DURKOPP ADLER beisler 2112-5 Service Instructions Manual Download

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Troubleshooting

Service Instructions 2112-5 - 00.0 - 02/2020

Error 43
Photocell lighted too early

Photocell FZ21 detects
intermittent reflection during
insertion

Adjust photocell sensitivity;
input test 21

Errors 45 - 48
I/O DAC, ULN, 485, RES

Internal hardware error
during data transmission to
adapter board 9020020

Replace 9020020

Error 56

Error in 3-phase stepper
motor-Power amplifier D900

Code

Meaning

Remedial action

Summary of Contents for beisler 2112-5

Page 1: ...Service Instructions...

Page 2: ...er AG and protected by copyright Any reuse of these contents including extracts is prohibited without the prior written approval of D rkopp Adler AG Copyright D rkopp Adler AG 2020 IMPORTANT READ CARE...

Page 3: ...tion of the clamp slide 21 7 1 3 Adjusting the parallel orientation of the clamp rail 23 7 2 Adjusting the downforce pressure of the assistance transport 24 7 3 Adjusting the guide laser 25 7 4 Adjust...

Page 4: ...osition 54 8 5 7 Actuating the thread clamp manually 55 8 5 8 Checking the cutters manually 55 8 5 9 Initializing the loading process 56 8 5 10 Winding the bobbin thread manually 56 8 5 11 Selecting m...

Page 5: ...ions With regard to minimum qualification and other requirements to be met by personnel please also follow the chapter Safety p 7 1 2 Representation conventions symbols and characters Various informat...

Page 6: ...for the user of the machine are specifically marked Since safety is of particular importance hazard symbols levels of danger and their signal words are described separately in the chapter Safety p 7...

Page 7: ...authorized modifications to the machine Use of untrained personnel Use of unapproved parts Transport D rkopp Adler cannot be held liable for breakage and transport damages Inspect the delivery immedia...

Page 8: ...About these instructions 6 Service Instructions 2112 5 00 0 02 2020...

Page 9: ...parts from the manufacturer Transport Use a lifting carriage or stacker to transport the machine Raise the machine max 20 mm and secure it to prevent it from slipping off Setup The connecting cable mu...

Page 10: ...s used in warnings Warnings in the text are distinguished by color bars The color scheme is based on the severity of the danger Signal words indicate the severity of the danger Signal words Signal wor...

Page 11: ...fatal injury if ignored This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored Puncture Crushing Environmental damage Symbol Type of da...

Page 12: ...vi ronmental damage if ignored This is what a warning looks like for a hazard that could result in property damage if ignored CAUTION Type and source of danger Consequences of non compliance Measures...

Page 13: ...disassemble the clamp rail 1 Lift the main clamp 3 2 Loosen the screw 2 3 Pull the clamp rail 1 down and out Assembling the clamp rail To assemble the clamp rail 1 Insert the clamp rail 1 into the fix...

Page 14: ...Slide the clamp to the left until it reaches the stop position 3 Loosen the screws 3 4 Disassemble the cover 2 5 Loosen the screws 8 6 Disassemble the cover 9 7 To release the tension of the toothed b...

Page 15: ...ed with holes 13 Positiontheendsof the toothedbelt 7 withthebelt clamps 11 exactly over the holes on the bearing bracket and tighten them using screws 14 To tension the toothed belt 7 tighten the scre...

Page 16: ...the left and right trouser components are each attached with a mounting bracket 3 to the bottom of the working plate To disassemble and assemble the cutter blocks 1 Disconnect the compressed air supp...

Page 17: ...5 Assistance transport 5 1 Changing the toothed belt for the assistance transport Fig 5 Changing the toothed belt for the assistance transport 1 To change the toothed belt for the assistance transport...

Page 18: ...9 and the slide roller 5 7 Positiontheendsofthetoothedbelt 6 togetherwiththebeltclamps 7 exactly over the holes on the holder and tighten them using screws 8 Tension the toothed belt 6 To tension the...

Page 19: ...nstructions 2112 5 00 0 02 2020 17 5 2 Pin assignment for the stepper motor of the assistance transport Fig 7 Pin assignment for the stepper motor of the assistance transport 1 Plug connections 2 Step...

Page 20: ...ling the control panel Fig 8 Disassembling and assembling the control panel To disassemble and assemble the control panel 1 Switch off the machine 2 Loosen the screws 2 3 Remove the control panel 1 fr...

Page 21: ...wnforce pressure of the clamp rail 1 Check to see if the main clamp exerts pressure on the sewing piece evenly along the entire length of the rail To do so position a piece of fabric at the loading po...

Page 22: ...ownforce pressure of the clamp rail 2 3 If the downforce pressure is uneven too strong or insufficient disas semble the clamp rail 1 4 Turn the screws 2 at the inner side of the clamp rail 1 in or out...

Page 23: ...de The disengagement position for the front and rear stop point of the clamp slide is set at the bearing bracket The front stop point 3 determines how far the clamp slide will approach the needle The...

Page 24: ...ush the main clamp below the sewing head 4 Lower the needle by hand 5 Loosen the counternut 2 6 Turn the screw 1 into position The distance A between clamp rail 4 and needle 5 is 1 1 5 mm 7 Tighten th...

Page 25: ...to see if the needle is positioned exactly parallel to the clamp rail along the entire length of the clamp rail To do so push the main clamp below the sewing head and check the distance between clamp...

Page 26: ...stamp 2 3 Try to pull the sewing material out of the stamp at several locations along the transport section The downforce pressure needs to be the same at all locations Adjusting the downforce pressur...

Page 27: ...g the guide laser Adjusting the height To adjust the height of the guide laser 1 Loosen the screw 6 on the rear of the worktable 2 Position the holder of the laser 6 at the desired height 3 Tighten th...

Page 28: ...tical alignment Information You can use the vertical alignment of the guide laser to determine the seam width when sewing the zipper fly If the alignment of the laser to the left is changed the seam w...

Page 29: ...e the main clamp into position To do so use the input output control functions Move the main clamp to the front stop point Lower the main clamp 2 Move the folder into position To do so use the input o...

Page 30: ...pick up plate 1 To fix the pick up plate 7 in place turn the adjusting wheel 6 all the way into the minus range 2 Move the folder 1 onto the pick up plate 7 To do so use the input output control funct...

Page 31: ...position of the folder The quick stitch width adjustment allows for the presetting of 4 seam widths Use the adjusting wheel 2 to adjust the stitch width between the trouser component 8 and the zipper...

Page 32: ...owers onto the work surface to the left of the clamp slide without any friction contact 4 Tighten the counternut 3 7 5 Aligning the stop for the right fly piece Fig 18 Aligning the stop for the right...

Page 33: ...urn the adjusting wheel 1 Adjusting the cutting depth of the gusset in the left fly piece The cutting depth of the gusset in the left fly piece depends on the cutter block s mounting position To adjus...

Page 34: ...n C To do so insert the locking peg into the hole to the left of the handwheel 3 Install the drive belt 1 so that the feather key 2 is flush with the marking 3 on the motor housing 4 Remove the lock 5...

Page 35: ...emaining thread monitor The remaining thread monitor is checked using a photocell If the messag es on the display do not match the filling state of the bobbin the photocell sensitivity must be checked...

Page 36: ...Y being displayed OR if the message BOBBIN EMPTY is displayed even though the bobbin contains more than 0 5 m of thread the photocell sensitivity must be adjusted To adjust the sensitivity of the phot...

Page 37: ...period The light conductor control will be locked automatically after 4 minutes 3 Use keys 4 and 5 to adjust the light sensitivity of the photocell 3 To increase light sensitivity Press the key 5 To r...

Page 38: ...Hook switches 7 and 8 NOTICE Property damage may occur Collision of moving machine parts Move the machine to its initial position before switching the machine on NOTICE Property damage may occur Damag...

Page 39: ...the PCB is adjusted correctly the LED 1 is illuminated The standby relay is energized Micro step DIP switch 2 DIP switch 3 Hook switch 7 open Signal 0 Hook switch 8 closed Signal 0 Hook switch 7 clos...

Page 40: ...Setting up the machine 38 Service Instructions 2112 5 00 0 02 2020...

Page 41: ...indicates the menus that can be requested using function keys 3 directly from the start level For all other menus the corresponding symbols are shown on the control panel display Function keys 3 The...

Page 42: ...kup copies of all program control data Programs can be copied to and stored on the memory stick and uploaded to the control again if required Numeric keypad 7 All variable number values are entered us...

Page 43: ...bobbin thread Global Parameters menu The Global Parameters menu is used to set parameters that control the basic functions of the machine p 60 Changing global parameters will result in changes to all...

Page 44: ...cessed one at a time in the order of the seam numbers from left to right The order of the seam number is freely selectable Memory Seam programs are stored in the memory M The program control memory ca...

Page 45: ...e program levels Fig 25 Overview of the program levels Start level Global Parameters menu parameter list Direct access Keys F1 F8 Level 1 service menu Special Parameters menu Operating levels with fun...

Page 46: ...46 Copy seam numbers p 47 Erase seam p 48 Enter seam name p 48 Copy seam program to memory stick p 49 Download seam program from memory stick p 49 Copy variables global parameters special parameters...

Page 47: ...rvice code Entering the service code allows you to access the access protected submenus of the system menu To enter the service code 1 Press the key 2 Press the key The submenu Service Code is called...

Page 48: ...seams The settings refer to the selected seam program The order for sewing the seams can be set at will When the order has been set existing seam numbers are overwritten or new seam numbers are creat...

Page 49: ...es of a seam program to other seam programs The existing seams of the seam program to which you transfer the proper ties will be overwritten completely To copy a seam program 1 Press the key 2 Enter t...

Page 50: ...ber on the numeric keypad 7 Press the key The seam has been erased 8 4 7 Submenu Enter seam name You can give each seam a name of its own To name a seam 1 Press the key 2 Press the Init parameters key...

Page 51: ...sired seam number on the numeric keypad 8 4 9 Downloading a seam program from the memory stick To restore or change seams you can download seam programs from the memory stick For this purpose an unuse...

Page 52: ...key 6 Confirm the safety prompt 7 Press the key 8 4 11 Downloading variables from the memory stick Important If this function is used to download all variables from the memory stick to the program co...

Page 53: ...he Clamp motor permanent test key 5 Confirm the safety prompt 6 Press the key 7 The clamp motor runs in continuous operation To exit continuous operation 1 Press the STOP key 8 4 13 Checking the threa...

Page 54: ...nctions on the start level 8 5 2 Calling up level 1 To call up level 1 of the service menu 1 Press the key Function key Description Reference F1 Call up service menu level 1 p 52 F2 Insertion distance...

Page 55: ...a new value enter the desired number combination on the numeric keypad 4 To confirm your input and exit the menu press the key 8 5 4 Submenu Photocell correction for seam end seam length and fixed sea...

Page 56: ...higher the input value the longer the seam Seam 2 The seam beginning is determined by the scan point of the photocell The seam end is determined by a fixed seam length The setting refers to the seam...

Page 57: ...vidually To call up the Cutter test menu 1 Press the key The display shows the submenu Fig 31 Checking the cutters manually To check the cutter for the left trouser component 1 Press the key The cutte...

Page 58: ...d p 33 8 5 9 Initializing the loading process This function depends on the mode of the machine cycle It refers only to machine movements that can be performed before the automatic cycle To initialize...

Page 59: ...Selecting machine control inputs outputs Important If an output is activated the machine performs the corresponding function Before activating the outputs remove all unnecessary objects within the op...

Page 60: ...pen close sliding table 06 X11 Pin26 5 2 way Y07 07 Lifting table up 07 X11 Pin27 5 3 way Y08 08 Stacker stamp up down 08 X11 Pin23 5 2 way Y09 09 Open close pocket bag clamp 09 X07 Pin10 5 2 way Y10...

Page 61: ...ay Y46 46 Zipper fly blowing 46 X07 Pin13 3 2 way Y47 47 Parts blowing 47 X07 Pin07 3 2 way Y48 48 Lifting table down 48 X11 Pin28 5 3 way Switch Input number Switch type Version Signal input S01 01 S...

Page 62: ...Lower clamp after clamp movement forward for part pickup 0 1 s 03 Till vacuum off Switch vacuum off after clamp down 0 2 s 04 Thrd length bobbin full 003 m 05 Till clamp inserting Clamp insertion del...

Page 63: ...open 0 0 s 23 Lift Table mod 00 01 99 Lower lifting table Input 00 Lower lifting table via photocell Input 01 99 Lifting table is lowered after corresponding number of pieces 0 0 24 Dur lifting table...

Page 64: ...ition for thread cutting 100 INC 37 Cutting speed 180 rpm 38 Duration of trimming Duty cycle for thread cutting 0 35 s 39 Turn Back Thread lever reversing angle 00 INC 40 Process in steps 00 No Parame...

Page 65: ...Press the key 09 Distance sewing speed 1 Distance for slow sewing sewing speed 1 10 Distance sewing speed 3 Distance for slow sewing at seam end sewing speed 3 12 Thread monitor on after Needle threa...

Page 66: ...g 33 Functions on level 2 To call up the special parameters level 2 1 Press the key on the start level The Service menu opens 2 Press the key in the Service menu The special parameters level 2 opens F...

Page 67: ...sired value using the keys and 4 To confirm your input press the key Values that can be set in Start mode and Blowing mode Start mode The selected start mode determines how the machine cycle is starte...

Page 68: ...arameter list is shown on the display Information The possible settings for the sewing speed refer to the following sewing ranges Sewing speed 1 Seam beginning Sewing speed 2 Seam center Sewing speed...

Page 69: ...er list is shown on the display Parameter Description 01 Clamp insertion as seen from the right end of the rail 02 Stop position 600 mm is a safety value Only values higher than 600 mm can be input 03...

Page 70: ...e menu opens 2 Press the key in the Service menu The special parameters level 2 opens 3 Press the key on special parameters level 2 The special parameters level 3 opens Function key Menu F1 Back to le...

Page 71: ...d on or off If the photocell that scans the end position of the seam is switched off the machine control requires a fixed point for the seam end for the machine cycle Switching off the photocell resul...

Page 72: ...menu opens 2 Press the key in the Service menu The special parameters level 2 opens 3 Press the key on special parameters level 2 The special parameters level 3 opens 4 Press the key on special parame...

Page 73: ...tic label feed system or on off Folded labels can only be sewn with the automatic label feed system Plain labels can be placed onto the pocket facing manually when the automatic label feed system is s...

Page 74: ...el The Service menu opens 2 Press the key in the Service menu The special parameters level 2 opens 3 Press the key on special parameters level 2 The special parameters level 3 opens 4 Press the key on...

Page 75: ...n the remaining thread monitor should always be switched on as the sewing program will otherwise not be stopped if the thread breaks To switch the remaining thread monitor on or off 1 Press the key Sw...

Page 76: ...Programming 74 Service Instructions 2112 5 00 0 02 2020...

Page 77: ...and cutting possible Prior to any maintenance work switch off the machine or set the machine to threading mode WARNING Risk of injury from moving parts Crushing possible Prior to any maintenance work...

Page 78: ...n cloth WARNING Risk of injury from flying particles Flying particles can enter the eyes causing injury Wear safety goggles Hold the compressed air gun so that the particles do not fly close to people...

Page 79: ...with skin Avoid skin contact with oil If oil has come into contact with your skin wash the affected areas thoroughly NOTICE Property damage from incorrect oil Incorrect oil types can result in damage...

Page 80: ...g 37 Adjusting the operating pressure To adjust the operating pressure 1 Pull the pressure regulator 1 up 2 Turn the pressure regulator until the pressure gage 2 indicates the proper setting Increase...

Page 81: ...collection tray 2 Fig 38 Draining the water oil mixture To drain the water oil mixture 1 Disconnect the machine from the compressed air supply 2 Place the vessel under the drain screw 3 3 Loosen the d...

Page 82: ...ew the filter element 1 5 Blow out the filter element 1 using the compressed air gun 6 Wash out the filter tray using benzine 7 Tighten the filter element 1 8 Tighten the collection tray 2 9 Tighten t...

Page 83: ...Maintenance Service Instructions 2112 5 00 0 02 2020 81 9 4 Parts list A parts list can be ordered from D rkopp Adler Or visit our website for further information at www duerkopp adler com...

Page 84: ...Maintenance 82 Service Instructions 2112 5 00 0 02 2020...

Page 85: ...om soiling 6 Cover the control to protect it from soiling 7 Cover the entire machine if possible to protect it from contamination and damage WARNING Risk of injury from a lack of care Serious injuries...

Page 86: ...Decommissioning 84 Service Instructions 2112 5 00 0 02 2020...

Page 87: ...le national regulations When disposing of the machine be aware that it consists of a range of different materials steel plastic electronic components etc Follow the national regulations when disposing...

Page 88: ...Disposal 86 Service Instructions 2112 5 00 0 02 2020...

Page 89: ...program empty Current seam program empty possibly distances and routes have not been input or the entire program was erased Insert program values manually copy from other program or retrieve from ROM...

Page 90: ...Error 09 Clamp can not leave the switch Clamp slide moves to limit switch during initialization but does not return direction not reversed Using test program Clamp motor actuation enter slow speed and...

Page 91: ...During thread cutting sewing motor did not reach cutting speed within error period Replace sewing motor or synchronizer Error 32 Thread cutting position does not come During thread cutting sewing mot...

Page 92: ...Z21 detects intermittent reflection during insertion Adjust photocell sensitivity input test 21 Errors 45 48 I O DAC ULN 485 RES Internal hardware error during data transmission to adapter board 90200...

Page 93: ...read tensions Thread guiding parts such as thread tube thread guide or thread take up disk are sharp edged Check threading path Throat plate hook or spread have been damaged by the needle Have parts r...

Page 94: ...material the sewing material thickness or the thread used Check thread tensions Needle thread and hook thread have not been threaded correctly Check threading path Needle breakage Needle thickness is...

Page 95: ...Unit 2112 5 Type of stitches 201 Hook type Horizontal hook small Number of needles 1 Needle system 134 SERV 7 or 797 Needle strength Nm 80 120 Thread strength Nm Max 30 3 Stitch length mm 1 6 5 Speed...

Page 96: ...Technical data 94 Service Instructions 2112 5 00 0 02 2020...

Page 97: ...ng speed 3 15 mm 12 Thread monitor on after 05 mm 13 Needle thread monitor filter 20 mm 14 Bobbin monitor filter 00 16 Start bartack length 08 mm 17 End bartack length 00 mm 18 Stitch length seam begi...

Page 98: ...or filter 00 16 Start bartack length 00 mm 17 End bartack length 08 mm 18 Stitch length seam beginning 1 5 mm 19 Distance of stitch length 08 mm 24 Stitch length main seam 3 0 mm 25 Stitch length seam...

Page 99: ...1 5 mm 19 Distance of stitch length 08 mm 24 Stitch length main seam 3 0 mm 25 Stitch length seam end 1 5 mm 26 Distance of stitch length 08 mm 27 Stitch length trimming stitch 1 5 mm 28 Choice of tr...

Page 100: ...e of stitch length 08 mm 27 Stitch length trimming stitch 1 5 mm 28 Choice of trimming stitch 00 30 Start mode insert 05 31 Clamp curve code 00 32 Blowing mode 01 33 Push retainer mode 00 34 Swing ret...

Page 101: ...Clamp curve code 00 32 Blowing mode 01 33 Push retainer mode 00 34 Swing retainer mode 00 37 Assist transport distance 00 cm 38 Assist transport synchron 120 Seam 20 left fly piece ladies trousers 01...

Page 102: ...3 0 mm 25 Stitch length seam end 1 5 mm 26 Distance of stitch length 08 mm 27 Stitch length trimming stitch 1 5 mm 28 Choice of trimming stitch 00 30 Start mode insert 06 31 Clamp curve code 00 32 Blo...

Page 103: ......

Page 104: ...33719 Bielefeld GERMANY Phone 49 0 521 925 00 E mail service duerkopp adler com www duerkopp adler com Subject to design changes Part of the machines shown with additional equipment Printed in German...

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