DURKOPP 867 Instruction manual

867

Spezialnähmaschine

Betriebsanleitung

Instruction manual

Instructions d’emploi

D

GB

F

Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld

Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com

Ausgabe / Edition: Änderungsindex

10/2010 Rev. index: 07.0

Printed in Federal Republic of Germany

Teile-Nr./Part.-No.:

0791 867740

Alle Rechte vorbehalten.

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

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

All rights reserved.

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.

Tous droits réservés.

Propriété de la société Dürkopp Adler AG et protégé par la loi sur le droit d’auteur. Une copie ou reproduction par quelque procédé que ce soit du contenu sans accord écrite de l’auteur est interdite.

Copyright © Dürkopp Adler AG - 2010

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:

Part 2: Installation Instructions Class 867 – Original Instructions

1

2

Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General and transport packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

6.6

6.7

6.8

6.9

6.1

6.2

6.3

6.3.1

6.3.2

6.3.3

6.4

6.5

5

5.1

5.2

5.3

5.4

5.5

5.6

4.

4.1

4.2

4.3

4.4

4.4.1

4.4.2

4.5

4.6

4.7

3

3.1

3.2

3.3

3.4

3.5

3.6

Assembling the stand

Assembling the stand components (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling the table plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling the stand components (Long arm) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling the table plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self-manufacture of the table top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the working height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sewing drives

Drive category, type and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the sewing drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the control unit on machines with direct drive. . . . . . . . . . . . . . . . . . . . . . . .

Fitting the set value initiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Fitting the sewing-drive control for machines with direct drive (only 867-190142-M) . . . .

Fitting the set value initiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Assembling the machine head

Fitting the machine head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the oil suction tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting and tensioning the V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attaching the knee lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the sewing lamp (optional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical connection

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the sewing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the clutch motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the coupling-positioning actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the direct-current positioning actuator . . . . . . . . . . . . . . . . . . . . . . . . .

Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the sewing drive to the mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive-control connection sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the proximity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the machine head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction of rotation of sewing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

5

9

10

9

9

7

7

17

17

19

20

21

21

23

23

24

25

23

23

23

23

25

26

26

27

15

15

15

16

11

12

12

13

14

GB

Contents Page:

7

7.1

8

6.9.1

6.9.2

Checking the direction of rotation with the coupling-positioning actuator (mounted under the table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the direction of rotation with the coupling-positioning actuator (mounted under the table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10

Connecting the sewing light transformer (optional equipment) . . . . . . . . . . . . . . . . . .

6.10.1

Attaching and connecting the sewing light transformer (optional equipment) . . . . . . . . .

6.10.2

Connection to the DA321G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10.3

Connection to the DAC Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11

Connecting the direct drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.1

Connecting the Hall sensor (optional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.2

Connecting the DA321G control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.3

Connecting the DAC Classic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12

6.13

Connecting the knee switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the M-Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14

Setting the switches on the M-Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15

Setting machine-specific parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.2

Autoselect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.3

Subclass 867-290342-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Pneumatic connection

Pneumatic sewing foot lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication

Sewing test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

33

34

35

36

37

37

37

37

30

31

31

33

27

28

28

29

40

41

42

3

GB

9

10

1

2

12

3

4

7

8

11

6

5

4

1 Scope of Delivery

What items are supplied depends on your order .

Prior to setting up, please check that all the required parts are present.

This description refers to a special sewing machine, of which all individual components can completely be delivered by Dürkopp Adler

AG.

–

1 Machine head incl. oil sump

Dürkopp Adler accessory set with:

–

2 Reel stand

Protection cover (not represented)

–

11 Oil tray

Set of electronic parts, depending on the order, for:

Machines with direct-current actuator

–

4 Sewing-drive control

–

10 Operating panel

–

12 Cover

Machines with positioning actuators

–

Main switch

–

Sewing-drive

–

Synchronizer

–

Belt guard

Optional equipment

–

7 Stand (option)

–

6 Pedal and pedal linkage (option)

–

3 Table top (option)

–

8 Drawer (option)

–

Knee lever

–

Pneumatic sewing foot lifting

GB

2.

General and transport packing

Caution:

The special sewing machine must be set up by trained specialist personnel.

If the special sewing machine you have bought is already set up, the following transport packing must be removed:

–

Safety straps and battens on the machine head, table and stand.

–

Safety block and straps on the sewing drive

5

6

11

3,5x17 (x 6)

10

12

Observe the punch-marks of the table plate!

13

1

4,5x15 (x 4)

3,9x15 (x 5)

3,5x17 (x 2)

7

2

3

14

4

5

6

9

B8x35 (x 4)

DIRECT DRIVE

8

3.

Assembling the stand

3.1

Assembling the stand components

–

Assemble the individual stand components as shown in the illustration.

–

Adjust the set screws 8 to insure the stability of the stand.

Make sure that the stand is safe by insuring that every single foot of the stand touches the ground.

3.2

Assembling the table plate

(867-190020, 867-190040, 867-190122, 867-190142, 867-190145,

867-290020, 867-290040, 867-190322, 867-190342, 867-190445,

867-290322, 867-290342, 867-290445, 867-392342, 867-393342,

867-490322)

In order to have an optimal arrangement of the components, follow the layout.

Stand Layout

MG55 400304

MG55 400314

0791 867710

0791 867711

–

Screw the drawer 10 with its holders onto the left side underneath the table plate .

–

Screw the oil sump 7 under the table plate.

With sewing machine equipped with direct drive, all the three stops should lie against the table opening.

With sewing machine equipped with the drive mounted under the table, the stop 14 must have 9 mm distance from the table top opening.

–

Screw the main switch 5* to the right side under the table plate.

–

Screw the cable duct 4 * behind the main switch 5 under the table plate.

–

Screw the holder 3 for the traction relief of the connecting cable behind cable duct 4 under the table plate.

–

Screw the sewing-lamp transformer 6 (optional equipment) under the table plate.

–

Put the cap 13 into the bore hole of the table plate.

–

Place the hinge bottoms 12 for the machine head into the cutout of the table plate 9 and tighten the screws.

–

Insert the rubber corner 2.

–

Attach the table plate 11 to the stand with woodscrews (B8 x 35)

(see sketch for position).

–

Insert the yarn stand 1 in the hole in the table plate and secure it with the nuts and washers. Fit and align the yarn reel and unwinding holders.

The yarn reel holder and the unwinding arm must be vertically in line.

–

Screw the holder for the oil-can 9 onto the left-hand stand brace.

* Not applicable with sewing machines with direct drive.

GB

9 mm oil sump

DRIVE UNDER THE TABLE table plate

7

3,9x15 (x 11)

1

MG58 400414

11

MG58 400404

4,5x15 (x 6)

12

5

4

2

3,5x17 (x 2)

6

7

8

3,5x17 (x 6)

10

9

8

B8x35 (x 4)

3.3

Assembling the stand components (Long arm)

–

Assemble the individual stand components as shown in the illustration.

–

Adjust the set screws 8 to insure the stability of the stand.

Make sure that the stand is safe by insuring that every single foot of the stand touches the ground.

3.4

Assembling the table plate

(867-190040-70, 867-190342-70*, 867-290040-70, 867-392242-70*)

In order to have an optimal arrangement of the components, please follow the layout.

Stand Layout

MG58 400414

MG58 400404

0791 867716

0791 867715

–

Screw the drawer 10 with its holders onto the left side underneath the table plate .

–

Screw the oil sump 7 under the table plate.

–

Put the cap 5 into the bore hole of the table plate.

–

Screw the cable duct 4 under the table plate.

–

Place the hinge bottoms 12 for the machine head into the cutout of the table plate and tighten the screws.

–

Insert the rubber corner 2 .

–

Attach the table plate 11 to the stand with woodscrews (see sketch for position).

–

Insert the reel stand 1 in the hole in the table plate and secure it with the nuts and washers.

Fit and align the yarn-reel and unwinding holders.

The yarn-reel holder and the unwinding arm must be vertically in line.

–

Screw the holder for the oil-can 9 onto the left-hand stand brace.

* MG58 400414 only available for the above-quoted underclass.

#

Not applicable with sewing machines with direct drive.

GB

3.5

Self-manufacture of the table top

If you manufacture the table top yourself, please take the measurements from the illustrations on pages 43 and 44.

9

3.6

Setting the working height

10

1

1

–

The working height is adjustable between 750 and 900 mm

(measured to the upper edge of the table plate).

–

–

Undo screws 1 on the stand braces.

Adjust the table plate horizontally to the required working height.

To prevent tilting, pull the table plate out or push it in by the same distance on both sides.

–

Tighten both screws 1.

4.

Sewing drives

4.1

Drive category, type and use

The following sewing drives are available:

Subclass

867-190020

867-190040

867-290020

867-290040

867-392342

867-393342

867-394342

867-190142-M

867-190122

867-190142

867-190322

867-190342

867-190125

867-190145

867-190425

867-190445

867-290445

867-290122

867-290142

867-290322

867-290342

867-490322

867-190020-70

867-190040-70

867-290020-70

867-290040-70

867-190122-70

867-190322-70

867-190342-70

867-290122-70

867-290322-70

867-290342-70

867-290342-100

Clutch motor

FIR 1147-F.752.3 *

FIR 1148.552.3

DC-positioning drive

*1 Efka DC1550/DA321G

Efka DC 1550/DA321G

DAC Classic

Efka DC1550/DA321G

Efka DC1550/DA321G

Efka DC1550/DA321G

*1 Efka DC1550/DA321G

Efka DC1550/DA321G

GB

* This clutch motor incorporates an electromagnetic brake that rapidly stops the rotor when it runs on after the motor has been switched off.

This prevents the sewing machine from starting up unintentionally if the pedal is operated shortly after switching off.

*1 only for machines with the drive under the table

11

4.2

Fitting the sewing drive

8

2

1

6

7

5

3

4

4

–

Attach the sewing drive 2 with its base 1 on the underside of the table plate.

By screwing the three hexagonal screws (M8x35) with washers into the table-plate nuts 8.

4.3

Fitting the pedal

–

Attach the pedal 4 to the stand brace 3.

–

For ergonomic reasons align the pedal 4 as follows:

The center of the pedal must be approximately under the needle.

There are slots in the stand brace 3 to help align the pedal.

–

Screw the ball pins from the middle to the front hole in the lever 7.

–

Attach pedal linkage 5.

–

Slightly undo screw 6.

–

Adjust the height of the pedal linkage 5 as follows: when released the pedal 4 should be at an angle of about 10°.

–

Tighten screw 6.

12

4.4

Fitting the sewing-drive control for machines with direct drive

8

1

7

2

6

3

4

5

–

–

Fix the sewing-drive control 1 with 4 screws underneath the table plate 8.

Fix the power supply cable of the sewing-drive control with the traction relief clip underneath the table plate .

GB

4.5

Fitting the set value initiator

–

Screw L-bracket 7 under the table plate 8.

–

Screw the set value initiator 2 onto the L-bracket 7.

13

4.6

Fitting the pedal

8

1

7

6

2

3

4

5

–


–




–


–

Hinge the pedal linkage 3 with the ball sockets on the set value initiator 2 and into the pedal 5.

–

Loosen screw 6.

–


–

Tighten screw 6.

14

4.5

Fitting the sewing-drive control for machines with direct drive (only 867-190142-M)

8

1

7

2

6

3

4

5

–

–

Fix the sewing-drive control 1 with 4 screws underneath the table plate 8.

Fix the power supply cable of the sewing-drive control with the traction relief clip underneath the table plate .

GB

4.5

Fitting the set value initiator

–

Screw L-bracket 7 under the table plate 8.

–

Screw the set value initiator 2 onto the L-bracket 7.

15

4.5.2 Fitting the pedal

6

2

3

4

5

–


–




–


–

Hinge the pedal linkage 3 with the ball sockets on the set value initiator 2 and into the pedal 5.

–

Loosen screw 6.

–


–

Tighten screw 6.

16

5 Assembling the machine head

5.1

Fitting the machine head

1

–

Fit the machine head 1 into the opening in the table plate.

5.2

Fitting the oil suction tube

GB

5 2 1 3 4

–

Remove the plug at the end of the suction tube 3.

–

Put the end of the suction tube 3 into the cover 1.

–

Snap the suction tube in the hose holder 5.

–

Screw the cover 4 to the bed plate.

17

2 1 3

18

7

5 4 6 4

8

5.3

Fitting and tensioning the V-belt

Remove protective devices

–

Remove the handwheel 2.

–

Remove the belt guard 1 on the machine head.

–

Remove the cover of the belt guard 3 on the sewing drive.

Fit the V-belt and reinstall the protective devices

–

Attach the belt pulley 5 (in the accessory pack) onto the sewing-drive shaft.

–

Place the V-belt 4 on the belt pulley of the machine head.

–

Pass the V-belt 4 down through the opening in the table plate.

–

Fold back the upper part of the sewing machine.

–

Place the V-belt 4 on the belt pulley 5 of the sewing drive.

–

Return the upper part of the sewing machine to its original position.

–

Fit the belt guard 1 to the machine head.

–

Replace the handwheel 2.

Tension the V-belt

–

Undo screws 7 on the base of the sewing drive.

–

Tension the V-belt 4 by swivelling the sewing drive.

When the belt is correctly tensioned it must be possible to depress it by about 10 mm by gently pressing on it with a finger at its mid-point.

–

Tighten screws 7.

GB

Fit the belt guard to the sewing drive

–

Adjust the anti-throw protectors 8 (either the cams or the brackets are adjustable, depending on the drive type) of the belt guard 3 as follows:

The V-belt 4 must remain on the belt pulleys when the upper part of the sewing machine is folded back.

See the motor manufacturers’ operating manuals.

–

Screw on the belt-guard cover 3.

19

5.4

Attaching the knee lever

4

3

5

1

2

The knee lever 2 mechanically raises the sewing foot.

–

Insert the lever 4 through the hole 5 of the oil sump.

–

Fix the lever 4 to the fork 6.

–

Fasten the lever 4 of the knee lever with the screw 7 and washer 8.

–

Undo the screws on the joint 1.

–

Adjust the knee lever so that it can be conveniently operated with the right knee.

–

Tighten the screws on joint 1 again.

–

Undo screw 3.

–

Align the knee-pad.

–

Tighten screw 3 again.

4 6 8 7

20

5.5

Fitting the operating panel

4 3 1

6 5

–

Unscrew the thread guide 2 from off the sewing machine head.

–

Fix the control panel fixing angle 1 together with the thread guide 2.

–

Lift off the arm cover 3 and the valve cap 4.

–

Lay the power supply cable 5 of the operating panel: along the arm and down through the opening in the table plate 6 or down through the arm and the base plate - and secure it.

–

Insert the connection plug into the B776 socket of the drive control.

–

Replace the arm cover 3.

–

Replace the valve cap 4.

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5.6

Fitting the sewing lamp (optional equipment)

Caution !

Turning off the main switch does not turn off the current to the sewing lamp.

Remove the mains plug before connecting.

21

22

4 3 1 6 5

7 8

The sewing lamp can be mounted on the operating-panel bracket if present.

–

Stick the safety warning label on the front of the main switch 7.

–

Fix the sewing light on the holder 2.

–

Lift off the arm cover 3 and the valve cap 4.

–

Lay the power supply cable in the cutout of the machine arm.

–

Pass the power supply cable down through the hole in the table plate or the arm and the base plate.

–

Attach the transformer 8 under the table plate with chipboard screws.

–

Attach the power supply cable under the table plate with cable ties.

–

Plug in the sewing-light transformer lead.

–

Fit the arm cover 1 and valve cap 4.

6 Electrical connection

6.1 General

Caution !

All work on the electrical equipment of this special sewing machine may only be carried out by qualified electricians or other appropriately trained persons.

The mains plug must be removed.

6.2

Checking the mains voltage

Caution !

The mains voltage must agree with the rated voltage specified on the model-identification plate.

6.3

Connecting the sewing drive

6.3.1

Connecting the clutch motor

–

Lay the connection cable from the main switch through the cable conduit to the sewing drive and connect it to the sewing drive. See connection diagram 9800 169002 B (in the connection pack) or the circuit diagram on the clutch motor.

–

Lay the mains cable from the main switch back through the cable conduit and attach to the mains-lead cleat.

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6.3.2

Connecting the coupling-positioning actuator

–

Lay the connection cable from the motor-protection switch through the cable conduit to the sewing drive and connect it to the sewing drive.

See connection diagram 9800 129002 B (in the connection pack) or the circuit diagram on the coupling-positioning actuator.

–


–

Plug the cable from the set-point generator into socket b80 of the drive control. See figure page 20.

6.3.3

Connecting the direct-current positioning actuator

–

Lay the connection cable from the main switch through the cable conduit to the sewing drive and connect it to the sewing drive. See connection diagram 9800 139001 B (in the connection pack).

–


–

Plug the lead from the set-point generator into socket b80 of the drive control. See figure page 20.

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6.4

Earthing

1

The earthing cable 1 is in the machine’s accessory pack.

The earthing cable 1 takes static charges from the machine head to earth via the motor base.

–

Connect the earthing cable 1 to the flat plug 2 (already screwed on the machine head) and lay it through the cable duct to the motor base.

–

Screw the earthing cable 1 onto the motor base at the point provided.

–

Attach the earthing cable 1 under the table plate with the nail clamps.

Caution!

Please make sure that the earthing cable 1 does not touch the drive belt.

Hint

You do not need to care for the earthing with machines having the sewing motor fit onto the machine head, since it is already established through the fitted motor.

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6.5

Connecting the sewing drive to the mains

Caution:

The sewing machine must be connected to the mains with a plug.

Clutch motors and coupling-positioning actuators must be connected to a 3 x 380 - 415V 50/60 Hz or 3 x 220 - 240V 50/60 Hz three-phase supply (see tables in section 4.1).

Connection takes place in accordance with connection diagram

9800 169002 B or 9800 129002 B.

The direct-current positioning actuator is operated with a single-phase alternating current of 190 - 240V 50/60 Hz. Connection takes place in accordance with connection diagram 9800 139001 B.

If it is connected to a three-phase supply of 3 x 380V, 3 x 400V or

3 x 415V the sewing drive is connected to one phase and the neutral conductor.

If the mains supply is three-phase 3 x 200V, 3 x 220V, 3 x 230V or 3 x

240V the sewing drive is connected to two phases.

If a number of direct-current positioning actuators are connected to a three-phase mains supply they should be equally distributed over all phases to avoid overloading any one of them.

6.6

Drive-control connection sockets

Control DA321G

Control DAC Classic

Check the operating instructions to see the wiring diagram.

GB

B 4 1

B 2

B 1 8

L S M . . .

B 8 0

E B . . .

B 7 7 6

V 8 . .

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6.7

Fitting the proximity switch

2 1

–

Push the proximity switch 2 onto the handwheel flange so that the retaining pin 1 on the belt guard engages in its groove.

–

Secure the proximity switch with the two screws.

6.8

Connecting the machine head

Connections

–

The 9870 367004 or 9870 867000 cable is plugged onto the

9850 867000 distributor in the upper part and passed down inside the upper part.

–

Plug the 37-pole plug of the cable into socket A of the sewing drive and secure with the screw.

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6.9

Direction of rotation of sewing drive

Caution:

Before the special sewing machine is started it is essential to check the direction of rotation of the motor.

Switching it on can cause damage if the direction of rotation is incorrect.

6.9.1

Checking the direction of rotation of the clutch motors (mounted under the table)

The direction of rotation of the clutch motor (three-phase motor) depends on its connection to the three-phase supply. The direction of rotation must be checked before use. Proceed as follows:

–

Connect the clutch motor and earthing and connect the sewing drive to the mains.

(see sections 6.3.1, 6.4 and 6.5).

–

Turn on the main switch.

–

Operate the pedal (or the motor’s clutch lever) until the belt pulley turns.

–

The belt pulley must turn anti-clockwise (looking at the belt pulley).

6.9.2

Changing the direction of rotation of the clutch motors (mounted under the table)

If the sewing drive rotates the wrong way, the phases on the terminals of the mains connection of the sewing drive 2 must be reversed. This is done as follows:

–

–

Turn off the main switch and remove the mains plug.

Reverse two of the three phase conductors in the mains plug.

–

Insert the mains plug and turn on the main switch.

–

Check the direction of rotation (see section 6.9.1).

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6.10 Connecting the sewing light transformer (optional equipment)

6.10.1

Attaching and connecting the sewing light transformer (optional equipment)

2 1

–

Remove the machine’s mains plug.

–

Pass the mains cable 1 of the sewing-lamp transformer through the cable conduit 2 to the main switch.

–

It is connected to the mains-connection side of the main switch (or motor-protection switch). See connection diagram 9800 169002 B,

9800 129002 B or 9800 139001 B.

–

Stick the adhesive label with the safety instruction on the front of the main switch .

–

If the sewing-lamp transformer is connected to a 3 x 380 - 415V three-phase supply it must have a neutral conductor.

Caution !

The sewing-light transformer is directly connected to the mains.

It is therefore live even when the main switch is switched off.

The mains plug must be removed before carrying out any work on the sewing-light transformer, e.g. changing the fuse.

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6.10.2

Connection to the DA321G

2 6 5 1 6 5 4 3

–

Loosen the 4 screws on the front plate of the controls.

–

Remove the front plate.

–

Push the cable from the back through the cable duct 1 into the controls.

–

Remove the black rubber grommet 2.

–

Push through the round opening of the rubber grommet with a screwdriver.

–

Guide the cable of the sewing light transformer through the resulting opening in the rubber grommet.

–

Insert the rubber grommet again.

–

With a small screwdriver press on the terminal openings 4 and 3 to open the terminals 5 and 6.

–

Connect the blue cable to terminal 6 and the brown cable to terminal 5.

–

Fasten the front plate with the 4 screws again.

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29

6.10.3Connection to the DAC Classic

2 1

4 3

–

Unscrew the control unit 1 from the table plate.

–

Remove the cover 2.

–

Connect the plug-in connections of the cable 3 to the terminal strip 4.

–

Replace the cover 2.

–

Fix the control unit 1 to the table plate again.

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6.11 Connecting the direct drive

6.11.1

Connecting the Hall-effect sensor (Optional Equipment)

Only with DC 1550 drive:

·

Motor mounted under the table

·

Gear reduction motor - machine 1,55:1

Attention !

Turn off the main switch.

Connect the Hall-effect sensor with the sewing machine switched off.

–

Fit the Hall-effect sensor 1 onto the machine head.

4 3

2 1

–

Check whether a magnet is fitted into the belt pulley 2 of the machine. The magnet is positioned on the inner side of the belt pulley towards the machine.

–

If no magnet is fitted into the belt pulley 2, it must be exchanged.

If the belt pulley is fitted correctly, the magnet must be positioned above the Hall-effect sensor, when the tip of the needle penetrates into the throat plate.

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32

B 4 1

B 2

B 1 8

L S M . . .

B 8 0

E B . . .

B 7 7 6

V 8 . .

–

Connect the 9-pole SuB-D plug of the Hall-effect sensor to the bushing “B18" (IPG / HSM / LSM) of the Efka control drive DA321G.

–

Set the correct machine class with parameter F-290 according to the corresponding parameter sheet 9800 331104 PBXX.

–

In order to position the machine correctly and to optimize all functions the following parameters must still be set:

Parameter F-111: set to 3,000 rpm or less.

Parameter F-270: set to 6 (selection according to the position sensor)

Parameter F-272: can be calculated according to the formula below:

Motor pulley diameter (teeth)

Machine pulley diameter (teeth) x 1000

Inserted needle: up to a thickness of 160.

Due to the gear reduction of 1,55:1 the maximum possible speed is 3.000 rpm.

Due to the new transmission ratio of 1,55:1 a higher torque and a higher penetration force of the needle of about 30% above a transmission rate of 1:1 is achieved.

In order to achieve an even higher penetration force, the parameter

F-225 can be set from value “0" to value ”1".

It may happen, that the motor produces a snarling noise.

If this is the case, the toothed belt between motor and machine must be tightened.

6.11.2

Connecting the DA321G control unit

B 4 1

B 2

B 1 8

L S M . . .

B 8 0

E B . . .

B 7 7 6

V 8 . .

2 1

–

Insert the lead from the controller (pedal) into socket B80 of the controls.

–

Insert the lead from the motor sensor 1 into socket B2 of the controls.

–

Insert the lead 2 from the motor into socket B41 of the controls.

–

Insert the lead to the sewing machine into socket A of the controls.

–

Lay all leads through the cable duct.

–

Insert the lead from the control panel (if present) into socket B776.

6.11.3

Connecting the DAC Classic control unit

Check operating instructions DAC Classic.

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33

6.12 Connecting the knee switch

1 2

Use with machines equipped with an electro-pneumatic rapid stroke adjustment

–

Plug the connector of the knee switch in the socket 1 of the control unit.

Use with machines equipped with binding device

–

Plug the connector of the knee switch in the adapter 2.

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6.13 Mounting the M-Control PCB

4 3 2 1 4

Machines with disconnectable needle bars

Mount the M-Control PCB 1 on the right of the set value initiator 2.

Machines equipped with binding device

Mount the M-Control PCB 1 between the stand 4 and the cable duct 3.

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2

4

6

10

8

5

10 9 8 7 6

–

Connect the compressed air hose 7 to the compressed-air maintenance unit 5.

–

Connect both compressed air hose 10 from the machine head to the solenoid valves 8 and 9.

–

Plug the electric cables into the corresponding sockets.

Note

–

If the function of the keys “ L ” and “ R ” are permuted, swap the compressed air hoses 10 at the solenoid valves.

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6.14 Setting the switches on the M-Control PCB

1

Machines equipped with binding device

The switch 3 on the M-Control PCB must be set to “1" on machines equipped with the moving binding device.

Machines with disconnectable needle bars

The switch 3 on the M-Control PCB must be set to “2" on machines with disconnectable needle bars.

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6.15 Setting machine-specific parameters

6.15.1

General

The functions of the sewing-drive control are determined by the program and the parameter settings.

All parameter values for the relevant machine class and subclass are pre-set by Efka prior to delivery of the sewing drives. For each class and subclass some parameters at technician and manufacturer level must be changed so that the control is perfectly coordinated with the machine. The parameters concerned are listed in the parameter sheet

(in the accessory pack).

6.15.2

Autoselect

The control “recognizes” which machine series is connected by measuring the Autoselect resistance in the machine. Autoselect selects control functions and the pre-set parameter values. If the control fails to recognize a valid Autoselect resistance (or any at all), the drive runs only with the so-called emergency operating functions to prevent machine damage.

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6.15.3

Subclass 867-290342-100

CAUTION Danger of breakage!

It is imperative that the maximum speed be reduced to 2,500 rpm !

Parameter F-290: set to 56.

Parameter F-111 : set to 2,500 rpm or less.

37

1

38

5

2

3

4

6 7

7 Pneumatic connection

Caution:

The pneumatic units will only operate properly at a supply pressure of 8 to 10 bar. The special sewing machine’s operating pressure is 6 bar.

Pneumatic-connection pack

A pneumatic-connection pack for stands with compressed-air maintenance units is available (Order no. 0797 003031).

It contains the following components:

- Connection hose, 5 m long (Ø = 9 mm)

- Hose nozzles and ties

- Plug-and-socket connector

Connecting the compressed-air maintenance unit

–

Attach the compressed-air maintenance unit 1 with bracket, screws and strap to the stand-brace.

–

Connect the unit to the compressed-air supply with the connection hose 4 (Ø = 9 mm) and connector R1/4".

Connecting the compressed-air maintenance unit to the upper part of the sewing machine

–

Unscrew and remove the cover 6.

–

Connect the hose 3 (in the accessory pack) to the distributor plate on the machine head.

–

Replace the cover 6.

GB

7.1

Adjusting the operating pressure

The operating pressure is 6 bar.

It can be read off at the pressure gauge 4.

–

To adjust the operating pressure raise and turn handle 2:

Clockwise to increase the pressure.

Counter-clockwise to reduce the pressure.

–

Press the handle 2.

Pneumatic sewing foot lifting

See Instructions 0791 867704.

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8 Lubrication

1

2

3

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 oil is subject to legal regulation.

Deliver used oil to an authorised collection point.

Protect your environment.

Take care not to spill oil.

To lubricate the special sewing machine use only DA 10 lubricating oil or an equivalent oil of the following specification:

–

Viscosity at 40° C :

–

Flashpoint:

10 mm

150 °C

/s

DA 10 is available from DÜRKOPP ADLER AG retail outlets under the following part numbers:

250 ml container:

1-liter container:

2-liter container:

5-liter container:

9047 000011

9047 000012

9047 000013

9047 000014

Lubricating the machine head (first filling)

NB:

All wicks and felts are saturated with oil prior to delivery. This oil is returned to the oil reservoir 1, which should therefore not be overfilled.

–

Top up the oil reservoir 1 through the hole 2 to the “ max.

” mark 3.

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9 Sewing test

A sewing test must be carried out when setting-up is complete.

–

Insert the mains plug.

Caution: danger of injury !


The needle and hook threads may only be threaded with the sewing machine switched off.

–

Thread the bobbin-winder thread (see operating instructions).

–

Turn on the main switch.

–

Lock the sewing feet in the up position (see operating instructions).

–

Fill the bobbin at low speed.

–


–

–

Thread the needle and hook threads (see operating instructions).

Select the material to be processed.

–

Carry out the sewing test, first at low speed and then gradually increasing it.

–

Check that the seams are of the requisite quality.

If not, alter the thread tensioners (see operating instructions).

If necessary the settings given in the servicing instructions should also be checked and corrected

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41

Notes:

42

43

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Notes:

44

45

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