DURKOPP ADLER 531 Operating instructions

531

CNC Knopfannähautomat

CNC Automat for Button Sewing

Bedienanleitung / Operating Instructions

Aufstellanleitung / Installation Instructions

Serviceanleitung / Service Instructions

Postfach 17 03 51, D-33703 Bielefeld  Potsdame r Straße 190, D-33719 Bie lefeld

Telefon +49 (0) 5 21/ 9 25-00  Telefa x +49 (0) 5 21/ 9 25 24 35  www.duerkopp-adler.com

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

02/2011 Rev. index: 01.0 Printed in Federal Republic of Germany 0791 531001

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

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

verboten.

All rights reser ved.

Property of Dürkopp Adler AG and copyrighted. R eproduction or publication of the content in any

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

Dürkopp Adler AG - 2011

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:

Foreword and general safety instructions

Part 1: Operating Instructions Class 531- Original instructions

(Version: 02.2011)

1 Product description ........................................... 5

2 Intended use ................................................ 6

3 Subclasses ................................................. 6

4 Additional equipment........................................... 7

5 Supporting frame ............................................. 7

6 Technical data

6.1 Technicaldataforthesubclasses.................................... 8

7 Operation

7.1 Threadingneedlethreads......................................... 9

7.2 Adjustingneedlethreadtension..................................... 10

7.3 Openingneedlethreadtensioner .................................... 10

7.4 Adjustingthreadregulator......................................... 11

7.5 Winding hook threads ........................................... 12

7.6 Changing hook thread bobbin ...................................... 13

7.7 Adjusting hook thread tension ...................................... 14

7.8 Changingtheneedle............................................ 15

7.9 Buttonshankshaper............................................ 16

7.10 Adjusting the button clamp hook feet .................................. 17

8 Operating the control unit

8.1 Theoperatingterminal........................................... 18

8.1.1 Thebuttons ................................................. 18

8.2 Userinterface................................................ 20

8.2.1 Menustructure ............................................... 20

8.3 Changingnumberandparametervalues,alternativeselection .................. 21

8.3.1 Changingnumbervalues ......................................... 21

8.3.2 Selectingaparameter........................................... 22

8.3.3 Alternativeselection............................................ 22

8.4 Sewingpattern ............................................... 23

8.5 Energysavingmode............................................ 23

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Contents Page:

8.6 Mainmenu.................................................. 24

8.6.1 Sewingpatternoperation......................................... 24

8.6.2 Programmingmode............................................. 29

8.6.3 Copyingfunctionforsewingpatternprograms............................ 33

8.6.4 Sewingpatternsequence(sequences)................................. 34

8.6.4.1 Switchingsewingpatternsequenceoperationonandoff...................... 34

8.6.4.2 Sequenceprogrammingmode...................................... 37

8.6.5 Technicianmode .............................................. 38

8.6.5.1 Machineconfiguration........................................... 40

8.6.5.2 Userconfiguration ............................................. 48

8.6.5.3 Servicefunction............................................... 52

8.6.5.4 Freecontours................................................ 64

8.6.5.5 Memory dongle ............................................... 73

8.7 Distributorcircuitboard.......................................... 80

8.8 Errormessages............................................... 82

8.8.1 Errorcategories............................................... 82

8.8.2 Applicationmessages........................................... 83

8.8.3 Machineerrors ............................................... 85

9Sewing.................................................... 89

10 Maintenance

10.1 Cleaning and checking ........................................... 90

10.2 Oillubrication................................................ 91

11 Standard sewing patter n ........................................ 92

12 Clamping feet ................................................ 95

13 Repair .................................................... 96

1 Product description

The Dürkopp Adler 531 is a CNC lockstitch button sewer. The

existing button patterns are scalable and can be saved in this

modified form. In addition it is possible to enter “free” stitch patterns

(programming). The button sewer is fitted with an automatic sewing

foot elevator, a thread cutter, a thread wiper, an electromagnetic

thread tensioner and an integral DC direct drive.

Technical features:

–

The sewing attachment is driven by an integral positioning drive. A

DAC control unit controls not only the sewing drive but also two

step motors for the X and Y movement to create the stitch

geometry.

–

The maximum size of the sewing area is 40 mm in the X direction

and 20 mm in the Y direction.

–

The thread is tensioned electromagnetically. It can be freely

configured in specific areas of the stitch patter n.

–

The wick is lubricated centrally for the top part and hook. Two

separate oil reservoirs are available for this that are both supplied

by the top container. There is only one refilling point.

–

A maximum of 50 standard button patterns are available. These

standard patterns can be modified temporarily (changing the

overall length, width, speed). When the machine is switched off

the modified values of the last used bar tack are retained when it

is switched on again.

–

40 modified standard patterns can also be stored.

–

There is also a maximum of 9 free stitch contours with a total of

3000 dynamically managed stitches available. Thus, for example,

free button patter ns can be sewn. The co-ordinates of the free

stitch contours are entered on the operating panel. No other

machine is required.

–

25 sewing pattern sequence programs each with up to 20 sewing

patterns can be created and saved.

–

The accuracy of the co-ordinate entry is 0.1 mm.

–

It is possible to block special button and/or button sequence

programs and/ or modifications so that unauthorized use or

modification can be stopped from the technician level.

–

It is possible to perform an intermediate cut without raising the

button clamp so that a connection thread can be avoided.

–

The control unit can respond to external signals (input) and can

also output signals itself (output).

–

There is a hook thread counter and a daily piece counter.

–

The arm shaft on the button sewer is driven directly by a brushless

direct current motor.

–

Speeds of 0 min

-1

(manual operation with full functionality of the X

and Y drives) up to 2700 min

-1

can be reached in 100 min

-1

steps.

–

Service and maintenance work is supported by extensive test

programs with which the individual functions can be tested

separately.

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2 Intended Use

The Class 531 is a button sewer that can be used as intended to sew

light to medium weight material. Such material is normally material

made out of textile fibers or leather. Such sewing materials are used in

the clothing, domestic upholstery and automobile upholstery industry.

In addition it is possible t hat even so-called technical seams can be

done with this button sewer. However, here the operator (in

co-operation with DÜRKOPP ADLER AG) must assess the possible

risks because such applications are on the one hand comparatively

rare and on the other hand there is an enormous variety. Depending

on the results of this assessment suitable precautions may need to be

taken.

Normally only dry material must be processed with this button sewer.

The material must not be thicker than 9 mm if it is to be compressed

through the lowered sewing feet. The material must not contain any

hard objects. The button sewer must not be operated without an eye

guard.

The seam is normally created with sewing threads made of textile

fibers (cotton thread, synthetic thread or braided yarns) with the

following dimensions:

Class 531-211 50/3 - 120/3 thread thickness

If you want to use other threads you must also the assess risks arising

from this and if necessary take precautions.

This button sewer must only be installed a nd operated in dry, tidy

premises. If the button sewer is used in other rooms t hat are not dry

and tidy other measures will be required that will have to be agreed

(see EN 60204-31: 1999).

As a manufacturer of industrial sewing machines we assume that at

least skilled operating personnel work on our product s o that all the

normal conditions and if necessary their risks can be assumed to be

known.

3 Subclasses

Cl. 531-211 Single needle lockstitch button sewer with automatic sewing foot

elevation, thread cutter and thread wiper and electromagnetic thread

tensioner.

Fitted with a special button clamp for:

- laundry = button sizes of Æ 7-Æ 18 mm

-DOB&HAKA=buttonsizesofÆ 11 - Æ 40 mm together

with optional button shank shaper unit.

The machine has a shank button rest.

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4 Additional equipment

The following additional equipment is available for the button sewer

531:

Order no. Additional accessories

9822 51 002 6 Sewing light

9822 51 002 7 Table clamp

9870 00 102 1 K lead (socket adapter set for sewing light)

0511 59 001 4 Laser marking (3 lights)

0510 59 003 4 Additional laser light

0511 59 003 4 Manual switch

0531 36 064 4 Button shank shaper unit inc. clamping feet

5 Frame

The following supporting frame is available for the button sewer 531.

MG55 40 029 4 Frame package

Table plate size 600 x 1060 mm

Frame height 1160 to 1,305 mm

6 Technical Data

Noises: Lc = 78 dB (A)

Work place-related emission value in accordance with DIN

45635-48-A-1-KL-2

Speed: 2,700 min

-1

Material: G1 DIN 23328 2 layers

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6.1 Technical data for the sub classes

Subclass: 211

Sewing stitch type: 301

Hook type: Oscillating hooks

Needle system: DPx17 (135x17)

Needle thickness: [ Nm] 80 - 110

Needle thickness [ Nm] 90

standard:

Thread thickness: 50/3 - 120/3

Stitch length: [mm] Depending on seam construction

Max. speed [min

-1

] 2700

Clamp elev ation [mm] 9

On delivery

maximum 13

Sewing area [mm]

max. in X direction: 40

max. in Y direction: 20

Number of standard 50

button patter ns

Number of patterns that can be saved

and/or modified 40

Number of sewing patter n

sequence programs 25

Number of sewing patter ns per

sewing patter n sequence program 20

Number of free max. 9

seam contours

Soft start can be switched on and off

Sewing drive: DC motor

Rated voltage: [V] 1 ~ 230V/ 50/60 Hz

Power rating: [ kW ] 0.45

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7 Operation

7.1 Threading needle threads

Caution, danger of injury!

Switch the main switch off.

Only thread needle threads when the button sewer is switched off.

–

Put reels of thread onto the thread stand and run the needle and

hook threads through the feed arm.

The feed arm must be vertically above the thread reels.

–

Thread needle threads as shown in the following illustration

.

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7.2 Adjusting needle thread tension

Pre-tensioning 3

When the main tensioner 2 is open a slight residual tension on the

needle thread is required. The residual tension is created by the

pre-tensioner 3.

At the same t ime the pre-tensioner 3 affects the length of t he cut

needle thread end (starting thread for the next seam).

–

Shorter starting thread:

Tur n the knurled nut 1 clockwise.

–

Longer starting thread:

Tur n the knurled nut 1 anti-clockwise.

Main tensioner 2

The main tensioner 2 must be set as low as possible.

The threads should intertwine in the middle of t he material.

If the thread tensions are too great this could lead to unwanted

crimping and thread tearing with thin material.

–

Adjust the main tensioner 2 so that an even stitch pattern is

achieved.

To increase tension = turn the knurled nut

clockwise

To reduce tension = turn the knurled nut

anti-clockwise

7.3 Opening needle thread tensioner

Automatic

The needle thread tension opens automatically when the thread is cut

and when the material clamping feet are raised.

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7.4 Adjusting thread regulator

Caution, danger of injury!

Switch the main switch off.

Only adjust the thread regulator when the button sewer is switched

off.

The thread regulator 3 adjusts the amount of needle thread required to

form the stitch.

Only a precisely adjusted thread regulator guarantees optimum

sewing results.

If the adjustment is correct the needle thread loop must slide over the

thickest part of the hook with slight tension.

–

Undo screw 1.

–

Change the position of the thread regulator 3.

Thread regulator to the left = greater needle thread quantity

Thread regulator to the right = smaller needle thread quantity.

–

Screw up screw 1.

Adjustment note:

If the greatest amount of thread is required the thread take up spring

2 must be pulled down about 0.5 mm from its final upper position.

This is the case if the needle thread loop passes the maximum hook

diameter.

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7.5 Winding hook threads

–

Put the bobbin on the bobbin winder 4.

–

Pull the thread through the guide 2 and round the tensioner 1 .

–

Wind the thread anti-clockwise about 5 times round the coil

bobbin.

–

Push the bobbin lever 3 onto the bobbin.

–

Sew

The bobbin lever ends the procedure as soon as the bobbin is full.

–

After winding break the thread on the thread clamp 5.

Note!

Should the thread be wound without sewing

the thread winding mode can be switched to in the “Special functions”

sub menu.

When the thread winding mode is switched on the sewing motor can

be started with the pedal or the manual switch regardless of the

sewing area drive (here unthread threads on the thread lever).

For settings see Section 8.5.1 “Thread winding mode”.

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7.6 Changing hook thread bobbin

Caution, danger of injury!

Switch the main switch off.

Only change the hook thread bobbin when the button sewer is

switched off.

Removing the empty bobbin

–

Pull the hook cover 3 downwards.

–

Lift up the bobbin case latch 1.

–

Remove bobbin case 2 with bobbin 6.

–

Take the empty bobbin out of the bobbin case 2.

To insert a full bobbin

–

Insert a full bobbin into the bobbin case 2.

–

Thread the hook thread through slit 5 under the tensioning spring

7 into the hole 4.

–

Pull about 2.5 cm of hook thread out of the bobbin housing.

The bobbin must tur n in the direction of the arrow when the thread

is being pulled out.

–

Replace the bobbin case 2.

–

Close the bobbin case latch 3.

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5

2

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7.7 Adjusting hook thread tension

Caution, danger of injury!

Switch the main switch off.

Only adjust the hook thread tension when the button sewer is

switched off.

The required hook thread tension should be created by the tensioning

spring 1. The bobbin case 3 should drop slowly under its own weight if

the threaded hook thread is to be held fast.

Adjusting the tensioning spring

–

Remove the bobbin case 3 and the bobbin.

–

Change the tensioning spring 1 with the adjustment screw 2 until

the required tension is reached.

–

Replace the bobbin case.

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7.8 Changing the needle

Caution, danger of injury!

Switch the main switch off.

Only change the needle when the button sewer is switched off.

–

Undo screw 1.

–

Push the new needle into the hole in the needle bar 2 until it can

go no further.

CAUTION!

The hollow channel 3 on the needle must point towards the hook.

–

Screw up screw 1.

CAUTION!

After changing to a different needle thickness the distance between

the hook and the needle must be adjusted (see Service instructions).

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7.9 Button shank shaper (optional)

The button clamp on the button sewer is fitted with a button shank

shaper 1.

Setting the shank length

–

To change the setting of the button shank shaper 2:

downwards = shank becomes shorter

upwards = shank becomes longer.

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7.10 Adjusting the button clamp hook feet

Caution, danger of injury!

Take great care when adjusting the button clamp when the button

sewer is switched on.

The button should be pushed as lightly as possible between the hook

feet on the button clamp and can be aligned.

But the button must be securely clamped so that it cannot tur n when

it is inserted into the material.

Stop 4 adjusts the amount the hook feet open.

–

Switch the button sewer on.

The button clamp lifts up.

–

Put the button to be sewn on between hook feet 1 and 2.

–

Undo knurled nut 3.

–

Move the stop towards the screw 5.

–

Tighten knurled nut 3.

–

Check whether the button can be inserted easily and aligned.

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8 Operating the control unit 531

8.1 The operating terminal

An operating terminal with an LCD display and function buttons is

used for entering and outputting data.

P button: S button:

Programming mode Sequence

programming

ESC key F key

Technician mode

Cursor keys

OK key

8.1.1 The buttons

Function button Function

Cursor keys

If no input field is s elected:

Press “ï” to get back to a sub menu in the higher menu.

If an input field is selected:

Switch between the positions (not when selecting the sewing patter n

or sequences).

In sewing mode with sequence mode:

Switch to the next or previous sewing pattern.

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DURKOPP ADLER 531 Operating instructions

DURKOPP ADLER 531 Operating instructions

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