DAC basic/classic
Service Instructions
Software version: B02.6
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR LATER REFERENCE
All rights reserved.
Property of Dürkopp Adler AG and protected by copyright. Any reuse
of these contents, including extracts, is prohibited without the prior
written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG - 2014
Table of Contents
1
About these instructions .................................................................... 3
1.1
1.2
1.3
1.4
1.5
1.5.1
1.5.2
Scope of the instructions ....................................................................... 3
Target group of the instructions............................................................. 3
Representation conventions – symbols and characters ........................ 3
Other documents ................................................................................... 5
Liability .................................................................................................. 5
Transport ............................................................................................... 5
Proper use ............................................................................................. 6
2
Safety.................................................................................................... 7
2.1
2.2
Basic safety instructions ........................................................................ 7
Signal words and symbols used in warnings......................................... 8
3
Components and functions .............................................................. 11
3.1
3.2
3.2.1
3.2.2
3.3
DAC basic/classic Controller ............................................................... 11
OP1000 control panel.......................................................................... 14
Display................................................................................................. 15
Buttons ................................................................................................ 15
Setpoint device .................................................................................... 19
4
Individual settings ............................................................................. 21
4.1
4.2
4.3
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.5
4.6
Initial start-up ....................................................................................... 21
Switching on the controller .................................................................. 22
Verifying the machine class................................................................. 23
Positions .............................................................................................. 23
Setting the reference position.............................................................. 23
Setting position 1 ................................................................................. 24
Setting position 2 ................................................................................. 24
Setting the indicator position ............................................................... 25
Setting the threading position .............................................................. 25
Calibrating the foot pedal .................................................................... 26
Switching off the controller .................................................................. 29
5
Service settings via the software..................................................... 31
5.1
5.1.1
5.1.2
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.3
5.4
Advanced operation ............................................................................ 31
Switching the user level....................................................................... 31
Enabling and disabling the button lock ................................................ 32
Thread settings.................................................................................... 33
Enabling the multiple start bar tack as a stuffing program .................. 34
Activating soft start .............................................................................. 34
Activating the sewing foot lifter ............................................................ 34
Setting the light barrier ........................................................................ 36
Setting up the function button.............................................................. 37
Function modules ................................................................................ 37
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1
Table of Contents
5.4.1
5.4.2
5.4.3
5.5
5.5.1
5.5.2
5.5.3
Setting function module 1 .................................................................... 37
Setting function module 2 .................................................................... 38
Setting function module 3 .................................................................... 38
Saving and loading data ...................................................................... 38
Saving data ......................................................................................... 38
Loading data........................................................................................ 39
Performing a master reset ................................................................... 40
6
Electrical connection ........................................................................ 41
6.1
6.2
Connecting the power supply .............................................................. 41
Connecting the sewing lamp ............................................................... 41
7
Software update ................................................................................ 43
7.1
7.2
Checking the version ........................................................................... 43
Performing the update ......................................................................... 44
8
Inspection .......................................................................................... 47
8.1
8.2
8.3
8.4
Checking the analog input ................................................................... 47
Checking the digital input .................................................................... 47
Checking the digital output .................................................................. 48
FLASH test .......................................................................................... 49
9
Disposal ............................................................................................. 51
10
Technical data ................................................................................... 53
11
Troubleshooting ................................................................................ 55
11.1
11.2
Error messages ................................................................................... 55
Customer service ................................................................................ 56
12
Appendix ............................................................................................ 57
2
Service Instructions DAC basic/classic - 00.0 - 12/2014
About these instructions
1 About these instructions
These service instructions for the DAC basic/classic have been
prepared with utmost care. They contain information and notes to
enable long-term and reliable operation.
Please contact us if you find any discrepancies or have any
suggestions ( 11.2 Customer service, S. 56).
Consider these instructions as part of the product and store it in
a place where it is readily available. Be sure to read these
instructions completely before using the product for the first time.
Only give the product to someone else along with the instructions.
These service instructions are delivered together with the
instructions for use and a list of parameters.
1.1 Scope of the instructions
These instructions describe how to set up the DAC basic/classic
and use it in the proper manner.
1.2 Target group of the instructions
The service instructions are intended for:
• Technicians:
This group has the appropriate technical training for
performing maintenance or repairing malfunctions.
With regard to minimum qualification and other requirements to
be met by personnel, please also follow chapter  2 Safety, S. 7.
1.3 Representation conventions – symbols and
characters
Various information in these instructions is represented or
highlighted by the following characters in order to facilitate easy
and quick understanding:
Proper setting
Indicates proper setting.
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3
About these instructions
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Cover
Specifies which covers have to be removed in order to access the
components to be set.
Steps to be performed when operating the machine (sewing
and equipping)
Steps to be performed for service, maintenance, and
installation
Steps to be performed via the software control panel
The individual steps are numbered:
1.
1. First step
2.
2. Second step
etc.
•
The sequence of the steps must always be followed.

Lists are identified by bullet points.
Result of performing an operation
Change on the machine or on the the display.
Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating options.
Order
Specifies the work to be performed before or after a setting.
References
 Reference to another section in the instructions.
4
Service Instructions DAC basic/classic - 00.0 - 12/2014
About these instructions
Safety Important warnings for the machine operator are specially
designated. Since safety is of particular importance, hazard
symbols, levels of danger and their signal words are described
separately in chapter  2 Safety, S. 7.
Orientation If the figure is unclear, indications of right or left are always from
the personnel's point of view.
1.4 Other documents
Some of the machine's built-in components have been made by
third-party manufacturers. Each manufacturer has performed a
hazard assessment for these purchased parts and confirmed their
design compliance with applicable European and national
regulations. The proper use of these components is described in
each manufacturer's instructions.
1.5 Liability
All information in this instructions was compiled with consideration
to the state of the art, and applicable standards and regulations.
The manufacturer cannot be held liable for damages resulting
from:
• Breakage and transport damages
• Failure to observe the instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
1.5.1
Transport
Dürkopp Adler cannot be held liable for breakage and transport
damages. Inspect the delivery immediately upon receiving it.
Report any damage to the last transport manager. This applies
even if the packaging is undamaged.
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5
About these instructions
Leave machines, equipment and packaging material in the
condition in which they were found when the damage was
discovered. This will ensure any claims against the transport
company.
Report all other complaints to Dürkopp Adler immediately after
receiving the product.
1.5.2
Proper use
The DAC basic/classic is not a standalone unit; instead, it is
intended for installation in a sewing machine (hereafter referred
to as machine) (for additional information refer to  Declaration
of conformity).
The controller is intended for industrial use.
The controller may only operate in rooms that are clean and dry.
Do not operate the controller when aerosols (sprays) or oxygen
is in use.
Proper use includes compliance with the operating, maintenance,
and repair conditions as specified by the manufacturer.
Only authorized persons may work on the controller
( 2 Safety, S. 7).
CAUTION
Possible hardware damage from improper use!
Follow all instructions in these instructions.
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Service Instructions DAC basic/classic - 00.0 - 12/2014
Safety
2 Safety
This chapter contains basic information for your safety. Read the
instructions carefully before setting up or operating the controller.
Make sure to follow the information included in this chapter. Failure
to do so can result in serious injury and damage to the machine.
2.1 Basic safety instructions
The DAC basic/classic controller may only be used as described
in these instructions.
The instructions should be available at the controller's location at
all times.
Work on live components is prohibited.
The controller was built and tested in compliance with all valid
ordinance and safety regulations, and left the factory in proper
working order.
The DAC basic/classic will only work safely and reliably when
the controller is used as intended ( 1.5.2 Proper use, S. 6).
Before leaving the workplace:
• Switch off the controller
• Wait until the machine stops
• Wait until the LEDs go out
Obligations Observe the country-specific safety and accident prevention
of the operator regulations and the legal regulations concerning industrial safety
and the protection of the environment.
All warnings and safety signs on the controller must always be in
legible condition and may not be removed. Missing or damaged
labels should be replaced immediately.
Requirements to The controller may only be set up by qualified technicians.
be met by the Qualified technicians are personnel with electronics and
personnel mechanical training.
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Safety
The following work may only be performed by qualified
technicians.
• Maintenance work
• Repairs
• Work on electrical equipment
Only authorized persons may work on the machine. Anyone
working on the machine belongs to the operating personnel.
Operating personnel must have read and understand the manual
before working on the system.
Setup Controller setup and start-up must be performed carefully by
qualified technicians to ensure no health risks for operating
personnel.
The power cable must have a plug authorized for the country in
which the machine is being used. The power plug may only be
connected to the power cable by a qualified specialist.
Operation Inspect the controller while in use for any externally visible
damage.
Stop working if you notice any changes. Report any changes to
your supervisor.
A damaged controller should no longer be used.
Conversions or changes to the controller are prohibited.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color
scheme is oriented towards the severity of the danger. Signal
words indicate the degree of risk:
Signal words Signal words and the hazard that they describe:
8
Signal word
Hazard
WARNING
Performing an action can have serious or hazardous
consequences.
Service Instructions DAC basic/classic - 00.0 - 12/2014
Safety
Signal word
Hazard
CAUTION
Performing an action can have undesirable consequences, such as loss of data or damage to hardware.
NOTE
Tips or more detailed information
to make operation easier for the user.
Symbols The following symbols indicate the type of risk to personnel:
Symbol
Type of danger
General risk
Electric shock
Puncturing
Crushing
Pollution
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9
Safety
Examples Examples of the layout of the warnings in the text:
WARNING
Type and source of risk!
Consequences of non-compliance.
Measures for avoiding the risk.
 This is what a warning looks like where non-compliance
could result in serious or hazardous consequences.
CAUTION
Type and source of risk!
Consequences of non-compliance.
Measures for avoiding the risk.
 This is what a warning looks like where non-compliance
could result undesirable consequences, such as loss of data
or damage to hardware.
NOTE
Tip.
 This is the more detailed information to simplify operation for
the user.
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Service Instructions DAC basic/classic - 00.0 - 12/2014
Components and functions
3 Components and functions
When delivered the DAC basic/classic consists of:
•
•
•
•
•
Control panel OP1000
Mounting parts
Foot pedal rods
Setpoint device
DAC basic or DAC classic controller
3.1 DAC basic/classic Controller
The controller is available in two different versions:
• DAC basic
• DAC classic
The DAC classic has more inputs and outputs in the back than
does the DAC basic.
Fig. 1: DAC basic/classic, front
⑤
①
②
③
(1)- Main switch
(2)- POWER LED
(3)- MESSAGE LED
Service Instructions DAC basic/classic - 00.0 - 12/2014
④
(4)- Connection for dongle
(5)- Switch for sewing lamp
11
Components and functions
Fig. 2: DAC basic, back
①
⑦
②
⑥
⑤
③
(1)(2)(3)(4)-
12
④
Connection for sewing motor
Connection for synchronizer
Connection for machine
Connection for machine ID
(5)- Connection for foot pedal
(6)- Connection for control panel
(7)- Connection for sewing motor
Encoder
Service Instructions DAC basic/classic - 00.0 - 12/2014
Components and functions
Fig. 3: DAC classic, back
①
②
⑨
③
⑧
⑦
④
⑥
⑤
(1)(2)(3)(4)(5)-
Connection for sewing motor
Connection for synchronizer
Connection for CAN
Connection for additional input
Connection for machine
Service Instructions DAC basic/classic - 00.0 - 12/2014
(6)(7)(8)(9)-
Connection for machine ID
Connection for foot pedal
Connection for control panel
Connection for sewing motor
Encoder
13
Components and functions
3.2 OP1000 control panel
The control panel is located at the top of the machine and is
connected to the controller.
The control panel consists of:
• Display
• Buttons
Using the control panel you can
• Use groups of buttons to select machine functions
• Read service and error messages ( S. 55)
Fig. 4: OP1000 control panel
①
⑦
①
②
(1)(2)(3)(4)-
14
①
⑥
③
Thread button group
Function button
Programming button group
Seam program button group
⑤
④
(5)- LED for second stitch length
(6)- POWER LED
(7)- Display
Service Instructions DAC basic/classic - 00.0 - 12/2014
Components and functions
3.2.1
Display
The display is divided into:
• User levels
• Categories
• Parameters ( Parameter list)
Fig. 5: Example of a display
(A) - User level
(B) - Category
(D) - Parameter
The user levels include:
• o
(operator)
• t
(technician)
The categories include the following enhanced machine functions:
• Production control (such as the bobbin stitch counter)
• Needle cooling
• Light barrier
Parameters are represented by a number from 00-99.
3.2.2
Buttons
The buttons are divided into the following groups:
• Thread
• Programming
• Seam program
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Components and functions
OP1000 buttons and functions
No.
①
16
Button
Function
Thread button group
Start bar tack
• Sets the start bar tack
Multiple start bar tack
• Sets the multiple start
bar tack
End bar tack
• Sets the end bar tack
Multiple end bar tack
• Sets the multiple end
bar tack
Thread cutter
• Activates or deactivates the thread cutter
Thread clamp
• Activates or deactivates the thread clamp
Needle position after
sewing stop
• Sets the needle position
after sewing stops
Sewing foot lifter after
thread cutter
• Activates or deactivates the sewing foot
lifter after the thread
cutter
Sewing foot lifter after
sewing stop
• Activates or deactivates the sewing foot
lifter after sewing stops
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Components and functions
No.
②
③
Button
Function
Soft start
• Activates or deactivates the soft start
Speed
• Reduces the motor
speed
Function button
• Activates or deactivates any stored function
Programming button group
ESC
• Ends parameter mode
A+
• Increases parameter
• Changes user level
• Selects subprogram
B+
• Increases parameter
• Changes to next higher
category
• Selects subprogram
C+
• Increases parameter
• Selects subprogram
D+
• Increases parameter
• Selects subprogram
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Components and functions
No.
18
Button
Function
OK
• Calls parameter or
saves it
P
• Starts or ends the
parameter mode
A-
• Decreases parameter
• Changes user level
• Selects subprogram
B-
• Decreases parameter
• Changes to next lower
category
• Selects subprogram
C-
• Decreases parameter
• Selects subprogram
D-
• Decreases parameter
• Selects subprogram
Service Instructions DAC basic/classic - 00.0 - 12/2014
Components and functions
No.
④
Button
Function
Reset
• Resets the (piece)
counter
Seam program button group
Seam program I
• Activates
seam program I
Seam program II
• Activates
seam program II
Seam program III
• Sets
seam program III
3.3 Setpoint device
The setpoint device converts the values from the foot pedal into
voltage values. The setpoint device specified the speed and starts
the thread cutter of the sewing foot lifter.
The setpoint device is attached under the frame with a mounting
bracket.
The setpoint device includes:
• a push/pull rod (1) that is connected to the machine foot pedal
through the set of rods
• a spring pre-load (2), enabling 3 settings for the push/pull rod
(none, 1/8, or 1/4 rotation)
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Components and functions
Fig. 6: Setpoint device
③
②
①
(1)- Push/pull rod
(2)- Spring pre-load
20
(3)- Mounting parts
Service Instructions DAC basic/classic - 00.0 - 12/2014
Individual settings
4 Individual settings
Every machine requires that you complete the specific settings
described below.
4.1 Initial start-up
Before starting up the DAC basic/classic for the first time, be
sure to read chapter  2 Safety, S. 7.
CAUTION
Overload from faulty connection!
Possible hardware damage.
If connecting additional devices or equipment to
the controller, operate them at low voltage only.
You need to ensure correct parameters for the:
• Selection of the machine class
• Position settings
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21
Individual settings
4.2 Switching on the controller
Fig. 7: Power supply
②
①
(1) - POWER LED
(2) - Main switch
1. Press and hold buttons
at the same time.
and
on the control panel
2. Press the main switch (1) down to position I.
 The POWER LED (2) illuminates. The POWER LED on the
control panel illuminates green.
3. Release buttons
and
.
4. Press the A+ button.
 The technician level has been enabled.
NOTE
The technician level will only remain enabled for as
long as the controller is switched on.
You can now adjust the individual settings.
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Individual settings
4.3 Verifying the machine class
All basic functions specific to the machine have already been
factory-installed on the machine ID of the machine head. For your
safety, verify if the set machine class corresponds to the machine
class specified on the serial tag.
To display the machine class:
1. Open parameter t 51 04.
2. Press
.
If you find that the displayed machine class is incorrect, you
need a dongle containing the current software version to alter
the machine class ( 7.2 Performing the update, S. 44).
4.4 Positions
You need to set the following positions after setting up the
machine:
•
•
•
•
•
Reference position
Position 1
Position 2
Indicator position
Threading position
4.4.1
Setting the reference position
The reference position is used to align the synchronizer with the
actual mechanical position.
To set the reference position:
1. Open parameter t 08 10.
2. Press
.
 Syn?: appears on the display.
3. Turn the handwheel.
 Ref.Pos?: appears on the display.
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23
Individual settings
4. Turn the handwheel in the throat plate feed direction of the
needle.
5. Confirm with
4.4.2
.
Setting position 1
Position 1 (bottom dead center) identifies the position where the
sewing machine needle is set to its lowest position.
To set position 1:
1. Open parameter t 08 12.
2. Press
.
 The LED of the
button flashes. The display shows the
position set at the factory.
3. Turn the handwheel in the throat plate feed direction of the
needle until the desired position has been reached.
4. Confirm with
.
Information
Apart from using the handwheel, you can also use the plus and/
or minus buttons (except A) to set the position values.
4.4.3
Setting position 2
Position 2 (top dead center) identifies the position where the
sewing machine needle is set to its highest position.
To set position 2:
1. Open parameter t 08 13.
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Service Instructions DAC basic/classic - 00.0 - 12/2014
Individual settings
2. Press
.
 The LED of the
button flashes. The display shows the
position set at the factory.
3. Turn the handwheel in the throat plate feed direction of the
needle until the desired position has been reached.
4. Confirm with
4.4.4
.
Setting the indicator position
The indicator position helps the operator find the ideal insertion
point for the beginning of the seam.
Important
The indicator position must be the function assigned to the function
button ( 5.3 Setting up the function button, S. 37).
To set the indicator position:
1. Open parameter t 08 14.
2. Press
.
 The LED of the
button flashes. The display shows the
position set at the factory.
3. Turn the handwheel in the throat plate feed direction of the
needle until the desired position has been reached.
4. Confirm with
4.4.5
.
Setting the threading position
The threading position helps the operator thread the sewing thread
without starting up the machine. All machine functions will be
blocked while the threader is activated.
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25
Individual settings
Important
The threading position must be the function assigned to the
function button ( 5.3 Setting up the function button, S. 37).
To set the threading position:
1. Open parameter t 08 15.
2. Press
.
 The LED of the
button flashes. The display shows the
position set at the factory.
3. Turn the handwheel in the throat plate feed direction of the
needle until the desired position has been reached.
4. Confirm with
.
4.5 Calibrating the foot pedal
The next step following the installation of the setpoint device is
the calibration of the foot pedal. The operator can also set a speed
curve affecting the acceleration of the machine head. The speed
curves are based on the set maximum speed, the minimum speed
and the subsequent pedal positions.
26
Service Instructions DAC basic/classic - 00.0 - 12/2014
Individual settings
Fig. 8: Foot pedal positions
POS.
POS.
POS.
POS.
Max
0
-1
-2
To calibrate the foot pedal:
1. Open parameter t 08 20.
2. Press
.
 The LED of the
the display.
button flashes. POS -2? appears on
3. Press foot pedal to position -2.
4. Confirm with
.
 POS -1? appears on the display.
5. Press foot pedal to position -1.
6. Confirm with
.
 POS -0? appears on the display.
7. Press foot pedal to position -0.
8. Confirm with
.
 POS Max? appears on the display.
9. Press foot pedal all the way forward.
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27
Individual settings
10. Press
.
 The display returns to parameter t 08 20.
You can move on to the next parameter and modify the pedal
speed stages.
Modifying the pedal speed stages
You can use the pedal speed stages to specify how quickly you
want the machine to achieve its maximum speed. The fewer the
number of pedal speed stages you set, the faster the machine will
reach its maximum speed.
To change the pedal speed stages:
1. Open parameter t 08 21.
2. Press
.
 The LED of the
button flashes. The display shows the
number of pedal speed stages that is currently set.
3. Press the D+ or D- button repeatedly until the desired number
appears on the display.
4. Confirm with
.
You can move on to the next parameter and modify the speed
curve.
Modifying the speed curve
To change the speed curve:
1. Open parameter t 08 22.
2. Press
.
 The LED of the
button flashes. The display shows the
value for the currently set speed curve:
28
Service Instructions DAC basic/classic - 00.0 - 12/2014
Individual settings
Fig. 9: Speed curves
①
②
(1)- Speed
(2)- Pedal speed stage
Once the desired value has been reached:
Press the D+ button repeatedly until the desired value
appears on the display.
3. Confirm with
.
If you do not need to adjust any additional settings, press
to exit parameter mode.
4.6 Switching off the controller
WARNING
Puncture or insertion due to switching on
unintentionally!
Mild injuries possible.
Before leaving the workplace and shutting down
the machine for an extended period
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29
Individual settings
1. Switch off the controller using the main switch.
 PowerOff appears on the display.
The POWER LED on the control panel illuminates red.
The MESSAGE LED on the control panel illuminates red as
well.
The LEDs will afterwards go out.
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Service settings via the software
5 Service settings via the software
The DAC basic/classic controller is operated exclusively using
the OP1000 control panel.
The following description assumes that you are familiar with the
basic functions of the machine (see  Instructions for use).
5.1 Advanced operation
In this section you will learn the advanced control options available
for working with the controller. These include:
• Switching the user level
• Enabling and disabling the button lock
5.1.1
Switching the user level
The only level activated by default is the user level. This limitation
keeps you from accessing a great number of additional functions.
To access these additional functions, enable the technician level.
To enable the technician level:
Important
The controller must be switched off.
1. Press and hold buttons
and
at the same time.
2. Switch on the controller using the main switch.
 The POWER LED illuminates. The POWER LED on the
control panel illuminates green.
3. Release buttons
and
.
 The following appears on the display:
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31
Service settings via the software
4. Press the A+ button.
 The following appears on the display:
The technician level has been enabled.
You can adjust settings on the control panel.
5.1.2
Enabling and disabling the button lock
The button lock allows you to prevent certain groups of buttons
from being used (inadvertently). This option also lets you lock the
buttons controlling the start bar tack and the end bar tack.
CAUTION
Undesired operational limitations by locking the
Programming button group!
The button lock can only be disabled by means of
a software update.
Enable the button lock only after careful
consideration.
Turning on the button lock for individual groups of buttons
The example below is intended to illustrate how you can turn on
the button lock for a specific button group.
To lock the button group Seam program:
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Service settings via the software
1. Press
.
 Parameter mode is started.
2. Open parameter t 52 43.
3. Press
.
 The LED of the
display.
button flashes. 0 appears on the
4. Press the D+ button.
 1 appears on the display.
 Confirm your selection with
.
 The button group Seam program has been locked.
5. Exit parameter mode with
.
 Ready appears on the display.
To turn the button lock back off, go to category 52 and set
parameter 43 to 0.
Information
Refer to the  Parameter list if you wish to lock additional groups
of buttons.
5.2 Thread settings
The following description of the settings available for the Thread
button group assumes that you are currently in parameter mode.
You can adjust the following settings:
•
•
•
•
Stuffing program
Soft start
Sewing foot lifter
Light barrier (if present)
Service Instructions DAC basic/classic - 00.0 - 12/2014
33
Service settings via the software
5.2.1
Enabling the multiple start bar tack as a stuffing
program
If the operating personnel are supposed to use the multiple start
bar tack as a stuffing program, you need to enable this function
accordingly.
To enable the multiple start bar tack as a stuffing program:
1. Open parameter t 00 23.
2. Press
.
 0 appears on the display.
3. Press the D+ button.
 1 appears on the display:
4. Confirm your selection with
.
 The stuffing program has been enabled.
5.2.2
Activating soft start
You can set the number of stitches for which you wish to activate
soft start.
To activate soft start:
1. Open parameter t 05 01.
2. Press
.
 The display shows the number of stitches set at the factory.
3. Press the D+ repeatedly until the desired number of stitches
appears on the display.
4. Confirm your selection with
5.2.3
.
Activating the sewing foot lifter
You can set a delay for the lifting of the sewing foot. This option
also lets you adjust the holding force of the magnet used to lift the
sewing foot.
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Service Instructions DAC basic/classic - 00.0 - 12/2014
Service settings via the software
Activation delay during a machine standstill
To set the activation delay during a machine standstill:
1. Open parameter t 03 11.
2. Press
.
3. Press the D+ button repeatedly until the desired duration
appears on the display.
4. Confirm your selection with
.
You can set the activation delay applicable for the end of the
seam.
Activation delay at the end of the seam
To set the activation delay for the end of the seam:
1. Open parameter t 03 12.
2. Press
.
3. Press the D+ button repeatedly until the desired duration
appears on the display.
4. Confirm your selection with
.
This option also lets you adjust the holding force of the magnet
used to lift the sewing foot.
Holding force of the magnet
The sewing foot is fully controlled and lifted by a magnet. The
controller will switch to partial power after a certain period to reduce
the load on the magnet.
CAUTION
Magnet overload due to excessive load!
Possible hardware damage.
Observe the maximum permissible activation
period of the magnet.
Service Instructions DAC basic/classic - 00.0 - 12/2014
35
Service settings via the software
To change the holding force of the magnet:
1. Open parameter t 03 51.
2. Press
.
3. Press the D+ button repeatedly until the desired duty cycle for
the duration of period t1 appears on the display.
A value of 100 corresponds to full power.
4. Confirm your selection with
.
5. Open parameter t 03 53.
6. Press
.
7. Press the D+ button repeatedly until the desired duty cycle for
the duration of period t2 appears on the display.
8. Confirm your selection with
5.2.4
.
Setting the light barrier
Activating the filter for knitted fabrics
The filter for knitted fabrics keeps the light barrier from being
tripped.
To activate the filter for knitted fabrics:
1. Open parameter t 16 03.
2. Press
.
 0 appears on the display:
3. Press the D+ button.
 1 appears on the display:
4. Confirm your selection with
36
.
Service Instructions DAC basic/classic - 00.0 - 12/2014
Service settings via the software
5.3 Setting up the function button
You can save your favorites on the function button
. What
you can activate with the function button is set at the factory
depending on the machine class. You can modify this setting.
The example below is intended to illustrate how you can assign a
function module to the function button.
To activate function module 1:
1. Open parameter t 52 20.
2. Press
.
3. Press the D+ button repeatedly until 8 appears on the display.
4. Confirm your selection with
.
 The display switches automatically to  Setting function
module 1, S. 37.
Refer to the section below to learn how to define which machine
functions you can execute using the function modules.
5.4 Function modules
5.4.1
Setting function module 1
1. Open parameter t 11 00.
2. Press
.
3. Press the D+ button repeatedly until the desired machine
function appears on the display.
4. Confirm your selection with
Service Instructions DAC basic/classic - 00.0 - 12/2014
.
37
Service settings via the software
5.4.2
Setting function module 2
1. Use parameter t 11 30.
5.4.3
Setting function module 3
1. Use parameter t 11 60.
5.5 Saving and loading data
You can use a dongle (see  Instructions for use, optional
equipment) to save or load sewing data and seam programs.
5.5.1
Saving data
1. Connect a DATA-type dongle.
2. Open parameter t 51 11.
3. Press
.
4. Press the D+ button repeatedly until 1 appears on the display:
5. Confirm your selection with
.
 The sewing data is stored on the dongle.
The display shows Store and Pl. Wait!.
The MESSAGE LED flashes until the process is complete.
6. Press the D+ button repeatedly until 3 appears on the display.
7. Confirm your selection with
.
 The seam programs are stored on the dongle.
The display shows Store and Pl. Wait!.
The MESSAGE LED flashes until the process is complete.
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Service Instructions DAC basic/classic - 00.0 - 12/2014
Service settings via the software
CAUTION
Storing will be canceled if dongle is removed
prematurely!
Loss of data.
Do not remove the dongle until the MESSAGE LED
has gone out.
8. Remove the dongle when the MESSAGE LED has gone out.
5.5.2
Loading data
1. Connect a DATA-type dongle.
2. Open parameter t 51 10.
3. Press
.
4. Press the D+ button repeatedly until 1 appears on the display:
5. Confirm your selection with
.
 The sewing data is loaded from the dongle.
The display shows Load... and Pl. Wait!.
The MESSAGE LED flashes until the process is complete.
6. Press the D+ button repeatedly until 3 appears on the display:
7. Confirm your selection with
.
 The seam programs are loaded from the dongle.
The display shows Load... and Pl. Wait!.
The MESSAGE LED flashes until the process is complete.
8. Remove the dongle when the MESSAGE LED goes out and
the parameter display comes up.
If the data stored on the dongle is unusable, you can perform a
master reset, i.e. reset the controller to its factory settings.
Service Instructions DAC basic/classic - 00.0 - 12/2014
39
Service settings via the software
5.5.3
Performing a master reset
1. Open parameter t 51 10.
2. Press
.
3. Press the D+ button repeatedly until 4 appears on the display:
4. Confirm your selection with
.
 The factory settings are loaded form the machine ID.
The display shows Load... and Pl. Wait!.
The MESSAGE LED flashes until the process is complete.
5. Switch the controller off when the MESSAGE LED goes out
and the parameter display comes up.
40
Service Instructions DAC basic/classic - 00.0 - 12/2014
Electrical connection
6 Electrical connection
WARNING
Electric shock from live components!
Severe injury to life and limb can occur.
Work on the electrical equipment may only be
performed by qualified technicians or personnel
who have undergone the necessary training.
ALWAYS pull the power plug before working on the
electrical equipment.
6.1 Connecting the power supply
Connect the controller to a grounded AC voltage supply network
as specified in the interconnection diagram ( Appendix, S. 57).
Always use a multi-terminal plug with circuit breaker
(9850 001313) to make the connection.
The controller can be connected to the following types of power
supply networks:
• TN mains
• TT mains
• IT mains
6.2 Connecting the sewing lamp
The controller offers the option of connecting sewing lamps, which
can be switched on using the switch at the front
( 3.1 DAC basic/classic Controller, S. 11).
The following connections are available:
• Terminal X5 (24 V)
• Terminal X3 (230 V)
• Terminal X4 (ground wire)
Important
Terminal X5 is only intended for sewing lamps designed for
specific machines by Dürkopp Adler.
Service Instructions DAC basic/classic - 00.0 - 12/2014
41
Electrical connection
Fig. 10: Connections on the controller
①
②
(1)- Connection for 24 V
(2)- Connection for 230 V
42
Service Instructions DAC basic/classic - 00.0 - 12/2014
Software update
7 Software update
The software of the DAC basic/classic and the standard
parameters of the machine can be updated.
A software update requires a dongle (see  Instructions for use,
optional equipment) and the utility Dongle Copy.
This optional equipment is available for download on Dürkopp
Adler's website:
Observe the correct order when performing the software update:
1. Checking the version
2. Switching off the controller
3. Performing the update
7.1 Checking the version
The controller offers the option of checking the installed software
version to determine if it corresponds to the latest version
available.
To check the installed software version:
1. Open parameter t 51 00.
Service Instructions DAC basic/classic - 00.0 - 12/2014
43
Software update
2. Press
.
 The controller type appears on the display.
3. Press
.
 The software version appears on the display.
4. Press
.
 The software release date (YYYY,MM,DD) appears on the
display.
You can now switch off the controller to perform the update. Do
not perform the update if the installed version is newer than the
version stored on the dongle.
NOTE
You can use the utility Dongle Copy to find out
which version is stored on the dongle.
7.2 Performing the update
CAUTION
The dongle will overwrite the installed software
version!
Loss of data.
Check the version of the installed software before
completing the software update.
Important
Before beginning with the update, make sure that the controller is
switched off.
To perform a software update:
1. Connect the dongle containing the downloaded software.
44
Service Instructions DAC basic/classic - 00.0 - 12/2014
Software update
2. Switch on the controller.
 The two LEDs on the controller (POWER and MESSAGE)
flash. The display indicates the current progress of the
update.
When the update is complete, the display will read
Default?.
CAUTION
Controller malfunction if dongle is removed
prematurely!
Loss of data.
Do not remove the dongle until the controller is
You can choose from the following options:
• Keep settings (recommended)
• Load default values
• Select machine class
Keeping the settings
1. Press
.
2. Switch off the controller.
3. Remove the dongle when the LEDs on the controller's control
panel have gone out.
Loading default values
1. Press
.
2. Switch off the controller.
3. Remove the dongle when the LEDs on the controller's control
panel have gone out.
Selecting the machine class
1. Select the machine class using button A+ or A-.
2. Press
2 times to confirm your selection.
Service Instructions DAC basic/classic - 00.0 - 12/2014
45
Software update
3. Confirm the prompt with
.
 The display shows Load... and Pl. Wait!.
4. Switch the controller off when the parameter display comes up.
5. Remove the dongle when the LEDs on the controller's control
panel have gone out.
46
Service Instructions DAC basic/classic - 00.0 - 12/2014
Inspection
8 Inspection
A hardware test allows you to determine the actual condition of
the controller and the corrective measures necessary, if any, for
future use. You can carry out the following tests:
• Analog input
• Digital input
• Digital output
8.1 Checking the analog input
Use the analog test the check all analog inputs.
To perform a hardware test:
1. Open parameter t 51 12.
2. Press
.
 1.Analog appears on the display.
3. Press
.
4. Press the A+ button repeatedly until the desired input appears
on the display.
5. Press
.
You can check additional inputs or continue with the test of the
digital input.
8.2 Checking the digital input
WARNING
Puncture or insertion from running
machine!
Mild injuries possible.
Use extreme caution when performing
the input test.
Service Instructions DAC basic/classic - 00.0 - 12/2014
47
Inspection
Use the input test to check all digital inputs. Varying with the
machine class, these inputs can be:
• Key block
• Knee lever
• Light barrier
To perform the test:
1. Open parameter t 51 12.
2. Press
.
3. Press the A+ button repeatedly until 2 Inputs appears on
the display.
4. Press
.
 The display shows an input.
5. Press the appropriate button.
6. Press
.
You can check additional inputs or continue with the test of the
digital output.
8.3 Checking the digital output
CAUTION
Risk of breakage from collisions with other
machine components!
Possible hardware damage.
Prior to switching on each output, check if
collisions can occur.
Use the output test to check all digital outputs.
To perform the test:
48
Service Instructions DAC basic/classic - 00.0 - 12/2014
Inspection
1. Open parameter t 51 12.
2. Press
.
3. Press the A+ button repeatedly until 3 Outputs appears on
the display.
4. Press
.
 The display shows an output.
5. Press the A+ button repeatedly until the desired output appears
on the display.
6.
Press.
A press on the D+ button enables the output.
A press on the D- button disables the output.
8.4 FLASH test
During a FLASH test you can have the system display a checksum
and compare this sum to the checksum listed on Dürkopp Adler's
website.
To perform the test:
1. Open parameter t 51 12.
2. Press
.
3. Press the A+ button repeatedly until 4 Flash appears on the
display.
4. Press
.
 A checksum appears on the display.
Contact customer service if the checksums are not identical
( S. 56).
Service Instructions DAC basic/classic - 00.0 - 12/2014
49
Inspection
50
Service Instructions DAC basic/classic - 00.0 - 12/2014
Disposal
9 Disposal
The DAC basic/classic must not be disposed of with regular
household trash.
The controller must be disposed of in a suitable and proper manner
and in accordance with all applicable national regulations.
ATTENTION
Risk of pollution from improper disposal!
Unless disposed of in the proper manner, the
controller can cause severe pollution.
ALWAYS comply with the legal regulations.
regarding disposal.
Keep in mind during disposal that the controller is made up of
different materials (steel, plastic, electronic components, ...).
Observe the applicable national regulations when disposing of
these materials.
Service Instructions DAC basic/classic - 00.0 - 12/2014
51
Disposal
52
Service Instructions DAC basic/classic - 00.0 - 12/2014
Technical data
10 Technical data
The technical data will change depending on the sewing motor.
Measurement data, limit values, and usage conditions
Data / motor type
Unit
9800
170038
9800
170040
0281
100453
(built-in
motor,
class 281)
0867
103203
(built-in
motor, M
type)
Dimensional data
Voltage
(VN)
[V]
230, single
phase
230, single
phase
230, single
phase
230, single
phase
Frequency
(fN)
[Hz]
50/60
50/60
50/60
50/60
Current (controller)
[A]
1.6
1.6
1.6
1.6
Power
(P2, delivered)
[W]
375
375
375
375
Speed
(nN)
[RPM]
4000
4000
4000
4000
Torque
(MN)
[Nm]
0.63
0.63
0.63
0.63
Motor moment of
inertia without
belt pulley
(Jmot)
[kg cm²]
0.5
0.5
0.5
0.5
Operating mode
S5 (40 % DC where ts = 2.5 s)
Intermittent periodic duty with electric braking,
relative duty cycle 40 %, length 2.5 s
IP class
IP40
Insulation class
E
Limit values
Voltage range
[V]
Speed
(nmax)
[RPM]
190-250, single phase
6000
6000
Service Instructions DAC basic/classic - 00.0 - 12/2014
6000
6000
53
Technical data
Data / motor type
Unit
9800
170038
9800
170040
0281
100453
(built-in
motor,
class 281)
0867
103203
(built-in
motor, M
type)
Torque
(Mmax, brief)
[Nm]
3.5
3.5
3.5
3.5
Power
(P2max, brief)
[W]
1500
1500
1500
1500
Machine moment
of inertia, reduced
to
the motor shaft
(Jmach)
[kg cm²]
4.5
4.5
4.5
4.5
Usage conditions
Ambient
temperature
54
[°C]
+ 5 to 45
Service Instructions DAC basic/classic - 00.0 - 12/2014
Troubleshooting
11 Troubleshooting
The DAC basic/classic controller has 3 types of error messages
displayed by the control panel.
Contact the manufacturer if an error occurs that is not described
in the  Parameter list. Do not attempt to correct the error
yourself.
11.1 Error messages
Error table
Type
Code
Description
Remedial action
Error
Err XXXX
Serious error:
Work cannot be
continued
• Switch off the
controller
• Contact trained
technicians to
correct the error
Warning
Wrn XXXX Error
Work cannot be
continued
Information Inf XXXX
Information:
Work can be
continued
• Correct the state
that resulted in the
error
•
Press
XXXX is the placeholder for the respective numerical code
A list of numerical codes can be found in the  Parameter list.
Service Instructions DAC basic/classic - 00.0 - 12/2014
55
Troubleshooting
11.2 Customer service
Contact for problems, repairs, or if the controller is damaged:
Dürkopp Adler AG
Potsdamer Str. 190
33719 Bielefeld, Germany
Tel: +49 (0) 180 5 383 756
Fax: +49 (0) 521 925 2594
E-Mail: service@duerkopp-adler.com
Internet: www.duerkopp-adler.com
56
Service Instructions DAC basic/classic - 00.0 - 12/2014
Appendix
12Appendix
Fig. 11: Interconnection diagram TN mains
Fig. 12: Interconnection diagram TT mains
Service Instructions DAC basic/classic - 00.0 - 12/2014
57
Appendix
Fig. 13: Interconnection diagram IT mains
58
Service Instructions DAC basic/classic - 00.0 - 12/2014
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Service Instructions - 0791 100639 EN - 00.0 - 12/2014
DÜRKOPP ADLER AG
Potsdamer Str. 190
33719 Bielefeld
Germany
Phone: +49 (0) 521 925 00
E-Mail: service@duerkopp-adler.com
www.duerkopp-adler.com
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