Duerkopp Adler 540-100 Service Manual
Manual, complete
540 - 100
CNC double lockstitch buttonholer
Operating Instructions
Installation Instructions
Service Instructions
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Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Phone + 49 (0) 5 21 / 9 25-00 • Fax + 49 (0) 5 21 / 9 25 24 35 • www.duerkopp-adler.com
Ausgabe / Edition: 04/2006 Printed in Federal Republic of Germany Teile-Nr./Part.-No.: 0791 540001
540 - 100
Manual, complete
Contents
Operating Instructions
Installation Instructions
Service Instructions
Interconnection-diagram
9890 540001 B
Software version
A04.1
B04.1
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 instruc ti o n m an ual contains i m po rt a nt i nf orm ation 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 instruc ti o n m an ual must alway s 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, i ncl u di n g e qu i pp i ng , t r ou bl e s ho ot i ng du r ing 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 o bl i g ed to c he ck th e m ac h i ne at l ea s t o nc e pe r shi f t f or
apparent da ma ge s and to immedia tl y r e po r t a ny c h an ge s ( inc l u di n g
the performanc e i n se r vi c e), wh i c h im pa i r th e sa fe ty.
The user comp an y mu s t e ns u re that the machi n e i s o nl y o pe r at ed i n
perfect working order.
Never remove or disable any safety devices.
If safety dev i c e s ne ed to be removed for equi pp i ng , r e pa i ri ng 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
manufacture r fo r da ma ge res u l ti n g f r om th i s .
Observe all safety and danger recommendations on the machine/unit!
The yellow -and-black str i pe d surfaces desig na t e pe rma ne nd 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.
It is absolutely necessary to respect
the safety instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.
Index Page:
Part 3: Service Instructions Class 540-100
1. Elements of the control panel
1.1 Alteringparametervalues......................................... 4
1.1.1 Numericalvalues.............................................. 4
1.1.2 Selectionofaparameter.......................................... 4
2. Menu structure technician mode (overview)
2.1 Submenumachineconfiguration(overview).............................. 6
3. Calling up the technician mode and entering the code ..................... 7
4. Main menu of the technician mode
4.1 Submenumachineconfiguration..................................... 7
4.1.1 Submenuuser................................................ 8
4.1.2 Submenuforsoftstartsetting....................................... 8
4.1.3 Submenu for determining the equipment ................................ 8
4.1.4 Submenuforthreadmonitorconfiguration............................... 9
4.1.5 Submenu for the configuration of condensed stitches ........................ 10
4.1.6 Submenuforenteringmachinetimes.................................. 11
4.2 Submenu for the configuration of the operating elements ...................... 11
4.2.1 Submenu for selecting the menu language ............................... 11
4.2.2 Submenuforsettingdateandtime ................................... 11
4.3 Submenufortestfunctions........................................ 12
4.3.1 SubmenuMultitest ............................................. 12
4.3.1.1 Submenuoutputtest............................................ 13
4.3.1.2 Submenu input test ............................................. 13
4.3.1.3 Submenu automatic input test ...................................... 14
4.3.1.4 Submenusewingmotortest........................................ 14
4.3.1.5 Submenustepmotortest ......................................... 14
4.4.1.6 SubmenuRAMtest............................................. 14
4.4.1.7 SubmenuEPROMtest........................................... 14
4.4.2 SubmenuDACIII.............................................. 15
4.4.3 Submenu memo-dongle .......................................... 15
4.4.3.1 Dongle contents ............................................... 15
4.4.3.2 Submenu loading .............................................. 16
4.4.3.3 Submenusaving .............................................. 17
4.4.3.4 Formatting.................................................. 18
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5. Knife setting
5.1 Aligningtheknifeandadjustingtheknifeheight ........................... 19
5.2 Settingoftheknifeincisiondamper................................... 20
Index Page:
6. Hook and needle bar
6.1 Needle position ............................................... 21
6.2 Reference position of the needle bar .................................. 21
6.3 Setting the adjusting sheet ........................................ 22
6.4 Loop formation stroke position and distance between hook and needle ............. 23
6.5 Needle bar height .............................................. 24
6.6 Needle protection .............................................. 25
6.7 Alignment of the bobbin case holder................................... 25
7. Aligning the throat plate as to the needle .............................. 26
8. Thread tension plate
8.1 Threadpulleradjustment ......................................... 26
8.2 Thread controller spring and thread regulator ............................. 27
9. Sewing basket
9.1 Settingoftheclothpresserblock(liftingstroke) ........................... 28
9.2 Lifting / Lowering speed of the sewing basket ............................. 28
9.3 Alignmentofthesewingbasketastothethroatplate ........................ 29
9.4 Referencepositionofthesewingbasket................................ 30
10. Bobbin thread scissors
10.1 Settingoftheclosingpath......................................... 31
10.2 Adjusting the spring sheet of the thread rest .............................. 32
11. Needle thread scissors
11.1 Function sequence ............................................. 33
11.2 Removal and check of the needle thread scissors .......................... 34
11.3 Alignmentofthescissorsblock...................................... 35
11.4 Scissorsswivelledin............................................ 37
11.5 Heightadjustment.............................................. 38
11.6 Scissorsswivelledout........................................... 38
11.7 Distance to the needle ........................................... 39
11.8 Opening the scissors ............................................ 39
11.9 Settingoftheclosingpath......................................... 40
11.10 Setting the time for opening the scissors ................................ 40
12. Machine stop position .......................................... 41
13. Bobbin winder ............................................... 42
14. Solenoid valves .............................................. 43
15. Exchange of the sewing basket .................................... 44
16. Stretching the drive belts ........................................ 45
1. Elements of the control panel
Key Function
If no text field is activated:
–
Change to the parent menu.
If a text field is activated:
–
Change between the figures tenth, unit, ten etc.
–
Change between the lines in the menus. The selected line is
always dark-shadowed.
If a text field is activated:
–
Increase or reduce the value of the respective figure by one or
change between the parameters in case of functions with several
choices, e.g. between “Push button on“ and “Push button off“.
–
Activate the text field. The value can be altered with the keys “ñ“
and “ò“.
If a text field is activated:
–
The set value is taken over.
–
You get back to the main menu from a submenu.
If a text field is activated:
–
An input is aborted. The previous value remains unchanged.
–
The control changes from the sewing mode to the programming
mode. The buttonhole parameters can be altered in this mode.
–
The control changes from the sewing mode or programming mode
to the sequence programming mode.
–
The control changes from the sewing mode to the technician mode.
This mode can only be activated by entering a code 25483.Inthis
operating state it is possible to set basic machine parameters and
to call up diagnosis and adjusting programs.
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1.1 Altering parameter values
1.1.1 Numerical values
1.1.2 Selection of a parameter
Numerical values can be altered as follows:
–
Selectthelinewiththevaluetobealteredwiththecursorkeysñ
and ò.
–
Actuate the OK key.
The cursor flashes under a digit of the numerical value.
–
Change between the digits with the cursor keys ï and ð.
–
Increase or reduce the value of the selected digit with the cursor
keys ñ and ò.
In case of parameters which cannot optionally be altered another
possible parameter value is indicated by actuating the cursor keys
ñ and ò.
–
Actuate the OK key.
The set value is taken over.
–
If the set value is not to be taken over, actuate the ESC key.
The initially set value is restored
Some parameters allow to choose between several possibilities.
The parameter can be altered as follow s:
–
Selectthelinewiththevaluetobealteredwiththecursorkeysñ
and ò.
–
Actuate the OK key.
–
Change between the possibilities with the cursor keys ñ and ò.
The selected parameter is displayed.
–
Actuate the OK key. The set parameter or value is taken over.
–
If the set parameter or value is not to be taken over, actuate the
ESC key.
The initially set parameter or value is restored.
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2. Menu structure technician mode (overview)
Parameter
Soft start
Equipment
X- /Y- Correction Submenu:
Thread monitor
Condensed stitches
Subclasses
Times
Display
Machine
User configuration
Service
Counter (totalizer) :
Language
Set date/time
Lock P: Selection
Hand switch: Selection
Machine configuration
Selection: German, English,
Italian, Parameter
Hour : Input
Minute: Input
Day:
Month:
Year: Input
Input
Input
Multitest
Events
DAC III
Data reset
Memo dongle
Output test
Input test
Auto input
Sewing motor test
Step motor test
RAM test
EPROM test
Time/Date:
Temperature DAC III: Display
Interm. circuit voltage: Display
Buttonhole data
Machine compl.
Content
Loading
Save
Format
Display
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2.1 Submenu machine configuration (overview)
Max. speed: Input
Speed basting stitches: Input
Scissors is moved out: Input
n-stitches b. u. bartack/bartack tension on: Input
n-stitches b. l. bartack/bartack tension on: Input
n-stitches b. lip there/lip tension on: Input
n-stitches b. lip back/lip tension on: Input
n-stitches b. seam beginning/lip tension on: Input
Parameter
Soft start
Equipment
Thread monitor
Condensed stitches
Times
Counter (totalizer)
Number of stitches: Input
Speed: Input
Cage length: Selection
Free cage length:
Cage width:
Free cage width:
Knife length:
Pressure monitor:
Input
Selection
Input
Input
Input
Number of stitches: Input
Stitch length x: Input
Stitch length y: Input
Position last stitch: Input
Repair mode:
Selection
Needle thread mon. on/off: Selection
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3. Calling up the technician mode and entering the code
In order to get into the technician mode a code has to be entered. For
this purpose please proceed as follows:
–
Press the F key in the sewing mode.
A window for entering the code appears.
–
Enter the technician code 25483.
Confirm with the OK key.
Note
If a wrong code has been entered, the automate returns to
the sewing mode.
4. Main menu of the technician mode
No. Parameter name Symbol Description
T1 Machine
T2 User configuration
T3 Service
Selection of the submenu for the machine
configuration
Selection of the submenu for the configuration
of the control elements
Selection of the submenu for test functions
4.1 Submenu Machine configuration
No. Parameter name Symbol Range Description
T1.1 Parameter -
T1.2 Soft start -
T1.3 Equipment -
T1.4 Thread monitor -
T1.5 Condensed stitches -
T1.7 Times -
Selection of the submenu for
parameter setting
Selection of the submenu for soft
start setting
Selection of the submenu for
equipment definition
Selection of the submenu for thread
monitor options
Selection of the submenu for setting
of condensed stitches
Selection of the submenu for
entering machine times
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T1.8 Counter (totalizer) -
buttonholes ever sewn
0 … 99.999.999
Display of the counter of all
buttonholes ever sewn
The value cannot be selected or
edited.
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4.1.1 User submenu
No. Parameter name Symbol Range Description
T1.1.1 Max. speed 200 … 4000
T1.1.2 Speed basting stitches 200 … 4000
T1.1.3 Move out the scissors 0 … 10
T1.1.4 Lip tension before the
0…10
upper bartack
T1.1.5 Lip tension before the
0…10
lower bartack
T1.1.6 Lip tension before the
0…10
lip back
T1.1.7 Lip tension before the lip
0…10
there
T1.1.8 Lip tension after the
0…10
seam beginning
Setting of the maximum speed in the
sewing mode.
The speed can be altered in steps of
100.
Setting of the speed for the basting
stitches
Number of stitches after which the
scissors moves out and releases the
clamped needle thread
Number of stitches before the upper
bartack with the bartack tension
switched on
Number of stitches before the lower
bartack with the bartack tension
switched on
Number of stitches before the lip
back with the lip tension switched on
Number of stitches before the lip
there with the lip tension switched
on
Number of stitches after the seam
beginning after which the lip tension
is switched on.
Only valid for taper bars.
4.1.2 Submenu for soft start setting
No. Parameter name Symbol Range Description
T1.2.1 Number of stitches 0 … 10
T1.2.2 Speed 200 … max.
Number of stitches of the soft start
Speed for the soft start
sewing speed
according to T1.1.1
4.1.3 Submenu for determining the equipment
No. Parameter name Symbol Range Description
T1.3.1 Cagewidth 3,4,6,Xmm
T1.3.2 Free cage width 1,0 … 6,0 mm
Selection of the cage width
Only visible if cage width X has been
selected for T1.4.1.
Enter value for cage width.
T1.3.3 Cage length 17, 22, 35, 48,
Selection of the cage length
70, X mm
T1.3.4 Free cage length 10,0 … 70,0 mm
Only visible if cage length X has
been selected for T1.4.3.
Enter value for cage length.
T1.3.5 Knife length 1,0 … 70,0 mm
Length of the knife used.
(Default-Value: 3.5 mm)
T1.3.6 Pres sure monitor 0 / 1
Pressure monitor available
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4.1.4 Submenu for the thread monitor configuration
No. Parameter name Symbol Range Description
T1.4.1 R epair mode A, B, C
T1.4.2 Needle thread monitor 0 … 10
Description repair modes T1.4.1
Method A:
The buttonhole has to be unstitched and sewn again.
–
After switching the automate on again the sewing basket lifts and
releases the material.
The automate is ready for a new sewing cycle.
Method B:
The buttonhole is completely stitched around anew.
–
After switching the automate on again the sewing basket remains
lowered. The material under the sewing basket remains in its
position.
–
Step the pedal forward (2nd step). The sewing cycle is started.
–
After the sewing cycle the automate runs in reference position and
the sewing basket is lifted.
–
The material can be taken out.
The automate is ready for a new sewing cycle.
Selection of the repair mode to be
used.
Number of stitches not registered by
the thread breakage monitor before
an error message is displayed.
At the value 0 the thread breakage
monitor is switched off.
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Method C:
The buttonhole is continued to be sewn from the recognized point of
thread breakage.
–
After switching the automate on again the sewing basket remains
lowered. The material under the sewing basket remains in its
position.
–
Step the pedal forward (2nd step). The sewing basket moves to the
recognized point of thread breakage with the material.
–
With the cursor keys ñ and ò you can move - not sewing - to the
position to continue the sewing cycle.
–
Step the pedal forward (2nd step). The sewing cycle is started.
–
After the sewing cycle the automate runs in reference position and
the sewing basket is lifted.
–
The material can be taken out.
The automate is ready for a new sewing cycle.
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4.1.5 Submenu for the configuration of condensed stitches
No. Parameter name Symbol Range Description
T1.5.1 Number of stitches 0 … 9
T1.5.2 Stitch length X 0,3 … 2,0 mm
T1.5.3 Stitch length Y 0,0 … 0,8 mm
T1.5.4 Position last stitch -4 … 4
Lip there Lip back
Enter the number of condensed
stitches
Enter the stitch distance of the
condensed stitches in direction X
Enter the stitch distance of the
condensed stitches in direction Y
Enter the position of the last knotting
stitch according to fig. 1
Fig. 1
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4.1.6 Submenu for entering machine times
No. Parameter name Symbol Range Description
T1.7.1 Ped ðStart 0 … 9000 ms
T1.7.2 End ðCage 0 … 9000 ms
T1.7.3 C ageðRef 0 … 9000 ms
Delay time between stepping down
the pedal position 2 and the sewing
motor start
Delay time between sewing end and
lifting of the cage
Delay time between lifting of the
cage and reference start
4.2 Submenu for the configuration of the operating elements
No. Parameter name Symbol Range Description
T2.1 Language -
T2.2 Set date/time -
T2.3 Locking P on / off
T2.4 Push-button on / off
Select the submenu for the choice
of the menu language
Select the submenu for setting date
and time
Switch the keyboard blocking for the
P key on or off. If the key blocking is
switched on, no buttonhole
programs can be established or
altered.
Select the push-button instead of
the foot pedal or in addition to the
foot pedal.
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4.2.1 Submenu for selecting the menu language
You can choose among the following languages:
–
German
–
English (Default setting)
–
Parameter display
(e.g.: T2.1 instead of Language, T2.3 instead of Locking P ,
T1.4.1 instead of Repair mode)
4.2.2 Submenu for setting date and time
No. Parameter name Symbol Range Description
T2.2.1 Minutes - 1 … 59 min
T2.2.2 Hours - 1 … 23 h
T2.2.3 D ay - 1 … 31
T2.2.4 Month - 1 … 12
T2.2.5 Year - 0 … 99
Tim e:
Input of the minutes
Tim e:
Input of the hours
Date:
Input of the day
Date:
Input of the month
Date:
Input of the year
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