Duerkopp Adler 540-100 Operating Instruction

Manual, complete

540 - 100

CNC double lockstitch buttonholer

Operating Instructions

Installation Instructions

Service Instructions

1

2

3

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.

Contents Page:

Foreword and general safety instructions

Part 1: Operating Instructions Class 540-100

1. Product description

1.1 Designated use ................................................ 5

1.2 Subclasses .................................................. 6

2. Technical data ................................................ 6

3. Operating the machine head

3.1 Needle threading ............................................... 7

3.2 Winding the hook thread .......................................... 8

3.3 Changing the bobbin ............................................. 8

3.4 Changing the needle ............................................ 10

3.5 Changing the knife .............................................. 11

3.6 Checkingtheknifeheight.......................................... 12

3.7 Threadtension................................................ 13

3.8 Regulating the sewing basket lifting height ............................... 14

3.9 Regulating the sewing basket pressure ................................. 14

1

4. Control panel and control

4.1 Control panel ................................................. 15

4.1.1 Control panel elements ........................................... 16

4.2 Changing parameter values ........................................ 17

4.2.1 Numericalvalues............................................... 17

4.2.2 Parameterselection............................................. 17

4.3 Mainmenu................................................... 18

4.4 Hookthreadmonitoring........................................... 19

4.4.1 Hook thread counter adjustment ...................................... 19

4.5 Softstarton/off ............................................... 20

4.6 Sequences ................................................... 20

4.6.1 General ..................................................... 20

4.6.2 Switching the sequence mode on / off .................................. 21

4.6.3 Select a sequence in the sequence mode (Main menu) ........................ 21

4.6.4 Automatic or manual mode ......................................... 21

4.7 Programming of sequences ......................................... 22

4.7.1 Programming of a single sequence .................................... 22

4.7.2 Adding a buttonhole at the end of a sequence ............................. 23

4.7.3 Deleting a buttonhole within the buttonhole sequence......................... 23

4.7.4 Inserting a buttonhole within the buttonhole sequence ........................ 23

Contents Page:

5. Buttonhole programming

5.1 Composition of a buttonhole ........................................ 24

5.2 Submenu programming (general view) .................................. 26

5.3 Parameterprogrammingmode....................................... 27

5.4 Adjusting the cut length ........................................... 28

5.5 Selectingastartvariant........................................... 28

5.6 Setting buttonhole seam .......................................... 29

5.7 Settingbartack ................................................ 30

5.7.1 Selectablebartacktypes .......................................... 30

5.7.2 Programmingmenu“bartack” ....................................... 31

6. Knitwear mode

6.1 Selectingorswitchingoffknitwearmode................................. 35

6.2 Submenubastingstitch........................................... 36

6.3 Submenuzigzag............................................... 36

7. Sewing procedure

7.1 Normal sewing procedure.......................................... 37

7.2 Interruption of sewing procedure ..................................... 37

7.2.1 Interruption by the operator......................................... 37

7.2.2 Clearingthreadbreakage.......................................... 37

8. Error messages ............................................... 39

9. Maintenance

9.1 Cleaning and inspection........................................... 42

9.2 Oillubrication................................................. 43

1. Product description

The Dürkopp Adler 540-100 is a CNC double lockstitch buttonhole
machine with stepping motor technology for the sewing of flat form
linen button holes in light to medium weight material. Maximum
buttonhole length is 65 mm and maximum buttonhole width is 6 mm
(equipment dependent).

Including a knife for all cutting lengths, longitudinal or transversal
setting possible, fine adjustment of the buttonhole with the push of a
button, integrated direct DC drive.

Additional functions:
–

Selectable bartack forms :
Cross tack (vertical), Cross tack (horizontal), Cross tack ( divided),
Round tack (to the middle point), Round tack (horizontal), Taper
tack, Eye tack, Simple tack, Snaffle-shaped tack

–

50 variable seam makers

–

20 Buttonhole – each sequence can be programmed with a
maximum of 20 buttonholes

–

Programmable sewing revolution to a max. of 4000 stitches/min

–

Soft start

–

Bobbin capacity meter

–

Daily quantity meter

–

Multi test functions

–

Voltage rating: 1 x 190 - 240V 50/60Hz

1

1.1 Designated use

The DÜRKOPP ADLER 540-100 is an automatic sewing machine
designed for sewing buttonholes in light to medium-heavy material.

Such material, which is generally made of textile or synthetic fibres, is
used in the clothing industry. This sewing machine can also be used to
produce so-called technical seams. In this case, however, the operator
must assess the possible dangers which may arise (with which
DÜRKOPP ADLER would be happy to assist), since such applications
are on the one hand relatively unusual and, on the other, they are 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 machine. The
material may b e no thicker than 4 mm when compressed by the
lowered upper material sewing basket.

The material may not contain any hard objects. The machine may only
be operated with finger and eye protection. The seam is generally
produced with sewing threads of gauge up to 65/2 Nm (synthetic
threads with or without cotton covering). Before using any other thread
the possible dangers arising must be assessed and appropriate safety
measures taken if necessary. This machine may be set up and
operated only in dry, well-maintained premises. If it is used in other
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.

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1.2 Sub classes

540-100
For the sewing of raised-form or flat-form linen buttonholes in light to

middle weight material, with pneumatically steered thread tensioner for
flat form sewing and a second pneumatically switchable /
programmable thread tensioner for raised form sewing. Buttonhole
length max. 70 mm, buttonhole width max. 6 mm. A knife for all cut
lengths.

2. Technical data

Machine head: Class 540-100

Needle system:

Needle thickness:

Threads:

Stitch type:

Stitch number:

Double stitch distance:

Sewing foot stroke:

Buttonhole length :

Buttonhole width:

Cut length:

Power rating:

Operating pressure:

Air consumption:

Rated voltage:

System 265 with slightly rounded head

70 – 100 (dependent on equipment )

Synthetic thread and synthetic thread with cotton covering
up to 65/2 Nm

Double lockstitch ( 304 )

Max. 4000 RPM (adjustable)

0,2-3mm

12 mm

6 - 70 mm (dependent on equipment)

3 - 6 mm (dependent on equipment)

6-65mm

1,3 kW

6 bar

apprx.4 NL per working cycle

1 ~ 230 V, 50/60 Hz
1~ 190 - 240 V, 50/60 Hz

Frame:

Work height:

Weight:

Rated noise level :

6

1060 x 620 x 1250 mm (L x B x H)

780 - 880 mm (Top edge of table top)

ca. 100 kg (with frame)
ca. 70 Kg (without frame)

Lc = 79 dB (A) Emission value per workplace according to
DIN 45635-48-B-1 (sewing cycle 3.6 s ON and 1.0 s OFF).
Buttonhole width: 4 mm
Cutting length: 17 mm
Speed: 4.000 min
Stitch length: 0.6 mm
Fabric: G1 DIN 23328 two-ply

-1

3. Operating the machine head

3.1 Needle threading

Caution: Danger of injury !

The needle should only be threaded when the sewing automat is
switched off.

- Thread needle according to diagram

1

Picture threading the needle

7

3.2 Winding the hook thread

1

2

3

Threading the hook thread is independent of sewing operation.
–

Put the thread on the thread stand.

–

Thread the hook as shown in the picture.

–

Put the empty bobbin onto the bobbin winder 1.

–

Wind the hook thread clockwise about 5 times around the bobbin
core.

–

Swing winder lever 2 towards spool and click in.
The thread will be wound on.

–

Winder lever 2 ends the spooling event when the bobbin is full.

–

After spooling snap out the bobbin thread from thread clamp 3.

3.3 Changing the bobbin

Caution: Danger of injury !

The bobbin should only be changed when the sewing automat is
switched off.

Remove empty bobbin.

–

Open bobbin case lid.

–

Flip up the clip 5 and remove the top of the bobbin housing with
bobbin.

–

Remove the bobbin from the top of the bobbin housing.

8

5

Threading the bobbin

–

Place the full bobbin in the bobbin housing top, whereby the bobbin
has to turn in anti-clockwise direction when the hook threader is
pulled.

–

Pass the hook thread through the slit 6 and under the spring.

–

Dependent on chosen buttonhole the hook thread has to go
through slit 9 for raised-form buttonholes and slit 10 for flat-form
buttonholes.

1

Setting the hook thread tension

–

Set the hook thread tension by turning screw 12 so that the bobbin
housing slowly sinks with its own weight when the hook thread is
held tight.

–

Flat-form buttonholes will require a higher tension.

Fitting of bobbin housing

–

Put the bobbin housing top along with the bobbin on the bobbin
housing bottom, make sure that the clip 5 audibly snaps into place.

–

Close bobbin case lid.

9

3.4 Changing the needle

Caution: Danger of injury !

Switch off at main power switch ! Only change the needle when the
sewing automat is switched off !

1

–

Loosen screw 1.

–

Pull needle form the needle bar.

–

Insert the new needle to the stop in the bore of the needle bar.

–

Set the needle so that the needle scarf lies on the backward facing
side of the knife.

–

Tighten screw 1.

CAUTION !

If the needle thickness is changed, the distance between the hook
and the needle may need to be changed.

10

3.5 Changing the knife

Caution: Danger of injury !

Switch off at main power switch ! Only change the knife when the
sewing automat is switched off !

CAUTION !

Ensure that the lifted basket has a minimum distance of 1mm between
the upper thread scissors and the bottom knife edge.

2

3

1

Knife removal

–

Loosen screw 2.

–

Remove knife 3.

Knife insertion

–

Insert new knife and set it right at the top.

–

Tighten screw 1.

Note!

If the cut does not occur in the middle of the buttonhole or not parallel
to the buttonhole seam, the knife needs to be readjusted.

Instructions for service 540-100, Chapter: Knife adjustment.

11

3.6 Checking the knife height

Rule:
The knife point is needed only when diving into the material. The knife

point should not leave the throat plate during the cutting procedure.

CAUTION !

Ensure that the lifted basket has a minimum distance of 1mm
between the upper thread scissors and the bottom knife edge.

Note !

When a knife is sharpened, its length will be shorter.
With the insertion of the sharpened knife the knife height may
need to be corrected.

Adjusting:

–

Position the material under the clamp and start the sewing process.

–

Stop the sewing process during the cutting process on the reverse
buttonhole seam stitch by pushing the pedal backwards.

–

Make the slit on the throat plate visible by pulling the material a
little away from the clamp.

–

Turn the hand wheel in the direction of rotation until the knife has
reached its highest position to the throat plate.

–

In this position 0.2mm of the knife point should remain dipped in
the throat plate slit.

–

Knife height adjustment: Loosen screw 1.
Push the knife as far as needed until the c orrect knife position has
been reached.
Re-tighten screw 1.

–

Loosen screw 3.

–

Push stop 2 right up to the knife

–

Re-tighten screw 3.

–

End the sewing process by pushing the pedal backwards.

12

3

2

1