DURKOPP ADLER 911 Product guide

911
CNC-controlled sewing unit with large
sewing area
Operating Instructions
Installation Instructions
Service Instructions
Postfach 17 03 51, D-33703 Bielefeld Potsdamer Straße 190, D-33719 Bielefeld
Telefon [phone] Telefax +49 (0) 5 21/ 9 25 24 35 www.duerkopp-adler.com
1
2
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
08/2010 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 911001
3

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 - 2010

Foreword
This instruction manual is intended to help the user to become familiar
with the machine and take advantage of its application possibilities in
accordance with the recommendations.
The instruction manual contains important information on how to
operate the machine securely, properly and economically. Observation
of the instructions eliminates danger, reduces costs for repair and
down-times, and increases the reliability and life of the machine.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the machine/sewing
unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
–Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
–Service (maintenance, inspection, repair) and/or
–Transport.
The user also has to assure that only authorized personnel work on the
machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

General safety instructions
The non-observance of the following safety instructions can cause
bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the
instruction book and operated by persons with appropriate training.
2. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot, needle
plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as
the entire sewing unit is found to comply with EC directives.
13. The line cord should be equipped with a country-specific mains
plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).
It is absolutely necessary to respect the safety
instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.

Contents Page:
Preface and General Safety Instructions
Part 1: Operating Instructions Cl. 911 - Original Instructions
(Edition 08/2010)
1 Product Description ..............................................3
2 Designated Use .................................................5
3 Subclasses ....................................................5
4 Optional Equipment...............................................6
5 Technical Data ..................................................7
6 Operation
6.1 Switchingon-Switchingoff-Safestop-Quickstop...........................8
6.2 Raisingthemachinehead...........................................11
6.3 Changingtheneedle..............................................12
6.4 Threadingtheneedlethread .........................................13
6.5 Adjustingthethreadregulator ........................................14
6.6 Winding on the hook thread..........................................15
6.7 Changing the hook-thread bobbin ......................................16
6.8 Setting the hook thread tension .......................................17
7 Operating the control unit of the 911
7.1 Thecontrolpanel................................................18
7.2 Operatingthetouchscreenpanel......................................18
7.3 Thestartscreen.................................................22
7.4 Themainscreen.................................................23
7.5 Popupmenustructure.............................................24
7.6 Menuitem“File”.................................................25
7.7 Menuitem“Edit” ................................................29
7.8 Menuitem“Extras”...............................................41
7.9 Menuitem“Correction”............................................49
7.10 Menuitem“?”..................................................50
7.11 Teach-in......................................................51
7.12 Repairmode...................................................55
7.13 Thread breakage ................................................56
8 DA-CAD 5000 ..................................................57
1

Contents Page:
9 Error messages/Information messages
9.1 Errormessages.................................................59
9.2 Informationmessages.............................................63
10 Maintenance
10.1 Cleaning and Checking ............................................64
10.2 OilLubrication..................................................65

1
1 Product Description
CNC-controlled sewing unit based on the class 867 with large sewing
area (sewing field size 300 x 200 mm) and a DAC III control unit with
special software.
For technical textiles manufacturers, motor vehicle equipment
manufacturers, seat manufacturers (automotive), bag, case and
backpack manufacturers (leather/textile), shoe manufacturers.
For the following applications:
Bartacks on load-bearing straps, lowering harnesses, safety
harnesses, lashing straps; Attaching of labels and facing pieces;
Decorative seams on shoes and legs of boots, decorative seams in
special applications.
Material:
Straps, ropes, leather, webbing, airbag materials, leather cut, foam
laminate, leather- laminate- and textile plastics
Double-lockstitch machine equipped with:
Automatic sewing foot and clamp lifting, sewing stroke adjustment,
thread trimmer, needle thread monitoring, thread pulling device and
multiple thread tension.
Technical specifications
The sewing unit is driven by a positioning drive.
With the control unit DACIII are operated apart from the sewing drive
also two step motors needed for the X and Y motions of the seam
geometry and a Z axis for the adjustment of the sewing foot.
The arm shaft of the sewing unit is directly driven by a brushless DC
motor.
·Max. speed 3,000 U/min.
·Stitch length up to 12.7 mm.
·99 program memory locations are available.
·The programs can be sewn individually or in sequences.
·Motor driven sewing foot lifting.
·Pneumatic driven clamp opening/closing.
·The maximum size of the sewing field is 300 mm in X direction and
200 mm in Y direction.
·Central oil wick lubricating for the machine head and the hook.
·Equipped with a vertical hook
·The BFT graphical control panel OP 7000 serves as control
element.
3

With electronic needle thread monitor.
In order to generate a clean seam pattern, the sewing unit is equipped
with a multiple thread tension device, permitting to assign to various
thread pulling directions the according tension value previously saved
in the sewing program.
The thread pulling device allows pulling the needle thread under the
sewing material during the first stitch.
The sewing unit is equipped with a programmable stitch counter for
the hook thread monitoring and a piece counter.
Integrated test and check program for service and maintenance
works. In addition to the monitoring of the sewing process, it is also
possible to check the motor functions, the inputs and outputs for the
reference switches, the valves and the feeding motors. The program
also serves for the adjustment of machine functions and the preparing
of sewing programs by the teach-in method.
Individual stitch parameter per stitch in order to control external units
like:
·The stroke position of the presser foot, thread trimmer, thread
clamp,
·Speed, thread tension etc.
The height of the stand can be adjusted with the telescoping feet from
a minimum work height of 760 mm to a maximum work height of 910
mm for stand-up working.
The foot pedal needed to operate the sewing unit can be shifted to
allow an ergonomic adaption to the operator.
4

2 Designated Use
The class 911 is a sewing unit that is designated for the sewing of
light to medium-heavy material. Such material is generally made of
textile fibers, composite materials but it may also consist of leather.
Suchlike material is used in the clothing industry and for domestic and
motor-vehicle upholstery.
This sewing unit can also be used to produce so-called technical
seams. In this case however, the operator must assess the possible
dangers which may arise (DÜRKOPP ADLER AG will be happy to offer
its assistance), since such applications are relatively rare and at the
same time can be so varied that no single set of criteria can cover
them all. The outcome of this assessment may require appropriate
safety measures to be taken.
Generally only dry material may be sewn with this sewing unit. The
material may be no thicker than 4 mm when compressed by the
lowered workclamp. The material may not contain any hard objects.
The seam is generally produced with textile-fibre sewing thread
(cotton threads, synthetic yarns of covering yarns) with the following
dimensions:
Class 911 thread thickness 15/3 - 120/3
Before using any other thread the possible dangers arising have to be
assessed and appropriate safety measures if necessary taken.
This sewing unit may be set up and operated only in dry,
well-maintained premises. If the sewing unit is used in
premises which are not dry and well-maintained it may be
necessary to take further precautions which should be agreed in
advance (see EN 60204-31:1999).
As manufacturers of industrial sewing machines we proceed on the
assumption that personnel who work on our products will have
received training at least sufficient to acquaint them with all normal
operations and with any hazards which these may involve.
3 Subclasses
Cl. 911-210 CNC-controlled sewing unit based on the class 867 with large sewing
area (sewing field size 300 x 200 mm) and a DAC III control unit with
special software.
1
5

6
4 Optional Equipment
For the sewing unit 911 the following optional equipment is available:
Optional equipment Order-No. Remark
Reception P.-Clamp 0911 457554 Kit for the reception of the parallel
clamp actuation
Bow f. P.- Clamp 0911 457604 Bow holding fixture for the clamping plate
P.-set of clamps HF 0911 417604 parallel set of clamps HF (bow bracket)
P.-set of clamps prg.1 0911 417634 Finished set of clamps f. parallel
clamp act. prg.1
P.-set of clamps prg.2 0911 417644 Finished set of clamps f. parallel
clamp act. prg.2
P.-set of clamps prg.3 0911 417654 Finished set of clamps f. parallel
clamp act. prg.3
L-bracket f. P.-Clamp 0911 457614 Kit L-bracket for reception of the divided
clamp (parallel)
P.-set of clamps HF div. 0911 417614 P.-set of clamps HF, divided, fastening with L-bracket
P.-set of clamps div. prg.1 0911 417664 Finished P.-set of clamps for divided clamp pgr.1
P.-set of clamps div. prg.2 0911 417674 Finished P.-set of clamps for divided clamp pgr.2
P.-set of clamps div. prg.3 0911 417684 Finished P.-set of clamps for divided clamp pgr.3
P.-set of clamps HF div. 0911 417624 P.-set of clamps HF, divided, fastening w. L-bracket
closed frame
P.-set of clamps div. prg.1 0911 417694 Finished P.-set of clamps, div., with
closed frame prg.1
P.-set of clamps div. prg.2 0911 417704 Finished P.-set of clamps, div., with
closed frame prg.2
P.-set of clamps div. prg.3 0911 417714 Finished P.-set of clamps, div., with
closed frame prg.3
Reception f. change-over clamp 0911 457564 Kit for the reception of the change-over clamp
C.-set of clamps HF 0911 417524 Change-over set of clamps HF
C.-set of clamps prg.1 0911 417554 Finished change-over set of clamps prg.1
C.-set of clamps prg.2 0911 417564 Finished change-over set of clamps prg.2
C.-set of clamps prg.3 0911 417574 Finished change-over set of clamps prg.3
Kit reduced pressure 0911 597544
Kit barcode reader 0911 597554
Set throat plate 0911 597504 Throat plate for processing thin materials
Set presser foot 0911 597514 Presser foot
Jumping foot 0467 220283 For thin material
Sewing lamp complete 9822 510026
Table clamp 9822 510027
Pneumatic connection package 0797 003031
Height adjustment 0911 407524 Table top height adjustable from 800mm to 1050mm

5 Technical Data
Type of stitch 301
Hook type Vertical hook
Needle system 134/35
Needle size [Nm] 80 until 180
Number of needles 1
Stitch length (programmable) [mm] depending on the seam pattern up to 12.7
max. speed [min-1 ] max. 3000 1/min
Clamp stroke [mm] 20
Foot lifting [mm] 20
Sewing field size [mm] 300 x 200
Number of free contour programs 99
Operating pressure [bar] 6
Air consumption [NL] 4
Table height (adjustable
manually via spindle)
-min [mm] 760
-max [mm] 910
Length, Width, Height [mm] 1200 x 1200 x 1150 (+120mm spindle length)
Weight (mounted) [kg] 225
Rated voltage [V] 230
Frequency [Hz] 50 / 60
Rated load [W] 450
Noise:
Lc = dB (A)
Workplace-related emission value in accordance with DIN 45635-48-A-1-KL-2
Sewing length: __ mm
Stitch: __
Speed: _____ min-1
Material: G1 DIN 23328 2 plies
Sewing cycle: 1.3 sec. on and 1.0 sec. off
1
7

6 Operation
6.1 Switching on - Switching off - Safe stop - Quick stop
6.1.1 Switching on
–Turn on the main switch 1.
The following request occurs on the display:
“Push Pedal backwards for referencing”
–Step the pedal backwards to start the reference run of the sewing
unit.
The main menu appears in the display.
6.1.2 Switching off
–Turn off the main switch 1.
All the drives and the control unit are immediately separated from
the mains.
8
1

6.1.3 Safe Stop
Caution: Risk of injury!
The sewing unit has to be switched off or switched to “safe stop”
before carrying out any work on it.
Only work in the hook area with “safe stop” activated when it is
illuminated.
Switching on “safe stop”
–Press key 2.
The key must snap in!
The sewing unit is in “safe stop” mode.
The lamp in the key shines.
The foot is moved to the lower position.
The area surrounding the hook cover 3 will be illuminated.
Switching off “safe stop”
–Press key 2 again.
The key must be released.
6.1.4 Quick stop
The safety system of the sewing unit provokes the immediate stopping
of the unit in case of faulty operation, needle breakage etc. with the
following options:
·Press the program-stop switch 4.
The running operations on the sewing unit will immediately be
aborted.
·Turn the main switch 1 counter-clockwise.
The sewing unit will immediately be dead.
9
1
43 2 1

10
2
3
4
1

6.2 Raising the machine head
The sewing head can be raised for maintenance work.
The carriage drive 2 must stand at the rear.
Caution: Risk of injury!
Turn the main switch off!
Maintenance may only be carried out with the sewing unit switched
off!
Raising the sewing head
–Release the locking lever 1 underneath the table top.
–Raise the machine head in the area of the face cover 3 and swing
it up carefully.
Additionally, the latch 4 will also snap in.
The space under the machine table can be accessed for cleaning
now.
Caution: Risk of injury!
Keep clear of the area within the table top cutout when the machine
head is tilted up.
Swinging the machine head back
–Keep hold of the machine head in the area of the face cover 3.
–Release the latch 4.
–Swing the machine head back carefully.
ATTENTION: Danger of breakage!
Keep hold of the sewing head until it has reached its final position.
–Engage the locking lever 1 underneath the table top.
11
1

6.3 Changing the needle
Caution: Risk of injury!
Turn the main switch off!
The needle may only be changed with the sewing unit switched off.
–Turn the machine with crank 4 until the needle bar 1 reaches its
highest position.
–Loosen screw 2.
–Pull the needle downwards out of the needle bar 1.
–Insert the new needle into the hole of the needle bar 1 and push it
until it stops.
Caution!
The needle scarf 3 must point towards the hook.
–Tighten screw 2.
ATTENTION!
When changing to another needle size, the distance between hook
and needle must be readjusted (see service instructions).
Ignoring the above mentioned hint can cause the following errors:
Use of a thinner needle:
·Missed stitches
·Thread damage
Use of a thicker needle:
·Damage on the hook tip.
·Damage of the needle
12
4
1
3
2

6.4 Threading the needle thread
Caution: Risk of injury!
Turn off the main switch!
The needle thread may only be threaded with the sewing unit
switched off.
–Put the thread reel on the thread stand and lead the needle thread
through the unwinder arm.
The unwinder arm must be in vertical position above the thread
reels.
–Thread in the thread through threading guide 1.
–Conduct the thread counter-clockwise around the pre-tensioner
wheel 2.
–Conduct the thread clockwise around the pre-tensioner wheel 3.
–Conduct the thread through threading guides 4 and 5.
–Conduct the thread clockwise around the deflector 6.
–Pull the thread underneath the thread take-up spring 7 and
conduct it through the threading guide 9, the thread regulator 10
to the thread lever 11.
–Conduct the thread through the thread lever 11 and the threading
guide 8.
–Conduct the thread through the needle thread monitor 12, the
thread clamp 13 and the threading guides 14 and 15.
–Thread the thread into the needle eye.
1
13
7654
1
2
3
11
10
9
8
12
13
14
15

6.5 Adjusting the thread regulator
Caution: Risk of injury!
Turn off the main switch.
The thread regulator may only be adjusted with the sewing unit
switched off.
The thread regulator 2 controls the quantity of needle thread required
for stitch formation.
The thread regulator must be precisely adjusted for an optimum
sewing result.
With correct setting the needle-thread loop must slide with low
tension over the thickest point of the hook.
–Loosen screw 1.
–Adjust the position of the thread regulator 2.
Thread regulator to the left = more thread
Thread regulator to the right = less thread
–Tighten the screw 1.
Adjustment information:
If the maximum quantity of thread is required the thread-tensioning
spring must be pulled upwards about 0.5 mm from its lower limit
position. This is the case when the needle-thread loop passes the
maximum hook diameter.
14
21

6.6 Winding on the hook thread
The separate bobbin winder makes it possible to wind the hook thread
independently from the sewing operation.
–Remove remaining thread from the bobbin hubs before winding.
–Put the thread reel on the thread stand.
–Thread the thread through the drill-hole 1 of the unwinder arm.
–Conduct the thread through threading guide 4.
–Conduct the thread through the bobbin thread tension 2.
–Wind up the thread to the right.
Press the bobbin retainer 3 against the bobbin hub.
The bobbin winder starts.
After reaching the set bobbin filling level the bobbin winder stops
automatically.
See Service instructions for setting the bobbin filling level.
1
15
43 2
1

6.7 Changing the hook-thread bobbin
Caution: Risk of injury!
The hook-thread bobbin may only be changed with the sewing unit in
“safe stop” mode.
–Remove the material holder 2 (only with change-over frame).
–Press the key 1 “safe stop”.
The drive carriage rides to the “bobbin change position”.
The cover plate 4 will pivot to the side.
The foot is moved to the lower position.
–The light 5 is switched on.
Remove the empty bobbin.
–Rise up the flap 6 and remove the empty bobbin.
Insert a full bobbin.
–Insert the bobbin 7 in a way that it moves in the opposite direction
of the hook when unwinding.
–Close the flap 6.
–Conduct the thread through slot 8 and underneath the spring 9.
–Pull the hook thread through the threading guide 10 and continue
pulling until it stands out about 3 cm.
–Release key 1 “safe stop”.
The cover plate 4 will pivot back into its original position.
16
32 1 54
10 9
6
7
8