10. Maintenance 10.1 Cleaning and checking Caution – Risk of Injury ! Turn the main switch off. Maintenance work of the automatic bartacker must only be carried out when the machine is switched off. All maintenance work must be carried out before or at the maintenance intervals defined in the table (refer to the “operational hours” column). When working with materials that are thick and fibrous, shorter maintenance intervals may be required. A clean automatic bartacker helps to prevent malfunctions.
10.2 Oil lubrication 1 3 2 1 Caution – Risk of Injury ! Oil can cause skin rashes. Avoid prolonged skin contact. If oil or grease contacts your skin, wash yourself thoroughly. CAUTION ! The handling and disposal of mineral oils is subject to legal constraints. Deliver used oil to an authorized reception point. Protect your environment. Take care not to spill any oil.
11. Tack type larger Cross 90 Standard Seam Patterns No. Stitch diagram Number of stitches Seam size (mm) X Y Clamping foot no. 1 42 16 2.0 1, 2 2 42 10 2.0 1, 2 3 42 16 2.5 1, 2 4 42 24 2.5 3 tack 5 28 10 2 1, 2 6 28 16 2.5 1, 2 7 36 10 2 1, 2 8 36 16 2.
Tack type No. Stitch diagram Number of stitches Seam size (mm) X Y Clamping foot no. 9 56 24 3 3 10 64 24 3 3 11 21 6 2.5 4, 8 larger crosstack 1 12 28 6 2.5 4, 8 13 36 6 2.
Tack type No. Stitch diagram Number of stitches Seam size (mm) X Y Clamping foot no.
Tack type No. Stitch diagram Number of stitches Seam size (mm) Clamping foot no.
Tack type No. Stitch diagram Number of stitches Seam size (mm) X Y 12 Clamping foot no.
Tack type No. Stitch diagram Number of stitches Seam size (mm) X Y Clamping foot no.
Tack type No. Stitch diagram Number of stitches Seam size (mm) X Y Clamping foot no.
Comment Description Valid standard seam pattern Default standard seam pattern number Rectangular inner frame Clamping feet Max. tack size I(X/Y) [mm] Clamping foot no. 12. 1 19.0 x 3.5 yes 1 all Cross tack Standard configuration Cl. 511-211 2 20.0 x 4.1 yes 1 all Cross tack Standard configuration Cl. 511-213 3 26.0 x 4.0 yes 4 all large cross-tack Optional 4 9.0 x 3.5 yes 2 all Small cross-tack Optional 5 4.6 x 20.0 yes 23 all Longitudinal tack Optional 6 18.
Notes: 98
