DURKOPP ADLER 906 User manual

906
Operating instructions

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Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents,
including excerpts, is prohibited without the prior written consent of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG 2014

Table of contents
Operating instructions 906 - Version 00.0 - 05/2014 1
1 About this operating instructions.............................................5
1.1 Scope ...........................................................................................5
1.2 For whom is this operating instructions?......................................5
1.3 Representation conventions – symbols and characters...............6
1.4 Other documents..........................................................................7
1.5 Liability..........................................................................................7
1.6 Transport ...................................................................................... 7
1.7 Proper use....................................................................................8
2 Performance description ...........................................................9
2.1 Characteristics..............................................................................9
2.2 Declaration of conformity............................................................11
2.3 Additional equipment..................................................................12
2.4 Technical data ............................................................................13
3 Safety Information....................................................................15
3.1 Basic safety instructions.............................................................15
3.2 Signal words and symbols used in warnings..............................17
4 Machine Description ................................................................19
5 Operation...................................................................................21
5.1 Switching the sewing unit on and off..........................................21
5.2 Switching on Safe Stop ..............................................................22
5.3 Switching on the Quick-stop.......................................................23
5.4 Sewing on pre-bound pockets....................................................24
5.5 Pivoting the machine upper section............................................27
5.5.1 Raising the machine upper section ............................................27
5.5.2 Lowering the machine upper section..........................................28
5.6 Changing needle ........................................................................29
5.7 Threading the needle..................................................................30
5.8 Setting the thread regulator........................................................32
5.9 Winding the hook thread.............................................................33
5.10 Replacing the hook thread bobbin..............................................34
5.11 Setting hook thread tension........................................................36
5.12 Changing the configuration set...................................................38
5.12.1 Activating function keys..............................................................38
5.12.2 Changing the outer frame and inner slider .................................39
5.12.3 Changing the transfer plate ........................................................41
5.12.4 Ending clamp change mode.......................................................42
5.13 Maintenance...............................................................................43
5.13.1 Cleaning .....................................................................................43
5.13.2 Oil lubrication..............................................................................44
5.14 Customer Service.......................................................................47
6 Setting up..................................................................................49
6.1 Checking the scope of delivery...................................................49
6.2 Transporting the sewing unit ......................................................51
6.3 Setting up the sewing unit ..........................................................52
6.3.1 Positioning the sewing unit.........................................................52
6.3.2 Removing the transport locks.....................................................52
6.3.3 Installing the automatic stacker..................................................53

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2Operating instructions 906 - Version 00.0 - 05/2014
6.3.4 Attaching the thread reel holders................................................54
6.3.5 Setting up the pedal....................................................................54
6.4 Electrical connection...................................................................55
6.5 Pneumatic connection ................................................................56
6.6 Oil lubrication..............................................................................58
6.6.1 Oil lubrication..............................................................................58
6.7 Commissioning...........................................................................60
7 Settings via the software .........................................................61
7.1 Structure of the software ............................................................62
7.2 Overview of the menu structure..................................................63
7.3 Starting the software...................................................................64
7.4 Basic functions for using the software........................................67
7.4.1 Entering a password...................................................................67
7.4.2 Closing windows.........................................................................67
7.4.3 Display principles........................................................................68
7.4.4 Scrolling the display....................................................................68
7.4.5 Selecting options from a list........................................................69
7.4.6 Using file filters ...........................................................................70
7.4.7 Entering text ...............................................................................71
7.4.8 Entering parameter values .........................................................72
7.4.9 Switching the full-screen display on and off ...............................73
7.4.10 Switching zoom on and off .........................................................73
7.5 Opening a seam program or sequence for sewing.....................74
7.6 Briefly sewing with modified values............................................75
7.6.1 Sewing with a modified thread tension.......................................75
7.6.2 Sewing with a modified sewing speed........................................76
7.7 Replacing the hook thread bobbin..............................................77
7.8 Continuing a seam in Repair mode after an error.......................78
7.9 Resetting the counter .................................................................78
7.10 Creating a new seam program...................................................79
7.11 Performing a contour test...........................................................83
7.12 Create a sequence.....................................................................84
7.13 Edit an existing sequence...........................................................85
7.14 Saving a seam program or sequence under a different name....86
7.15 Copying a seam program or sequence ......................................87
7.16 Deleting a seam program or sequence ......................................88
7.17 Editing an existing seam program ..............................................89
7.17.1 Adjusting a contour.....................................................................89
7.17.2 Changing the parameters...........................................................93
7.18 Editing machine parameters.....................................................100
7.19 Checking and changing the technical settings .........................105
7.19.1 Adjust the contour data.............................................................105
7.19.2 Display system information.......................................................107
7.19.3 Testing MultiTest machine functions ........................................ 108
7.19.4 Initializing the controller, performing updates...........................115
8 Error and information messages ..........................................119
8.1 Error messages ........................................................................ 119
8.2 Information messages ..............................................................123
9 Creating programs with DA CAD 5000 .................................125

Table of contents
Operating instructions 906 - Version 00.0 - 05/2014 3
10 Decommissioning...................................................................127
10.1 Decommissioning the machine.................................................127
10.2 Dismantling the automatic stacker............................................128
11 Packaging, transportation .....................................................131
11.1 Fitting the transport locks .........................................................131
11.2 Rotating the frame feet upwards ..............................................131
11.3 Packing the machine................................................................132
11.4 Transporting the machine.........................................................132
12 Disposal...................................................................................133
13 Appendix ................................................................................. 135

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4Operating instructions 906 - Version 00.0 - 05/2014

About this operating instructions
Operating instructions 906 - Version 00.0 - 05/2014 5
1 About this operating instructions
This operating instructions for the 906 CNC sewing unit has been com-
piled with the utmost care. It contains information and notes in order to
ensure long-term and reliable operation.
Please contact us if you find any discrepancies or have any suggestions,
5.14 Customer Service, page 47.
Considerthisoperatinginstructionspartoftheproductandkeep itonhand
at all times. Be sure to read the manual completely before using the prod-
uct for the first time. Only give the product to someone else along with the
operating instructions.
1.1 Scope
This operating instructions describes the set-up and intended use of the
906 CNC sewing unit.
1.2 For whom is this operating instructions?
This operating instructions is for:
• Operators:
This group is familiar with the machine and has access to the operating
instructions. Specifically, 5 Operation, page 21 is important for this
group.
• Technicians:
This group has the appropriate technical training for performing mainte-
nance on the sewing machine or repairing malfunctions. Specifically,
6 Setting up, page 49 is intended for technical personnel.
A service manual will be provided separately.
With regard to minimum qualifications and other requirements to be met
by the personnel, please also observe 3 Safety Information, page 15.

About this operating instructions
6Operating instructions 906 - Version 00.0 - 05/2014
1.3 Representation conventions – symbols and characters
Proper setting
Indicates proper setting.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Steps to be performed when operating the machine
(sewing and equipping)
Steps to be performed for servicing, maintenance, and installation
Steps to be performed via the software control panel
The individual steps are numbered:
1. First step
2. Second step
The sequence of the steps must always be followed.
Result of performing an operation
Change to the machine or in the display.
Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating possibilities.
Order
Specifies the work to be performed before or after a setting.
References
Reference to another section in the manual.
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 3 Safety Informa-
tion, page 15.
Orientation If the figure is unclear, indications of "right" and "left" are always from the
operator's point of view.
1.
2.
...


About this operating instructions
Operating instructions 906 - Version 00.0 - 05/2014 7
1.4 Other documents
This equipment includes components from other 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 manual.
1.5 Liability
All information in this operating instructions was compiled with consider-
ation to the state of the art, and applicable standards and regulations.
The manufacturer cannot be held liable for damages resulting from:
• Damage during transport
• Failure to observe operating instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
1.6 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 undam-
aged.
Leave machines, equipment and packaging material in the condition in
which they were found when the damagewas discovered. This will ensure
any claims against the transport company.
Report all other complains to Dürkopp Adler immediately after receiving
the product.

About this operating instructions
8Operating instructions 906 - Version 00.0 - 05/2014
1.7 Proper use
The Dürkopp Adler 906 CNC sewing unit is used for sewing pre-bound
or other pockets onto jeans. The material requires a needle strength
of 120 - 140.
The machine is only intended for use with dry material. The material can-
not contain any hard objects.
The seam is created with thread made of textile fibers (cotton threads,
synthetic threads/core-spun threads).
The CNC sewing unit is intended for industrial use.
The CNC sewing unit may only be set up and operated in dry conditions
on well-maintained premises. If the machine is operated on premises that
are not dry and well-maintained, then further measures may be required
which must be compatible with EN 60204-31:1999.
Only authorized/trained personnel may operate the machine.
Any other use of the CNC sewing unit can lead to hazards and is
prohibited.
WARNING
Risk of electric shock, crushing and punctures!
Improper use can result in injury.
Please observe all instructions in the manual.
ATTENTION
Improper use can result in material damage.
Please observe all instructions in the manual.

Performance description
Operating instructions 906 - Version 00.0 - 05/2014 9
2 Performance description
The Dürkopp Adler 906 CNC sewing unit is used for automatically sewing
pre-bound or other pockets onto jeans.
Depending on the working method, various optional equipment is used.
2.1 Characteristics
Base type
CNC-controlled, double lockstitch sewing unit based on class 867,
with a DAC III controller and specific software.
Use
Sewing pre-bound pockets, mainly back pockets up to a size
of 210 x 210 mm, onto jeans.
Material to be sewn
Lightweight to medium-weight cotton and synthetic fiber materials.
Equipment:
• Automatic sewing foot ventilation
• Stroke position adjustment
• Short thread cutter
• Threading device
• Programmable upper thread tension
• Automatic material feeder
• Automatic stacker for stacking the material
• Overlapping mode of operation (while sewing or stacking, the next
material can be inserted and the next cycle can be started)
Hook
Vertical hook (32 mm bobbin diameter)
Drive
• Drive via positioning drive:
In addition to the sewing drive, the DACIII controller controls 2 stepper
motors for the X and Y motion for creating the seam geometry and
a Z axis for sewing foot adjustment.
• Pneumatic drive for the material feeder and the stacker.
• The arm shaft is driven by a brushless DC motor
• Maximum speed: 3000 min-1 intermittent
(depending on the stitch length and material thickness)

Performance description
10 Operating instructions 906 - Version 00.0 - 05/2014
Programming
• Operated via the graphic control panel OP 7000
• 99 program storage locations, each with a maximum of 16000 stitches
• Programs can be sewn individually or in sequences
• Storage of up to 20 sequences, with up to 30 programs in each
sequence
• Setting of individual stitch parameters per stitch for controlling stroke
position of pressure foot, thread cutter, thread clamp, speed, thread
tension etc.
• Integrated test program for servicing/maintenance work:
• Monitoring of the sewing process
• Configuration of machine functions
• Creation of seam programs via a teach-In procedure. The precision
of the entry of coordinates for teaching is 0.1/1 mm
• Testing of motor functions, inputs and outputs for reference switches,
valves and transport motors, RAM memory and EPROM functions
Sewing foot ventilation
Motorized sewing foot ventilation
Clamp opening
Pneumatic opening and closing of the clamps
Sewing field size
Maximum sewing field size: 210 × 210 mm
Lubrication
Central oil-wick lubrication for upper section and hook
Number of stitches
Recommended number of stitches: 2700/min
Stitch length
Maximum stitch length: 12.7 mm

Performance description
Operating instructions 906 - Version 00.0 - 05/2014 11
Thread handling
• Electronic upper thread monitor
• Programmable upper thread tension:
Tension values for different thread extraction directions stored in seam
program. This creates a clean seam.
• Threading device:
Pulls the needle thread under the sewing material on the 1st stitch.
• Programmable stitch counter for hook thread monitoring and item
counter
• Optional:
• Electronic residual thread monitor
• Stitch position optimization kit: For seam optimization in the removal
direction of 0 - 90°
Ergonomics
• Adjustable feet to even out the level of the floor and secure stance of
the unit
• Working height of the front edge of the table top for operation of the unit
while standing: 880 × 910 mm
• Table top tilted by 15° towards the operator
• Foot pedal freely movable within the available cable length
2.2 Declaration of conformity
The machine complies with the European regulations specified in the
declaration of conformity or in the installation declaration.

Performance description
12 Operating instructions 906 - Version 00.0 - 05/2014
2.3 Additional equipment
The following optional additional equipment is available:
Additional equipment Part number
Barcode reader kit 0911 597554
Residual thread monitor kit 0911 597754
Stitch position optimization kit 0911 597774
Laser attachment set 0911 597524
Laser light with power pack 0911 597534
Single lamp 0510 590034
Pressure line 0797 003031
Height adjustment 0911 407524
DA CAD 5000 programming software 9835 200352
Configuration set assemblies
(Description: 0906 FXXXXX; see configuration set for number)
Inner slider for configuration set 0906 929901
Outer frame for configuration set 0906 929902
Transfer plate for configuration set 0906 929903

Performance description
Operating instructions 906 - Version 00.0 - 05/2014 13
2.4 Technical data
Characteristic 906-01
Stitch type 301
Hook type Vertical hook
Needle system 134/35
Needle strength [Nm] 120 - 140
Number of needles 1
Stitch length (programmable) [mm] Maximum 12.7mm
(dependent on seam
appearance)
Maximum speed [min-1]
(intermittent and dependent on the stitch length
and sewing material thickness)
3000
Recommended [min-1]
(intermittent and dependent on the stitch length
and sewing material thickness)
2700
Foot stroke [mm] 20
Sewing field size [mm] 210 x 210
Number of free seam contours 99
Operating pressure [bar] 6
Air consumption with needle cooling Dependent on the setting
Length/width/height [mm]
• Without height adjustment
• With height adjustment 1900/1520/880-910 1900/1520/920-1270
Weight (fitted) [kg] 370
Voltage [V] 230
Frequency [Hz] 50/60
Power [W] 450

Performance description
14 Operating instructions 906 - Version 00.0 - 05/2014

Safety Information
Operating instructions 906 - Version 00.0 - 05/2014 15
3 Safety Information
This section contains basic information for your safety. Read the instruc-
tions carefully before setting up or operating the machine. Make sure to
follow the information included in this section. Failure to do so can result
in serious injury and damage to the machine.
3.1 Basic safety instructions
The machine may only be used as described in this operating instructions.
The operating instructions should be available at the machine's location at
all times.
Work on live components and equipment is prohibited. Exceptions are
defined in the specifications in DIN VDE 0105.
For the following work, the machine must bedisconnected from the power
supply using the main switch or by disconnecting the power plug:
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing maintenance work and repairs
• Threading
Missingorfaultysparepartscouldimpairsafetyand damagethemachine.
Make sure you only useoriginal replacement parts from the manufacturer.
Transport Use a sturdy lifting carriage or forklift for transporting the machine.
Raise the machine max. 20 mm and secure it against slipping off.
Setup 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.

Safety Information
16 Operating instructions 906 - Version 00.0 - 05/2014
Operator's
obligations Observe the country specific safety and accident prevention regulations
and the legal regulations concerning industrial safety and the protection of
the environment.
All warnings and safety signs on the machine must always be in legible
condition and may not be removed. Missing or damaged labels should be
replaced immediately.
Requirements
to be met by
the personnel
The machine should only be set up by qualified technicians.
Maintenance work and repairs should only be carried out by qualified tech-
nicians.
Work on electrical equipment may only be carried out by qualified special-
ists.
Only authorized persons may work on the machine. Every person who
works on the machine must have read the operating instructions first.
Operation Inspect the machine while in use for any externally visible damage.
Stop working if you notice any changes to the machine. Report any
changes to your supervisor. A damaged machine should no longer
be used.
Safety equipment Safety equipment should not be removed or deactivated. If this cannot be
avoided for a repair operation, the safety equipment must be refitted and
put back into service immediately afterwards.

Safety Information
Operating instructions 906 - Version 00.0 - 05/2014 17
3.2 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:
Symbols The following symbols indicate the type of risk to personnel:
Examples Examples of the layout of the warnings in the text:
Signal word Hazard
DANGER Will result in serious injury or death.
WARNING Can result in serious injury or death.
CAUTION Can result in minor or moderate injury.
ATTENTION Can result in property damage.
Symbol Type of danger
General risk
Risk of electric shock
Risk of puncturing
Risk of crushing
DANGER
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
will result in serious injury or even death if ignored

Safety Information
18 Operating instructions 906 - Version 00.0 - 05/2014
WARNING
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
could result in serious injury or even death if
ignored.
CAUTION
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
could result in moderate or minor injury if the warn-
ing is ignored.
CAUTION
Type and source of risk
Measures for avoiding the risk
This is a warning note for a hazard that could result
in environmental damage if ignored.
ATTENTION
Type and source of risk
Measures for avoiding the risk
This is what a warning looks like for a hazard that could result in
material damage if ignored.