DURKOPP ADLER 838 User manual

838
Spezialnähmaschine
Betriebsanleitung
Instruction manual
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 Teile-Nr./Part.-No.:
10/2008 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 838740
D
GB

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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.
Copyright ©Dürkopp Adler AG - 2008

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.

GB
Contents Page
Part 2: Installation instructions –Class 838
1. Items delivered ............................................... 3
2. General and transport packaging ................................... 4
3. Assembling the stand
3.1 Assembling the stand components .................................... 4
3.2 Completing the table plate and mounting to the stand ........................ 5
3.3 Adjustingtheworkingheight........................................ 6
4. Assembling the sewing machine head
4.1 Integrating the sewing machine head into the stand.......................... 7
4.2 Assembling the protective belt cover on the sewing machine head................. 7
4.3 Pedal adjustment .............................................. 8
4.4 Assemblingthekneeleverandoilpumphose............................. 9
4.5 Assembling the connection cable, control panel, and diode illumination on the machine head . . 10
5. The special sewing machine’s electrical connections
5.1 Connecting the special sewing machine to the low voltage supply ................. 11
5.1.1 Connecting the sewing light transformer to the supply voltage ................... 12
5.2. Establishing equipotential bonding .................................... 13
5.3 Connecting the sewing machine head to the sewing drive ...................... 14
6. Adjusting the Efka positioning drive
6.1 Adjustingthepositioningdriveparameters............................... 15
6.1.1 Adjustingtheparameterswiththe“Auto-select”function ...................... 15
6.1.2 Class-838specificadjustmentstotheparametersoftheEfkadrive................ 15
6.1.3 SpecificparametervaluesfortheClass838.............................. 16
6.2 Adjustingthemachinepositioning .................................... 16
6.2.1 Definingthepositions ........................................... 16
6.2.2 Adjusting the machine positioning for the DC1550/DA321G drive ................. 16
6.2.2.1 General .................................................... 16
6.2.3 Checkingthesetpositions ........................................ 17
6.3 Masterreset ................................................. 17
7. Pneumatic connections.......................................... 18
8. Lubrication ................................................. 18
9. Sewing test ................................................. 19

For your notes:

1. Items delivered
It is possible to order either a complete sewing unit or only individual
components. Before setup, please check that all the required
components are present.
This description is valid for the special sewing machine whose
individual components are delivered directly and completely from
Dürkopp Adler AG. These directions describe the assembly and
installation of the special sewing machine.
Required components:
–Upper section (machine head) (1)
–Accessory pack (contains oil collector (2), reel stand (3), tools and
additional items)
–Parts set (contains direct drive (4), protective belt cover (5), and
additional parts)
Optional components:
–Stand (6)
–Operating panel (7)
–Compressed air maintenance unit (8)
–Pneumatic connection kit (9)
GB
3
1
2
3
4
5
7
8
6
9

2. General and transport packaging
Caution!
The special sewing machine may only be set up by trained personnel.
Transport packaging
If you have purchased a mounted sewing machine, you must remove
the following packaging:
–Safety straps and battens from the upper machine head, table and
stand,
–Safety blocks and straps from the sewing drive.
3. Assembling the stand
3.1 Assembling the stand components
–Assemble the stand components according to the illustration.
Fasten the pedal (1) to the stand brace (3). Align the pedal after
you have assembled the complete machine.
–Turn the adjusting screw (2) to ensure a secure mount on the
stand. The stand must be resting with all four feet on the floor.
4
1
2
3

3.2 Completing the table plate and mounting to the stand
–Turn over the table plate (1).
–Screw on the cable channel (2).
–Screw on the setpoint director device (3).
–Screw on the cable clamp (4).
–Position the oil collector (5) in direction of arrow (6) so that the
edge of the oil collector is aligned with the table plate edge. Screw
on the oil collector.
–Screw on the drawer (7) together with its fixtures.
–Screw on the control unit (8) (the drill holes for the wood screws
are pre-drilled).
–Screw on the sewing light transformer (9) (optional equipment).
–Mount the electrical cable according to the instructions in
Chapter 5.
–Mount the table plate (1) to the stand using the wood screws
(B8x35). Drill the holes (10) for the wood screws. Turn the stand so
that it is positioned in its normal position.
–Put the reel stand (11) into the drilled hole in the table plate.
Fasten with nut and washer.
Mount and align the reel holder and unwinder holder.
These two holders must be positioned on top of each other.
–Put the support (12) in the drilled hole.
–Insert the lower hinge section (13) for the machine head into the
space on the table plate (1). Then screw it in.
–Insert the wedges (14) into the clearance space in the table plate
(for the rubber corners).
–Insert the rubber corners (15).
–Remove the plug (16) on the oil collector for the knee lever (17).
–Remove the knee lever (17) and guide through the opening, as
shown in the illustration.
GB
5
328
30
80
770
72
185
15
368 80
15
4
10 2 69 58 13 10
14
12
15
11
260
13
17
460
180
15
7
50
16
30

3.3 Adjusting the working height
–The stand height can be adjusted between 750 and 900 mm.
–Loosen the screws (1).
–Set the horizontal height of the table plate as needed. Check the
scale on the stand spar. The height of the stand should be
appropriate to the height and operating position of the operator.
–Tighten the screws (1).
Caution Danger of Injury!
Ergonomic-related, operator injuries can result if the stand height is
not adjusted to fit the operator.
6
1

4. Assembling the sewing machine head
4.1 Integrating the sewing machine head into the stand
–If the special sewing machine is equipped with a drive (direct drive)
on the machine head, then you should insert the head section (1)
diagonally into the space on the table plate.
–Be sure to screw in the installation plate (2) immediately after
inserting the head section. This will prevent the head section from
falling out if tilted or turned over.
The installation plate is included in the machine head’s accessory
pack.
4.2 Assembling the protective belt cover on the sewing machine head
–Take off the handwheel (1).
–Mount the Hall sensor (2) to the machine head. This part is
included in the “motor part set”.
–Mount the protective belt covers (3) and (4). (These are included in
the “motor part set”.)
–Mount the handwheel (1). Be sure to maintain the proper angled
position: when the needle position is “high”, the handwheel
pointer “0" should be aligned with the mark on the machine head.
GB
7
2
1
2
1
3
4

4.3 Pedal adjustment
–For proper ergonomic function, set the pedal (1) as follows:
The middle of the pedal should be position approximately under the
needle.
The stand brace (3) is fitted with slotted holes to help in aligning
the pedal properly.
–Adjust the tie rod (2) so that the foot axis is perpendicular to the
pedal surface.
Caution Danger of Injury!
Ergonomic-related, operator injuries can result if the proper pedal
position is not maintained.
8
2
1
2
90
3

4.4 Assembling the knee lever and oil pump hose
–Use the hand lever to lift the sewing foot.
–Tilt the machine head (1) to the rear.
–Insert the shaft (3) into the lever (4).
–Screw the screw (5) with the washer (6) into the shaft (3).
–Press the hose (7) into the clamps (8) and pull on to the
strainer (9).
–Reposition the machine head vertically and adjust the knee
lever (10) as shown in the illustration.
–Align the knee cushion.
GB
9
10°± 5°
10
1
8
9
7
4
6
5
3

4.5 Assembling the connection cable, control panel, and diode illumination on the
machine head
–A connection cable (1) is included in the delivery of all machines
that come with a positioning drive.
–The operating panel (2) must be ordered separately (optional
equipment). When the operating panel is ordered, the thread
guide (3) is also included in the delivery.
The diode illumination (5) must also be ordered separately
(optional equipment). With it are delivered two types of holder
brackets. This allows you to choose between two different
mounting positions for the light. Position (5) is the home (starting)
position. Position (7) is used when a material guide is mounted
onto the sewing machine.
–Take off the arm cover (9) and the valve cover from the machine
head.
–Install the connection cable with the connector (1) as shown in the
illustration.
–Mount the operating panel (2) with the thread guide (3). Install
cable (4) as shown in illustration.
–Install lighting (5) and cable (6) as shown in illustration.
–Lead the connection cables through the opening in the table plate
and fasten with the self-adhesive clamp (8).
10
5
3
7
2
41
8
69

5. The special sewing machine’s electrical connection
The sewing machine drive is supplied from the low voltage power
supply.
Caution!
Work on the electrical equipment of the sewing machine may only be
carried out by qualified electricians or other appropriately trained
persons.
It is strictly required to carefully read the drive instructions provided by
the manufacturer!
The power cord must always be disconnected while working on the
electrical equipment!
5.1 Connecting the special sewing machine to the low voltage supply
Caution!
The voltage of the mains must comply with the voltage specified on the
ratings plate!
The following items are part of the low voltage system:
–Connection cable
–Sewing drive
–Sewing light transformer (optional equipment)
–Cable
When the sewing machine is delivered, some of these items are
included in the “drive set” while other items are included in the “motor
part set”.
The connection to the low voltage supply should be carried out
according to the circuit diagram included in the “motor part set”.
Caution Danger of Injury!
The drive may only be operated with a protective earth conductor.
It must be connected to protect personnel from fire or electric shock, in
compliance with accident prevention regulations.
It is unsafe to operate the sewing machine while the protective earth is
disconnected. This protection may not be cancelled out in any way (for
example, by the use of an extension cable without grounding/earth).
GB
11

5.1.1 Connecting the sewing light transformer to the supply voltage
Caution Danger of Injury!
The sewing light cannot be turned off with the main switch
(EN 60 204-31)! The mains power supply must be disconnected before
mounting the illumination, repairing the transformer or changing fuses.
–Pull the plug out of the socket.
–Loosen the four screws on the front plate of the control cabinet.
–Take off the front plate.
–Guide the sewing light transformer cable through the cable duct (1)
into the control cabinet.
–Take off the black rubber guide track (2).
–Make a hole in the guide track (2) with a screw driver.
–Guide the cable for the sewing light transformer through this new
opening.
–Re-mount the rubber guide track (2).
–Use a thin screwdriver to press on the terminal openings (3) and
(4). This opens up the terminals (5) and (6).
–Connect the blue cable to terminal (6) and the brown cable to
terminal (5).
–Screw the front plate back on.
–Install a strain relief mechanism (e.g., a cable tie) for the
transformer cable.
12
26 5 1 65 4 3

5.2 Establishing equipotential bonding
The earth (grounding) cable (1) is included in the machine’s accessory
pack.
The earth cable (1) conducts static charges from the machine head via
the motor foot to the earth.
–Attach the earth cable (1) to the tab connector (2) (which is already
screwed on to the machine head). Guide the other end of the cable
under the table plate.
–Screw the end of the earth cable to the earth (grounding) point on
the drive ( ).
–The earth cable (1) should also be fastened under the table plate
with nail clips.
Caution: For sewing machines with a sewing drive (direct drive)
integrated into the machine head, there is no need to establish
equipotential bonding since this is implemented with the attached
sewing drive.
GB
13
1
2

5.3 Connecting the sewing machine head to the sewing drive
The electrical connection to the machine head is described in
section 4.5.
–Plug the connection cable from the machine head into the plug
connector (1).
–Plug the cable from the operating panel into the plug connector (2).
–Plug the connector (3) from the motor sensor (6) into the plug
connector (4).
–Plug the connector (5) from the motor (6) into the plug
connector (7).
–Plug the cable from the setpoint (pedal) device (8) into the plug
connector (9).
–Plug the cable from the handwheel proximity switch into the B18
socket.
14
741 2 935 6 8
B 7 7 6
V 8 . .
B 1 8
L S M . . .
B 2
M
B 8 0
E B . . .
B 4 1
M
A

6. Adjusting the Efka positioning drive
The programming and setting of parameters is used to specify the
function of the sewing drive controller.
All parameter values for the corresponding sub-classes are already
assigned when the complete sewing machine is delivered. Some
pre-set values for the controller (e.g., maximum rotational speed) may
also be changed. When replacing the controller, these
machine-specific parameters must be re-specified on the new
controller.
6.1 Adjusting the positioning drive parameters
Drive parameters are set in two steps. In the first step, the function
“Auto-select” is used to set the machine class parameters. In the
second step, some pre-set parameters are changed in order to set the
machine-specific parameters in the sub-class.
6.1.1 Adjusting the parameters with the “Auto-select” function
The sewing drive controller detects which sewing machine class is
connected by measuring the auto-select resistance from the machine.
Auto-select is used to select control function and the pre-set values of
the parameters.
Caution! If the controller detects an invalid or absent auto-select
resistance, then the sewing drive will only operated with
emergency-run functions. This serves to protect the machine from
damage.
6.1.2 Class-838 specific adjustments to the parameters of the Efka drive
Caution!
Be very careful when adjusting the parameter values. The machine can
be damaged when settings are made improperly.
Note:
All parameter values can be reset to their default (pre-set) values by
using the Master Reset function (refer to section 6.3).
A description of parameter settings can be found at www.efka.net or in
the Efka operating instruction booklet provided by the drive
manufacturer.
GB
15

6.1.3 Specific parameter values for the Class 838
Changing machine parameters for machines with 18/28 tooth drive
ratios
Parameter Original value New value Description of parameter
290* 0 4 Sewing machine class
111 1700 - Max. sewing speed
170 - - Reference position
171-2E 315 325 Position 2
180 20 30 Angle of turn back after cutting
250 16 4 1 stitch with the second stitch length
* This parameter must be selected first.
Note: In order to changing tooling-level parameters, the code 3312
must be entered with program access rights.
6.2 Adjusting the machine positioning
6.2.1 Defining the position
Position 1
At stop position, the needle is down in the seam. The number 225 on
the handwheel scale is aligned with the mark on the arm.
Position 2
After the thread cut, the needle is in the up position. The number 35 on
the handwheel scale is aligned with the mark on the arm.
6.2.2 Adjusting the machine positioning for the DC1550/DA321G drive
6.2.2.1 General
An incremental proximity switch is attached to the handwheel for
helping to position the needle. It delivers 512 pulses (value is shown
on the display) and an additional pulse per rotation. In general, the
specific position is specified by the angle between this position and the
reference position. The angle is specified by the value of the
corresponding parameter. (But it is not identical with the parameter
value.) The parameter values and positions are already set (refer to
section 6.1.3). The reference position is not set and must be specified.
The reference position is the starting position used for all other
positions. This position is defined when the handwheel number 105 is
aligned with the mark on the arm.
After disassembly, assembly, or replacement of the motor, the
reference position must be specified again.
The description of changing the reference position is found in the
booklet entitled “Instructions for Efka Operation”.
16