Page 1
650-16
Service instructions
Page 2
All rights reserved.
Property of Dürkopp Adler AG and copyright protected. Any use of this content, or part of it, is
prohibited without prior written permission of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG - 2012
Page 3
Table of contents
1 General...................................................................................................................... 3
1.1 Scope of this Guide.................................................................................................... 3
1.2 Declaration of conformity ........................................................................................... 3
1.3 Applicable documents................................................................................................ 3
1.4 Transport damage...................................................................................................... 3
1.5 Limited liability............................................................................................................3
2 Safety instructions...................................................................................................4
2.1 General Safety instructions........................................................................................ 4
2.2 Marking of safety instructions..................................................................................... 5
3 Environmental protection notes............................................................................. 7
3.1 General environmental protection notes....................................................................7
3.2 Highlighting of environmental protection notes.......................................................... 7
4 Work principles........................................................................................................ 8
4.1 Symbols in the text.....................................................................................................8
4.2 Order of settings.........................................................................................................9
4.3 Cable routing..............................................................................................................9
4.4 Bolts in safety covers.................................................................................................9
4.5 Removing covers ..................................................................................................... 10
4.5.1 Access to the underside of the machine..................................................................10
4.5.2 Removing and replacing the top cover..................................................................... 11
4.5.3 Removing and replacing the rear arm cover............................................................ 11
4.5.4 Removing and replacing the fabric base and column cover .................................... 12
4.5.5 Removing and replacing the needle plate................................................................ 13
4.6 Surfaces on shafts ................................................................................................... 14
4.7 Locking the sewing machine.................................................................................... 14
5 Adjusting the lightbeam sensor disk................................................................... 16
6 Adjusting the hook and the needle bar................................................................ 18
6.1 Adjusting the looping stroke position and hook spacing .......................................... 19
6.2 Adjusting the needle bar height................................................................................ 20
7 Adjusting the thread passage on the centre part mount ................................... 21
8 Adjusting the needle plate position ..................................................................... 22
9 Adjusting the thread trimmer................................................................................23
9.1 Adjusting the control curve.......................................................................................23
9.1.1 Position of the control curve..................................................................................... 23
9.1.2 Distance between control curve and roller............................................................... 25
9.2 Replacing and adjusting thread puller blades.......................................................... 27
9.3 Replacing the counter-blade....................................................................................28
9.4 Adjusting the counter-blade and cutting pressure.................................................... 29
9.5 Adjusting the thread puller blade stroke................................................................... 30
10 Adjusting the central foot...................................................................................... 31
11 Adjusting the toothed belt..................................................................................... 32
11.1 Toothed belt between top and bottom shaft............................................................. 32
11.2 Toothed belt for hook drive ...................................................................................... 33
12 Replacing and adjusting the top transport belts ................................................ 35
12.1 Replacing the top transport belts ............................................................................. 35
12.2 Adjusting the top transport belts............................................................................... 37
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 1
Page 4
Table of contents
13 Replacing and adjusting the bottom transport belts.......................................... 39
13.1 Replacing the bottom transport belts ....................................................................... 39
13.2 Adjusting the bottom transport belts......................................................................... 41
13.3 Replacing sprockets.................................................................................................42
14 Checking the sewing foot lifting gear..................................................................43
15 Electrical thread tensioner.................................................................................... 46
15.1 Fitting and removing the electrical thread tensioner ................................................ 46
15.2 Replacing the thread tensioning spring.................................................................... 48
15.3 Adjusting the spring force......................................................................................... 50
15.4 Adjusting the spring stroke....................................................................................... 51
16 Adjusting the thread regulator.............................................................................. 52
17 Adjusting the bobbin winder................................................................................. 53
17.1 Setting the fill volume............................................................................................... 53
17.2 Setting the winding form of the bobbin winder......................................................... 54
17.3 Setting the winding tension of the bobbin winder..................................................... 54
18 Service settings via software................................................................................ 55
18.1 Basic software operation..........................................................................................55
18.2 Accessing technician level.......................................................................................56
18.3 Menu items at technician level................................................................................. 58
18.3.1 Menu item default program ...................................................................................... 58
18.3.2 Menu item Machine config ....................................................................................... 59
18.3.3 Menu item user config.............................................................................................. 62
18.3.4 Menu item service.................................................................................................... 63
18.4 Installing software with a dongle..............................................................................73
18.5 Checking the key functionality at the control panel.................................................. 74
19 Maintenance work.................................................................................................. 75
19.1 Lubrication................................................................................................................75
19.2 Cleaning................................................................................................................... 76
20 Appendix................................................................................................................. 77
20.1 Software error messages......................................................................................... 77
20.2 Circuit diagram.........................................................................................................81
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 2
Page 5
General information
1 General information
1.1 Scope of this Guide
This guide describes settings and maintenance work on the Custom Machine 650-16 for sewing in sleeves. It applies to all subclasses. Intended
use and installation are described in the Operating instructions.
1.2 Declaration of conformity
The machine conforms with the European regulations stated in the declaration of conformity or incorporation.
1.3 Applicable documents
The machine contains built-in components by other manufacturers, e.g.
drive motors. The respective manufacturers have performed risk assessment for these supply parts and declared the conformity of their design
with pertinent European and national regulations. Intended use of the
built-in components is described in the individual third party manufacturers' guides.
1.4 Transport damage
Dürkopp Adler is not liable for breakage and transport damage. Please
check the deliver carefully immediately on receipt. Claim against the forwarder for damage. This also applies if the packaging is undamaged.
Leave the machine device and packaging material in the state it was in
when you ascertained the damage. This will help you assert your claim
against the forwarder.
Report all other complaints without delay after receipt of delivery to
Dürkopp Adler.
1.5 Limited liability
All details and information in this guide were compiled taking the current
state of the art and applicable standards and regulations into consideration.
The manufacturer accepts no liability in case of damage due to:
• failure to observe this guide
• unintended use
• unauthorized modifications to the machine
• use of untrained staff
• breakage and transport damage
• use of non-approved spare parts
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 3
Page 6
Safety instructions
2 Safety instructions
This chapter contains basic instructions for your safety. Read these instructions carefully before you install, program, maintain or operate the
machine.
Always follow the provisions in the safety instructions. Failure to observe
can lead to severe injury and damage to property.
2.1 General safety precautions
Unauthorized persons must not work on or with the machine. Every person working on or with the machine must read the operating instructions
before doing so.
Use the machine in line with the guide only.
The operating instructions must be kept at the machine's place of use.
Observe the general safety and accident protection regulations and legal
requirements on occupational safety and environmental protection.
If you use supply parts, always observe the safety instructions and oper-
ating guides by the third party manufacturers.
All warning signs on the machine must always be kept in legible state and
must not be removed. Missing or damaged signs must be replace immediately.
In the following situations, always de-energize the machine at the main
switch or by unplugging the mains plug:
• Threading
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing servicing, maintenance and repairs
Check the machine during use for signs of visible damage. Interrupt your
work if you notice any change in the machine's behavior. Report all changes to your superior. Do not continue to use a damaged machine.
Machines or machine parts that have reached the end of their service life
must not be operated. Dispose of these machines in line with environmental legislation.
Only qualified and trained staff are allowed to install the machine. Any person installing the machine must read the installation instructions before
doing so.
Only qualified and trained staff are allowed to perform servicing, maintenance and repairs. Any person maintaining or adjusting the machine must
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 4
Page 7
Safety instructions
General danger
Danger due to pointed objects
Danger due to electric shock
Danger due to crushing
read the service instructions before doing so.
Do not remove or disable safety equipment. If this is unavoidable for repairs or servicing, immediately replace and enable the safety equipment
after completing the work.
Work on the machine's electrical equipment must be performed by a qualified electrician.
The connecting cable must have a plug with country-specific approval.
Only qualified and trained staff are allowed to connect th e plug to the power cable.
Work on live parts and equipment is prohibited. Exceptions are regulated
in DIN VDE 0105.
Only use original spare parts by the manufacturer. Incorrect or faulty spare
parts can impair safety and damage the machine.
2.2 Marking of safety instructions
Colored bars highlight the safety instructions in the text.
Signal words indicate the severity of the risk:
• Danger:
Certainty of serious or fatal injury.
• Warning:
Risk of serious or fatal injury.
• Caution:
Risk of moderate or minor injury.
• Attention:
Risk of damage.
In case of dangers for persons, these symbols indicate the type of danger:
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 5
Page 8
Safety instructions
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe will lead to fatal or
serious injury.
Danger
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to fatal or
serious injury.
Warning
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to moderate or minor injury.
Caution
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to damage to property.
Attention
Examples for marking of safety instructions in the text:
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 6
Page 9
Environmental protection notes
Note on responsible disposal
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to damage to
property.
Environmental
3 Environmental protection notes
3.1 General environmental protection notes
Dispose of machines or machine parts that have reached the end of their
service life responsibly, observing the legal requirements on environmental protection.
Use consumables conservatively and dispose of them responsibly, observing the legal requirements on environmental protection.
3.2 Highlighting of environmental protection notes
Green bars mark environmental protection notes in the text.
The following symbols state the type of environmental measure:
Example for marking of environmental protection notes in the text
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 7
Page 10
Work principles
1.
2.
3.
...
4 Work principles
4.1 Symbols in the text
The following symbols at the margins and in the text show what type of information the text includes.
Correct setting
Indicates the correct setting.
Malfunctions
Indicates malfunctions that can occur in case of incorrect settings.
Cover
States which covers you need to remove to access the compon ents to be
adjusted.
Steps for servicing, maintenance and installation
Steps via the software control panel
The individual steps are numbered:
1. First individual step
2. Second individual step
3. Third individual step, etc.
You must observe the order of the individual steps.
Results of an action
If a change to the machine is made in an individual step, or a new message appears in the display, which is important for you as feedback, this
change is indicated by an arrow:
Important
Shows you what to pay attention to in the current step.
Information
Provides additional information.
Order
States which work you must perform before or after the setting.
References
This is followed by a reference to another part of the text.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 8
Page 11
Work principles
Damage to machine possible due to incorrect order.
Always keep to the work order stated in this guide.
Attention
Machine damage and functional impairment possible due to incorrect cable routing.
Excess cable can impair the function of moving machine parts. This impairs the sewing function and can cause damage.
Route excess cable as described above.
Attention
4.2 Order of settings
Observe order Always observe the stated order for the individual setting steps.
Always observe all notes marked with a in the margin on preconditions
and follow-up settings.
4.3 Cable routing
Bundle cables Make sure that all cables are routed in the machine that they do not inter-
fere with the function of moving parts.
1. Lay over length cables in tidy loops.
2. Tie up loops with cable ties.
Attach loops to stationary parts where possible. The cables must be
fixed in place.
3. Cut off protruding cable ties.
4.4 Bolts in safety covers
There is no need to fully remove bolts in safety cover from their holes. As
soon as the bolts have been loosened sufficiently for you to remove the
cover, you can remove the cover. The bolts either stay in the housing or
in the cover. In the text, these bolts are marked with the supplement (safety
cover).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 9
Page 12
Work principles
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you remove or replace covers.
Warning
1
2
3
3
3
3
3
(1) - Upper part of machine
(2) - Tray
(3) - Bolts
4.5 Removing covers
For many adjustments you first need to remove the machine covers to access the components.
This describes how to remove and replace the covers. The text for the individual settings then simply states which cover you need to remove.
4.5.1 Access to the underside of the machine
To access the components on the underside of the machine, you must tilt
the upper part of the machine back.
Figure 1: Tilting the machine upper part back and returning to upright position
Tilting the machine upper part back
1. Tilt the upper part of the machine (1) back to the stop
2. Release all 5 bolts (3) (Safety cover p. 9).
3. Remove the tray (2) in downward direction.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 10
Returning the machine upper part to upright position
1. Replace the tray (2).
2. Tighten all 5 bolts (3) (Safety cover p. 9).
3. Prop up the machine upper part (1).
Page 13
Work principles
1
2
(1) - Top cover bolts (2) - Top cover
(1) - Bolts (2) - Rear arm cover
4.5.2 Removing and replacing the top cover
Figure 2: Removing and replacing the top cover
Removing the top cover
1. Loosen both top cover bolts (1)
2. Remove the top cover (2)
Replacing the top cover
1. Replace the top cover (2)
2. Tighten both top cover bolts (1)
4.5.3 Removing and replacing the rear arm cover
Figure 3: Removing and replacing the rear arm cover
2
1
Removing the rear arm cover
1. Release all 5 bolts (1) (Safety cover p. 9) on the rear arm cover.
2. Remove the rear arm cover (2).
Replacing the rear arm cover
1. Replace the rear arm cover (2).
2. Tighten all 5 bolts (1) (Safety cover p. 9) on the rear arm cover.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 11
Page 14
Work principles
3
2
1
3
(1) - Bolts
(2) - Column cover
(3) - Fabric base
4.5.4 Removing and replacing the fabric base and column cover
Figure 4: Removing and replacing the fabric base and column cover
Removing the fabric base and column cover
1. Release both bolts (1) (Safety cover p. 9).
2. Slightly raise the fabric base (3) and pull off to the left.
3. Slightly raise the column cover (2) and pull off to the left.
Replacing the fabric base and column cover
1. Replace the column cover (2) from the top left.
2. Replace the fabric base (3) from the top left.
3. Tighten both bolts (1) (Safety cover p. 9).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 12
Page 15
Work principles
(1) - Pins
(2) - Centre part holder
(3) - Guide piece
(4) - Bolts
(5) - Needle plate
(6) - Recess
(7) - Hook
4.5.5 Removing and replacing the needle plate
Figure 5: Removing and replacing the needle plate
1
4
5
6
7
2
3
Removing the needle plate
1. Remove the fabric base and column cover. ( Chap. 4.5.4, p. 12)
2. Loosen the bolts (4)
3. Remove the guide piece (3)
4. Take off the needle plate (5) in upward direction.
Replacing the needle plate
1. Replace the needle plate (5) from the top.
2. Insert the guide piece (3) so that the pins (1) lock into the needle plate (5)
and the central part holder (2) fits into the recess (6) on the hook (7).
3. Secure the guide piece (3) with bolts (4).
4. Replacing the fabric base and column cover.( Chap. 4.5.4, p. 12)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 13
Page 16
Work principles
2
1
(1) - Surface (2) - Shaft
1
3
4
2
(1) - Locking pin
(2) - Arm shaft crank with insert groove
(3) - Handwheel
(4) - Mark
4.6 Surfaces on shafts
Bolt onto the sur-
face
Figure 6: Surfaces on shafts
Some shafts have flat surfaces at the parts where the components are
bolted on. This makes the connection more stable and adjustment easier.
Always take care that the bolts are fully seated on the surface.
4.7 Blocking the sewing machine
For some adjustments, the machine must be blocked. To do so, insert the
blocking pin from the accessory kit into a groove on the arm shaft crank to
block the arm shaft.
Figure 7: Locking pin and insert groove on the arm shaft crank
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 14
The handwheel (3) is marked with numbers for orientation. If you turn the
handwheel to a position where one of the number is next to the mark (4),
the corresponding groove on the arm shaft crank (2) is located below the
opening for the locking pin (1).
Page 17
Work principles
4
1
2
3
(1) - Plug
(2) - Locking opening
(3) - Locking pin
(4) - Mark
There are 3 locking positions for the following settings:
• Position 1
• Loop stroke position
• Hook clearance to needle
• Position 4
• Control curve for thread cutter
• Position 6
• Reference position for control unit with needle at top dead centre
Positions 2, 3 and 5 are not used.
Figure 8: Blocking the sewing machine
Blocking the machine
1. Pull the plug (1) out of the locking opening (2)
2. Turn the handwheel until the number for the desired locking position is
next to the mark (4).
3. Push the locking pin (3) through the locking opening (2) into the groove
on the arm shaft crank.
The numbers on the handwheel provide rough orientation. To hit the
groove precisely, you might need to turn the handwheel slightly.
Releasing the lock
1. Remove the locking pin (3)
2. Insert the plug (1) into the locking opening (2)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 15
Page 18
Adjusting the lightbeam sensor disk
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the lightbeam sensor disk
Warning
5 Adjusting the lightbeam sensor disk
The lightbeam sensor disk is used as a reference for positioning by the
control unit.
It must be adjusted so that the incoming edge of the 180° disk lines up precisely at the height of the lightbeam slot - in rotational direction of the machine - when the needle is at bottom dead centre.
Check the correct setting
Lock the machine in Position 6 ( p. 15).
Th e 180° disk points to the front and it lower edge is precisely lined up
with the lightbeam slot.
Malfunctions in case of incorrect settings.
• Damage to fabric, wrinkling
• Incorrect needle position, needle jams in hole
• Incorrect transport times
• Incorrect thread trimming
• Poor sewing results
Cover
• Access to the underside of the machine ( Chap. 4.5.1, p. 10)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 16
Page 19
Adjusting the lightbeam sensor disk
(1) - Grub screws (2) - Lightbeam slots
(3) - 180° disk
Figure 9: Adjusting the lightbeam sensor disk
1
2
3
Adjusting steps
1. Lock the machine in Position 6 ( p. 15).
2. Remove both grub screws (1) on the sensor disk.
3. Turn the sensor disk so that the 180° disk (3) points to the front and its
lower edge is precisely lined up with the lightbeam slot (2).
Important: The sensor disk must be aligned laterally so that the 180°
disk (3) does not touch the lightbeam housing.
4. Tighten both grub screws (1) without changing the posit ion of the sensor
disk.
5. Release the lock ( p. 15).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 17
Page 20
Adjusting the hook and the needle bar
1
3
2
(1) - Centre line of needle (2) - Hook tip
(3) - Hollow groove
6 Adjusting the hook and the needle bar
The following 3 settings must be adjusted to match one another:
• Loop stroke position
• Hook clearance to needle
• Height of needle bar
Loop stroke position and loop stroke
The loop stroke position is the position of the hook at which the hook tip
points precisely at the centre line of the needle.
The looper stroke is the length of the stroke from bottom dead centre of
the needle bar to the height at which the hook is in looper stroke position.
The looper stroke on the 650-16 is 1.8 mm.
Figure 10: Loop stroke position
Check the correct setting
When the machine is locked in looper stroke position (locking position 1)
( p. 15), the hook tip must point directly at the centre line of the needle.
The needle must be aligned so that the surface of the hollow groove is parallel to the running direction of the hook tip. In terms of height, the hook tip
must be in the lower third of the hollow groove.
Malfunctions in case of incorrect settings.
• Damage to the hook
• Damage to the needle
• Incorrect sewing
• Thread break
Order
Preconditions:
• Make sure a straight and undamaged needle is fitted ( Operating
instructions Chap. 8.7 Replacing the needle)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 18
Page 21
Adjusting the hook and the needle bar
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before adjusting the looping stroke position and hook spacing
Warning
(1) - Hook (2) - Fastening screws
(3) - Hook tip
6.1 Adjusting the looping stroke position and hook spacing
Cover
• Remove the fabric base and column cover( Chap. 4.5.4, p. 12)
• Remove the needle plate( Chap. 4.5.5, p. 13)
Figure 11: Adjust the looping stroke position and hook spacing
3
1
2
Adjusting steps
1. Lock the machine in Position 1 ( p. 15).
2. Loosen the 3 fastening screws (2) on the hook.
3. Adjust the looper stroke position:
Turn the hook (1) so that the hook tip (3) points precisely at the centre
line of the needle.
4. Adjust the hook distance:
Move the hook laterally so that the distance between the hook tip (3)
and the hollow groove on the needle is between 0.05 – 0.1 mm.
5. Tighten the 3 fastening screws (2) on the hook without changing the
looper stroke position or the hook clearance.
Order
After changing the looper stroke position or the hook clearance, check the
needle bar height ( Chap. 6.2 Adjusting the needle bar height, p. 20).
6. After finally aligning the looper stroke position, hook clearance and needle bar: release the lock ( p. 15).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 19
Page 22
Adjusting the hook and the needle bar
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you adjust the needle bar height.
Warning
1
2
(1) - Screw (2) - Needle bar
6.2 Adjusting the needle bar height
Cover
•Top cover( Chap. 4.5.2, p. 11)
Figure 12: Adjusting the needle bar height
Adjusting steps
1. Lock the machine in Position 1 ( p. 15).
2. Release the screw (1).
3. Adjust the needle bar (2) height so that the hook tip is in the lower third
of the hollow groove on the needle.
Important: Do not turn the needle bar laterally in doing so.
4. Tighten the screw (1)
Order
After changing the needle bar height, also check the looper stroke position and hook clearance ( Chap. 6.1 Adjusting the looping stroke
position and hook spacing, p. 19).
5. After finally aligning the looper stroke position, hook clearance and needle bar: release the lock ( p. 15).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 20
Page 23
Adjusting the thread passage on the centre part holder
Risk of injury
Crushing hazard due to moving parts
Switch the sewing machine off before adjusting the th read
passage on the centre part holder
Warning
(1) - Grub screw
(2) - Guide piece
(3) - Centre part holder
(4) - Hook
(5) - Recess
7 Adjusting the thread passage on the centre part
holder
Check the correct setting
The centre part holder must only be inserted up to a certain depth in the
hook centre part so that the thread can pass freely through the centre part
holder and the recess on the hook.
Malfunctions in case of incorrect settings.
• Thread break
•Loops forming
Cover
• Remove the fabric base and column cover ( Chap. 4.5.4, p. 12)
Figure 13: Adjusting the thread passa g e on th e cen tre part holder
1
2
Adjusting steps
1. Turn the handwheel and check the thread passage.
2. Loosen the grub screw (1).
5
4
3
3. Push or pull out the centre part holder (3) so that the thread can pass
freely between the centre part holder (3) and the hook recess (5) without
the gap becoming unnecessarily large.
4. Tighten the grub screw (1).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 21
Page 24
Adjusting the needle plate position
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you adjust the needle plate position.
Warning
2
1
3
4
1
(1) - Column head
(2) - Fastening screws
(3) - Needle plate
(4) - Hole
8 Adjusting the needle plate position
Check the correct setting
The needle must pass precisely through the hole in the needle plate.
Malfunctions in case of incorrect settings.
• Poor sewing results
Because the needle plate is anchored on the column head, the position of
the needle plate is set by turning and displacing the column head.
Cover
• Remove the fabric base and column cover( Chap. 4.5.4, p. 12)
Figure 14: Adjusting the position of the needle plate
Adjusting steps
1. Remove the lower transport belts ( Chap. 13.1 Replacing the botto m
transport belts, p. 39) to be able to turn the column head (1).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 22
2. Loosen both fastening screws (2).
3. Turn down the needle with the handwheel so that you can test that the
needle is punching into the hole.
4. Turn the column head (1) and displace laterally so that the needle passes
precisely through the hole (4) in the needle plate (3).
5. Tighten both fastenings screws (2) without changing the position of the
column head (1).
Page 25
Adjusting the thread trimmer
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the position of the control curve.
Warning
1
2
3
(1) - Small recess
(2) - Roller
(3) - Thread trimmer lever
9 Adjusting the thread trimmer
For the thread trimmer to work correctly, you must set the control curve
and the thread puller blade and the counter-blade.
9.1 Adjusting the control curve
The control curve defines the path and timing of the blade movement and
syncs the blade movement with the needle movement. For the correct setting, the position of the control curve and the distance between the control
curve and the roller must be set.
9.1.1 Position of the control curve
Check the correct setting
Lock the machine in Position 4 ( p. 15).
When you push the thread trimmer lever (3) upward, the roller (2)
latches precisely in the small recess (1) in the control curve.
Figure 15: Correct position of the control curve
Malfunctions in case of incorrect settings.
• Damage to the needle
• Threads are not cut
Cover
• Access to the underside of the machine( Chap. 4.5.1, p. 10)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 23
Page 26
Adjusting the thread trimmer
4
3
2
1
5
(1) - Small recess
(2) - Thread trimmer lever
(3) - Control curve
(4) - Roller
(5) - Control curve grub screws
Figure 16: Adjusting the position of the control curve
Adjusting steps
1. Lock the machine in Position 4 ( p. 15).
2. Release the control curve grub screws (5).
3. Push the thread trimmer lever (2) upward and turn the control curve (3)
so that the roller (4) latches precisely in the small recess (1).
4. Tighten both control curve grub screws (5) without changing the position
of the control curve.
5. Release the lock ( p. 15).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 24
Page 27
Adjusting the thread trimmer
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the position between the control curve and the roller.
Warning
9.1.2 Distance between control curve and roller
Check the correct setting
In idle position of the thread trimmer, the distance between the roller and
the control curve at its maximum diameter is 0.2 mm.
Important: The distance must not be measured at one of the recesses.
For checking and adjusting, thus turn the control curve so that the recesses do not point towards the roller.
Malfunctions in case of excessive gap
• Thread puller blade and counter-blade can jam
Cover
• Access to the underside of the machine( Chap. 4.5.1, p. 10)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 25
Page 28
Adjusting the thread trimmer
6
4
3
2
1
5
(1) - Recesses
(2) - Fastening screw
(3) - Thread trimmer lever
(4) - Roller
(5) - Control curve
(6) - Screw opening in housing
Figure 17: Adjusting the distance between the control curve and the roller
Adjusting steps
1. Turn the handwheel so that the recesses (1) on the control curve (5) do
not point towards the roller (4).
2. Loosen the fastening screw (2) on the thread trimmer lever (3) through
the screw opening (6) in the housing.
3. Push the thread trimmer lever (3) upward or downward until the distance
between the roller (4) and the control curve (5) at its maximum diameter
is 0.2 mm.
Important: The anchor of the thread trimmer solenoid must be fu lly extended.
4. Tighten the fastening screw (2) on the thread trimmer lever (3) through
the screw opening (6) in the housing without changing the lever position.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 26
Page 29
Adjusting the thread trimmer
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you replace and adjust the position of the thread puller blades.
Warning
(1) - Thread trimmer lever (2) - Fastening screws
(3) - Thread puller blade
9.2 Replacing and adjusting thread puller blades
Check the correct setting
Push the cutouts on the thread puller blade up to the stop against the fastening screws.
Malfunctions in case of incorrect settings.
• Threads are not cut
• Cut threads are too long
Cover
• Access to the underside of the machine( Chap. 4.5.1, p. 10)
• Remove the fabric base and column cover( Chap. 4.5.4, p. 12)
• Remove the needle plate( Chap. 4.5.5, p. 13)
Figure 18: Replacing and adjusting thread puller blades
3
1
2
Adjusting steps
1. Push the thread trimmer lever (1) up and turn the handwheel until the
thread puller blade (3) swivels forward and the fastening screws (2) are
accessible.
2. Loosen the fastening screws (2).
3. Pull the old thread puller blade out to the back and release the thread
trimmer lever (1) downward while doing so.
4. Insert a new thread puller blade
5. Push the thread puller blade (3) up to the front stop against the fastening
screws (2)
6. Tighten the fastening screws (2).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 27
Page 30
Adjusting the thread trimmer
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you replace the
counter-blade.
Warning
(1) - Thread puller blade
(2) - Counter-blade
(3) - Counter-blade screw
9.3 Replacing the counter-blade
Cover
• Remove the fabric base and column cover ( Chap. 4.5.4, p. 12)
Figure 19: Replacing the counter-blade
1
2
3
Adjusting steps
1. Fully unscrew the counter-blade screw (3).
2. Pull out the old counter-blade to the front.
3. Insert a new counter-blade
4. Tighten the counter-blade screw (3).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 28
Page 31
Adjusting the thread trimmer
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you adjust the counter-blade and cutting pressure.
Warning
(1) - Thread puller blade
(2) - Counter-blade
(3) - Counter-blade screw
9.4 Adjusting the counter-blade and cutting pressure
The shape of the thread puller blade and counter-blade causes a scissor
effect. The aim is to cut the threads with the lowest possible pressure. Do
Wear on blades in
case of
excessive pres-
sure
not set the pressure higher than needed. The higher the pressure is, the
more wear there is on the blades.
Check the correct setting
2 threads with the largest thickness to be used for sewing are cleanly cut
at the same time.
Malfunctions in case of incorrect settings.
• Increased wear on blades
• Threads are not cut, or not cut correctly
Cover
• Access to the underside of the machine ( Chap. 4.5.1, p. 10)
• Remove the fabric base and column cover ( Chap. , p. 12)
• Remove the needle plate ( Chap. , p. 13)
Figure 20: Adjusting the counter-blade and cutting pressure
1
2
3
Adjusting steps
1. Push the thread trimmer lever up and turn the handwheel until the thread
puller blade (1) swivels forward.
2. Release the (3) counter-blade screw
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 29
3. Displace the counter-blade (2) upward or downward so that the blades
on the thread-puller (1) and counter-blade (2) touch but do not jam.
4. Tighten the counter-blade screw (3).
5. Perform a cutting test and repeat steps 2 to 4 if needed.
Page 32
Adjusting the thread trimmer
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you adjust the
thread puller blade stroke.
Warning
1
4
2
3
(1) - Tip of counter-blade
(2) - Blade lever
(3) - Lever screws
(4) - Tip of thread puller blade
9.5 Adjusting the thread puller blade stroke
Check the correct setting
If the thread puller blade is not swiveled out, the tips of the thread puller
blade and counter blade are precisely lined up one on top of the other.
Malfunctions in case of incorrect settings.
• Threads are not cut
• Cut threads are too long
Cover
• Access to the underside of the machine( Chap. 4.5.1, p. 10)
• Remove the fabric base and column cover( Chap. 4.5.4, p. 12)
• Remove the needle plate( Chap. 4.5.5, p. 13)
Figure 21: Adjusting the thread pulle r bl a d e stro ke
Adjusting steps
1. Release the lever screws (3).
2. Push the blade lever (2) up or down so that the tip of the thread puller
blade (4) lines up precisely with the tip of the counter-blade (1).
3. Tighten the lever screws (3).
4. Perform a cutting test and repeat steps 1 to 3 if needed.
If the threads are cut too long: push the thread puller blade further
back.
If the threads are not cut, pull the thread puller blade toward the
front.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 30
Page 33
Adjusting the central foot
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the central foot.
Warning
(1) - Screw
(2) - Central foot
(3) - Needle plate
10 Adjusting the central foot
In as-delivered state, the clearance between the needle plate (3) and the
central foot (2) is exactly 0.6 mm.
Correct setting
The correct height of the central foot depends on the fabric thickness.
• Thick fabric: set the central foot higher
• Thin fabric: set the central foot lower
Malfunctions in case of incorrect settings.
Foot too low with thick fabric:
• Curve support does not work properly
• Additional width is not worked in correctly.
• Crinkled seams
• Unsuitable stitch length
Foot too high with thin fabric:
• Crinkled seams
Figure 22: Adjusting the central foot
1
2
3
Adjusting steps
1. Removing the needle ( Operating instructions Chap. 8.7).
2. Release the screw (1).
3. Push the central foot (2) up or down so that the height matches the fabric
thickness.
4. Tighten the screw (1)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 31
Page 34
Adjusting the toothed belt
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the
toothed belt between the top and bottom shaft.
Warning
(1) - Toothed belt (front loop)
(2) - Tensioning pulley screw
(3) - Plug in housing opening
View from underside View from side
11 Adjusting the toothed belt
11.1 Toothed belt between top and bottom shaft
Correct setting
On the front loop, the toothed belt tension is 60 – 80 Hz.
Cover
• Access to the underside of the machine( Chap. 4.5.1, p. 10)
Figure 23: Adjusting the toothed belt between top and bottom shaft
1
2
3
Adjusting steps
1. Remove the plug (3)
2. Insert a spanner from the right through the housing opening into the
tensioning pulley screw (2).
3. Release the tensioning pulley screw (2).
4. Use the tensioning pulley to change the tension:
• Greater tension: Adjust the pulley to be closer to the belt
• Less tension: Adjust the pulley to be further away from the belt
5. Tighten the tensioning pulley screw (2).
Order
After replacing a toothed belt between the top and bottom shafts, you must
complete the following settings:
• Adjusting the lightbeam sensor disk ( Chap. 5, p. 16)
• Hook position ( Chap. 6.1 Adjusting the looping stroke position and
hook spacing, p. 19)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 32
Page 35
Adjusting the toothed belt
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the
toothed belt for the hook drive.
Warning
(1) - Cover
(2) - Fastening screws
(3) - Screw (do not release)
11.2 Toothed belt for hook drive
Correct setting
On the front loop, the toothed belt tension is 55 Hz.
The toothed belt is centred on the top belt pulley and on the large belt pul-
ley.
The toothed belt has a clearance of 1 mm each to the securing rings on
the lower belt pulleys.
Cover
• Access to the underside of the machine ( Chap. 4.5.1, p. 10)
• Remove the fabric base and column cover ( Chap. , p. 12)
Figure 24: Toothed belt for hook drive - removing the cover
1
2
3
Adjusting steps
1. Release the fastening screws (2) on the front and back of the hook
toothed belt cover (1).
Important: Do not loosen screw (3). If you loosen screw (3), you must
readjust the hook ( Chap. 6.1 Adjusting the looping stroke position
and hook spacing, p. 19).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 33
2. Slightly raise the cover (1) and pull off to the right.
Page 36
Adjusting the toothed belt
(1) - Toothed belt
(2) - Screw openings
(3) - Securing rings
(4) - Lower belt pulleys
(5) - Large belt pulley
(6) - Grub screws
(7) - Upper belt pulley
Figure 25: Toothed belt for hook drive - aligning the belt pulleys
1
7
6
5
4
2
3
3. Release the axle retainer on the lower belt pulleys (4) through the screw
openings (2).
4. Release the grub screw (6) on the large belt pulley (5).
5. Align the belt pulleys:
• displace the lower belt pulleys (4) with their axles
• displace the large belt pulley (5) on the shaft
Displace the 3 pulleys so that:
the toothed belt is centred on the top belt pulley (7) and on the large
belt pulley (5).
the toothed belt on the lower belt pulleys (4) has a clearance of
1 mm each to the retaining rings (3).
6. Tighten the grub screw (6) on the large belt pulley (5).
7. Tighten the axle ret ainer on the lower belt pulleys (4) through the screw
openings (2).
8. Replace the cover from the top right.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 34
9. Tighten the fastening screws on the cover front and rear.
Order
After replacing a toothed belt or releasing the large pulley, you must always check the following settings:
• Hook position( Chap. 6.1 Adjusting the looping stroke position and
hook spacing, p. 19)
Page 37
Replacing and adjusting the top transport belts
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you replace the top
transport belts.
Warning
1
2
3
4
6
5
(1) - Screw
(2) - Sewing feet
(3) - Central foot
(4) - Top transport belts
(5) - Guide
(6) - Pulleys
12 Replacing and adjusting the top transport belts
12.1 Replacing the top transport belts
Cover
• Rear arm cover( Chap. 4.5.3, p. 11)
Figure 26: Remove the top transport belts
Remove the top transport belts
Adjusting steps
1. Remove the needle ( Operating instructions Chap. 8.7).
2. Release the screw (1).
3. Remove the central foot (3).
4. Push the right sewing foot up.
5. Remove the left transport belt from the sewing foot.
6. Take the left transport belt off the pulley (6) and remove from the
guide (5).
7. Push the left sewing foot up and the right sewing foot down.
8. Remove the right transport belt from the sewing foot.
9. Take the right transport belt off the pulley (6) and remove from the
guide (5).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 35
Page 38
Replacing and adjusting the top transport belts
1
2
3
4
6
5
(1) - Screw
(2) - Sewing feet
(3) - Central foot
(4) - Top transport belts
(5) - Guide
(6) - Pulleys
Fitting the top transport belts
Important: When fitting new transport belts, observe the arrow marks: the
arrows must point in direction of rotation.
Figure 27: Fitting the top transport belts
Adjusting steps
1. Push the right sewing foot down and the left sewing foot up.
2. Insert the right transport belt in the right sewing foot.
3. Route the right transport belt through the guide (5).
4. Place the right transport belt on the larger of the two pulleys (6).
5. Turn the transport belt wheel (6) slowly so that the belt lines up.
6. Push the right sewing foot up and the left sewing foot down.
7. Insert the left transport belt in the left sewing foot.
8. Insert the central foot (3) and secure with screw (1).
9. Route the left transport belt through the guide (5).
10.Place the left transport belt on the smaller of the two pulleys (6).
11.Turn the pulley (6) slowly so that the belt lines up.
Order
After replacing the top transport belts you must adjust the central foot
( Chap. 10 Adjusting the central foot, p. 31).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 36
Page 39
Replacing and adjusting the top transport belts
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the top
transport belts.
Warning
12.2 Adjusting the top transport belts
Check the correct setting
The transport belt tension should be as low as possible without the belts
drooping.
The run-off protection must not impair the right transport belts run. The
correct distance between the run-off protection and the right transport belt
is 0.2–0.3mm.
Checking via software
Test options for the transport belt step motors are in the software's Multitest menu ( Section Test Step Motor, p. 67).
Malfunctions in case of incorrect settings.
• Irregular stitch length in case of insufficient tension
• Transport problems and wrinkling in case of excessive tension
• Incomplete lowering of the feet
• Increased wear on belts and feet
Cover
• Rear arm cover( Chap. 4.5.3, p. 11)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 37
Page 40
Replacing and adjusting the top transport belts
2
1
5
4
3
1
2
(1) - Eccentric (was?)
(2) - Fastening screws
(3) - Top right transport belt
(4) - Run-off protection
(5) - Screws
Figure 28: Adjusting the top transport belts
Adjusting steps
Adjusting the tension
1. Loosen the fastening screw (2).
2. Turn the correspondin g eccentric was? (1) with a standard screwdriver
in order to change the tension.
3. Tighten the fastening screw (2).
4. Repeat steps 1 – 3 for the other transport belt
Setting the distance to the run-off protection
1. Release both screws (5) on the run-off protection (4).
2. Push the run-off protection (4) up or down until the clearance to the top
right transport belt (3) is 0.2 – 0.3 mm.
3. Tighten both screws (5) on the run-off protection (4).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 38
Page 41
Replacing and adjusting the bottom transport belts
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you replace the bottom transport belts.
Warning
1
2
3
5
6
4
(1) - Sprockets
(2) - Bottom transport belts
(3) - Base plate cut-out
(4) - Fastening screws
(5) - Bottom pulley
(6) - Mounting brackets
13 Replacing and adjusting the bottom transport
belts
13.1 Replacing the bottom transport belts
Cover
• Access to the underside of the machine ( Chap. 4.5.1, p. 10)
• Remove the fabric base and column cover ( Chap. 4.5.4, p. 12)
• Remove the needle plate ( Chap. 4.5.5, p. 13)
Figure 29: Removing the bottom transport belts
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 39
Adjusting steps
Removing the bottom transport belts
1. Move the needle up by turning the handwheel.
2. Pull both transport belts (2) off the lower pulley (5).
Tip: Release the fastening screws (4) and push the mount brackets (6)
up so that you can remove the belts more easily.
Important: Then re-adjust the position of the mount bracket (6) (
Chap. 13.2 Adjusting the bottom transport belts, p. 41).
3. Pull the transport belts (2) up through the cut-out in the base plate (3).
4. Pull both transport belts one after another off the sprockets on the needle
plate (1).
Page 42
Replacing and adjusting the bottom transport belts
1
2
3
5
6
4
(1) - Sprockets
(2) - Bottom transport belts
(3) - Base plate cut-out
(4) - Fastening screws
(5) - Bottom pulley
(6) - Mounting brackets
Fitting new transport belts
Important: When fitting new transport belts, observe the arrow marks: the
arrows must point in direction of rotation.
Figure 30: Fitting the lower transport belts
Adjusting steps
1. Pull the right transport belt over the right sprocket (1).
2. Route the transport belt down through the base plate cut-out (3).
3. Pull the transport belt over the lower sprocket (5).
4. Repeat steps 1 – 3 for the left transport belt.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 40
Page 43
Replacing and adjusting the bottom transport belts
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the bottom transport belts.
Warning
(1) - Fastening screws (2) - Mounting brackets
13.2 Adjusting the bottom transport belts
Correct setting
The transport belt tension should be as low as possible without the belts
drooping.
Malfunctions in case of incorrect settings.
• Irregular stitch length in case of insufficient tension
• Transport problems and wrinkling in case of excessive tension
• Increased wear on belts
Checking via software
Test options for the transport belt step motors are in the software's Multitest menu ( Test Step Motor, p. 67).
Cover
• Access to the underside of the machine ( Chap. 4.5.1, p. 10)
• Remove the fabric base and column cover ( Chap. , p. 12)
Figure 31: Adjusting the bottom transport belts
1
2
Adjusting steps
1. Loosen the fastening screws (1) on the mounting brackets (2).
2. Move the mounting brackets (2) with the wheels and transport belts up
or down:
• Increase tension: push the unit down.
• Reduce tension: push the unit up.
3. Tighten the mounting bracket (2) with the fastening screws (1).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 41
Page 44
Replacing and adjusting the bottom transport belts
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you replace the
sprockets.
Warning
(1) - Front sprocket
(2) - Guide screws
(3) - Rear sprocket
13.3 Replacing sprockets
Cover
• Access to the underside of the machine ( Chap. 4.5.1, p. 10)
• Remove the fabric base and column cover ( Chap. 4.5.4, p. 12)
• Remove the needle plate ( Chap. 4.5.5, p. 13)
Figure 32: Replacing sprockets
1
2
Removing the sprockets
Adjusting steps
1. Remove the bottom transport belts ( Chap. 13.1, p. 39).
2. Pull off the front sprocket (1) to the left
3. Release all 3 guide screws (2).
4. Pull off the rear sprocket (3) to the left
Fitting sprockets
Adjusting steps
1. Push on the rear sprocket (3) from the left
3
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 42
2. Tighten all 3 guide screws (2).
3. Push on the front sprocket (1) from the left
4. Fitting the lower transport belts ( Chap. 13.1, p. 39)
Page 45
Checking the sewing foot lifting gear
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the sewing foot lifting gear.
Warning
14 Checking the sewing foot lifting gear
Check the correct setting
1. Switch off the machine.
2. Move the sewing feet manually up and down.
The sewing feet must move up and down easily.
Checking and adjusting the sewing foot lifting gear via software
You can adjust the following sewing foot settings via the software:
• Sewing foot lifting ( Section Submenu Foot, p. 61)
• Sewing foot calibration ( Section Subitem Foot Calib, p. 69)
Test options for the step motors are available in the software's Multitest
menu ( Section Test Step Motor, p. 67).
Checking for mechanical problems
1. Remove the lifting gear as described below.
2. Check components for defects.
3. Fit the lifting gear as described below.
Malfunctions in case of incorrect settings.
• Curve support does not work properly
•Foot jams
Order
• After checking for mechanical problems, you must recalibrate the sewing feet in the software ( Section Subitem Foot Calib, p. 69).
Cover
• Rear arm cover ( Chap. 4.5.3, p. 11)
•Top cover ( Chap. 4.5.2, p. 11)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 43
Page 46
Checking the sewing foot lifting gear
3
5
2
1
4
(1) - Bearing points
(2) - Clamping screws
(3) - Clamping blocks
(4) - Screws on clamping blocks
(5) - Motor fastening screws
Figure 33: Removing the lifting gear
Removing the gearbox
Adjusting steps
1. Push the right sewing foot up for free access.
2. Release the screws (4) on the clamping blocks (3). Access is via the
machine head.
3. Release the 8 fastening screws (5) on the step motors from the rear.
4. Pull off the step motors towards the rear.
5. Release the clamping screws (2).
6. Remove the electrical thread tensioner to be able to access the right
gearbox bearing point. There is no need to unplug the cable on the
thread tensioner to do so. ( Chap. 15.1 Fitting and removing th e elec-
trical thread tensioner, p. 46)
Important: When pulling out the thread tensioner, make sure that you
do not damage the cable.
7. Release the bearing points (1).
Access for the left gearbox is via the machine head. Access for the right
gearbox is possible via the opening for the removed thread tensioner.
8. Remove the gearbox.
Check the gearbox:
1. Move all joints on the gearbox:
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 44
All rotation and bearing points must move freely and must be free of
play.
Page 47
Checking the sewing foot lifting gear
(1) - Bearing points
(2) - Clamping screws
(3) - Clamping blocks
(4) - Screws on clamping blocks
(5) - Motor fastening screws
Figure 34: Fitting the sewing foot lifting gear
1
2
5
4
3
Installing the gearbox
Adjusting steps
1. Put the gearbox back into position.
2. Tighten the bearing points (1)
Access for the left gearbox is via the machine head. Access for the right
gearbox is possible via the opening for the removed thread tensioner.
3. Fitting the electrical thread tensioner
( Chap. 15.1 Fitting and removing the electrical thread tensioner, p.
46)
Important: When fitting the thread tensioner, make sure that you do not
damage the cable, and that over-length cables are routed tidily.
4. Tighten the clamping screws (2).
Important: The top edge of the clamping block must be flush with the
top end of the sewing foot bar.
5. Place the step motor in position.
6. Place the clamping block (3) on the step motor shaft.
7. Secure the step motors from the rear with 8 fastening screws (5).
Important: Before fastening into place, move the gearbox slightly back
and forth to ensure that it is not skewed, but still moves freely after securing.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 45
8. Tighten the clamping blocks (3) with the screws (4). Access is via the
machine head.
Order
After mechanical work on the sewing foot lifting gear, always calibrate the
sewing feet with the software ( Subitem Foot Calib, p. 69).
Page 48
Electrical thread tensioner
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch the sewing machine off before removing and fitting
the electrical thread tensioner
Warning
(1) - Electrical thread tensioner
(2) - Access drill hole in the front face of the
housing
(3) - Plug
(4) - Wire blade terminal
15 Electrical thread tensioner
15.1 Fitting and removing the electrical thread tensioner
Cover
•Top cover ( Chap. 4.5.2, p. 11)
• Rear arm cover ( Chap. 4.5.3, p. 11)
Figure 35: Removing the electrical thread tensioner
1
Only when fitting
a new thread ten-
sioner
4
3
2
Removing the thread tensioner
1. Release the grub screw through the access drill hole (2).
2. Pull out the electrical thread tensioner (1) approx. 1 cm and rotate anticlockwise so that the cables are pointing down and can be pulled out
through the cable passageway.
Important: Pull out the thread tensioner carefully to ensure that you do
not damage the cable.
3. Pull out the electrical thread tensioner (1) as far as the cable length
allows you to do so.
You can now perform the following settings:
• Checking the lifting gear( Chap. 14, p. 43)
• Replacing the thread tensioning spring( Chap. 15.2, p. 48)
• Adjusting the spring force( Chap. 15.3, p. 50)
To fit a new thread tensioner, you must pull out the thread tensioner completely:
4. Pull out the blade terminals (4) from the transparent plugs (3) on the
rear above the step motors.
5. Carefully pull out the cable to the front.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 46
Page 49
Electrical thread tensioner
2
3
4
1
(1) - Thread tensioner
(2) - Access drill hole in the front face of the
housing
(3) - Plug
(4) - Wire blade terminal
Figure 36: Fitting the electrical thread tensioner
Adjusting steps
Fitting the thread tensioner
1. Pull the cable on the thread tensioner through the opening in the machine
arm and route back to the transparent plug (3).
2. Insert the thread tensioner (1).
3. Plus the blade terminals (4) into the transparent plug (3).
4. Make sure that all over-length cables are routed in loops so they do not
interfere with the function of moving machine parts.
Thread tension
factory preset
Cutting
tension
5. Tie up cable loops with cable ties.
6. Tighten the grub screw through the access drill hole (2).
New thread tensioner as a spare part
If you purchase a new thread tensioner as a Dürkopp Adler genuine spare
part, it is pre-calibrated. The adjusting screw for thread tension is locked.
You only need to enter the values specified on the label for calibration
points 2 and 1 in the software.
( Section Subitem Thread Calib, p. 69)
Adjusting the tension for thread trimming in the software
The thread tension for thread trimming is set in the software ( Section
Submenu Thread Trim, p. 60).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 47
Page 50
Electrical thread tensioner
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you replace the
thread tensioner spring.
Warning
6
5
4
7
1
3
2
(1) - Grub screw
(2) - Inner cylinder
(3) - Tensioning washers
(4) - Trigger pin
(5) - Grub screw on cylinder
(6) - Slot
(7) - Thread tensioning spring
15.2 Replacing the thread tensioning spring
The thread tensioner spring needs to keep the needle thread tensioned
until the tip of the needle penetrates the fabric.
Cover
•Top cover( Chap. 4.5.2, p. 11)
Figure 37: Removing the thread tensioning spring
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 48
Removing the spring
Adjusting steps
1. Removing the thread tensioner ( Chap. 15.1, p. 46).
2. Loosen the grub screw (1).
3. Pull out the entire inner cylinder (2).
Important: Make sure you do not lose the trigger pin (4).
4. Release the grub screw (5) on the cylinder.
5. Remove the tensioning bolt and tensioning washers (3).
6. Remove the thread tensioning spring (7) from the cylinder. To do so,
pull out the spring thread from the inside with a screwdriver.
7. Pull the open end of the spring through the slot (6).
Page 51
Electrical thread tensioner
7
6
5
1
3
2
8
4
(1) - Grub screw
(2) - Inner cylinder
(3) - Tensioning washers
(4) - Trigger pin
(5) - Grub screw on cylinder
(6) - Slot
(7) - Thread tensioning spring
(8) - Hook
(1) - Contour washer
(2) - 1st tensioning washer
(3) - 2nd tensioning washer
(4) - Rubber o-ring
(5) - Adjusting nut
(6) - Grub screw
Figure 38: Fitting a thread tensioning spring
Installing the spring
Adjusting steps
1. Pull the loose end of the thread tensioning spring (7) through the slot (6).
2. Insert the thread tensioning spring (7) into the cylinder.
3. Insert the tensioning bolt and tensioning washers (3) into the cylinder.
Important: There is a groove on the bottom of the tensionin g bolt. This
must be pushed onto the hook (8) on the spring.
4. Tighten the grub screw on the cylinder (5).
Tensioning
washers
5. Push the inner cylinder (2) into the housing on the thread tensioner.
Important: The trigger pin (4) must be at the bottom of the cylinder.
6. Tighten the grub screw (1).
7. Fitting the thread tensioner ( Chap. 15.1, p. 46).
Tensioning washer order
Important: Leave the tensioner washers on the tensioner bolt.
If the tensioner washers are removed, you must recalibrate the thread tension in the software ( Section Subitem Thread Calib, p. 69).
If the tensioning washers are removed from the tensioning bolt, replace
the elements in the following order:
Figure 39: Tensioning washer order
1
2
4
5
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 49
3
6
Page 52
Electrical thread tensioner
Risk of injury
Crushing hazard and puncturing injuries due to mov-
ing and sharp parts
Switch off the sewing machine before you adjust the
spring force.
Warning
(1) - Grub screw
(2) - Inner cylinder
(3) - Grub screw on cylinder
(4) - Tensioning washers
(5) - Tensioning bolt
15.3 Adjusting the spring force
Check the correct setting
The spring force must be between 20 and 50 cN (1 cN = 1 g). The precise
setting depends on the fabric and the thread thickness.
Cover
•Top cover( Chap. 4.5.2, p. 11)
Figure 40: Adjusting the spring force
1
4
5
2
3
Adjusting steps
1. Removing the electrical thread tensioner ( Chap. 15.1, p. 46)
2. Release the slotted screw (1).
3. Pull the inner cylinder (2) out of the thread tensioner.
4. Loosen the grub screw on the cylinder (3).
5. Twist the tensioning bolt (5) and tensioning washers (4).
• Greater tension: Turn clockwise
• Less tension: Turn anticlockwise
6. Tighten the grub screw on the cylinder (3).
7. Insert the inner cylinder (2) into the thread tensioner.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 50
8. Tighten the grub screw (1).
9. Fitting the electrical thread tensioner ( Chap. 15.1, p. 46).
Page 53
Electrical thread tensioner
2
3
1
(1) - Spring stroke
(2) - Grub screw
(3) - Bushing
15.4 Adjusting the spring stroke
Check the correct setting
The recommended spring stroke length (1) is 6.5 mm. The precise se tting
depends on the fabric and the thread thickness.
Figure 41: Adjusting the spring stroke on the thread tensioner
Adjusting steps
1. Loosen the grub screw (2).
2. Turn the complete bushing (3) to achieve the desired spring stroke:
• Longer spring stroke: Turn clockwise
• Shorter spring stroke: Turn anticlockwise
3. Tighten the grub screw (2).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 51
Page 54
Adjusting the thread regulator
(1) - Thread regulator
(2) - Fastening screw
16 Adjusting the thread regulator
The thread regulator decides what needle thread length is fed around the
hook. The required thread length depends on the thickness of the fabric
and thread and the stitch length.
Greater thread length for
• thick fabric
• thick thread
• long stitches
Lesser thread length for
• thin fabric
• thin thread
• short stitches
Check the correct setting
Remove the fabric base and column cover( Chap. 4.5.4, p. 12) and ob-
serve the thread running around the hook:
The needle thread loop runs without surplus and without jumping
around the largest hook diameter.
Malfunctions in case of incorrect settings.
• Poor sewing results
Figure 42: Adjusting the thread regu lator
1
2
Adjusting steps
1. Turn the handwheel and monitor the thread running around the hook.
2. Loosen the fastening screw (2).
3. Displace the thread regulator (1).
• Larger thread length: Push regulator to left
• Shorter thread length: Push regulator to right
4. Tighten the fastening screw (2).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 52
Page 55
Adjusting the bobbin winder
Damage to machine possible due to winding without sewing.
When running without thread, the sewing feet and bobbin case in the
hook can be damaged.
Enable winding mode ( Operating instructions Chap. 9.4 Manual
Mode) and remove the bobbin case from the hook to perform test winding.
Attention
1
2
3
4
(1) - Adjusting screw
(2) - Clamping screw
(3) - Thread guide plate
(4) - Actuating lever
17 Adjusting the bobbin winder
17.1 Setting the fill volume
Correct setting
1. Winding onto an empty bobbin ( Operating instructions Chap. 8.4).
Winding stops automatically when the bobbin is filled to approx.
0.5 mm below the bobbin edge.
Figure 43: Setting the bobbin winder fill volume
Adjusting steps
Rough setting
1. Release the clamping screw (2).
2. Align the actuating lever (4).
• Smaller fill volume: Push towards bobbin
• Larger fill volume: Push away from bobbin
3. Tighten the clamping screw (2).
Fine adjustment
4. Release the adjusting screw (1).
5. Move the thread guide plate (3).
• Smaller fill volume: Push towards bobbin
• Larger fill volume: Push away from bobbin
6. Tighten the adjusting screw (1).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 53
Page 56
Adjusting the bobbin winder
(1) - Guide bolt
(2) - Adjusting knob
(3) - Joint
(4) - Knurled nut
17.2 Setting the winding form of the bobbin winder
The height of the joint determines how the hook thread is wound on the
bobbin.
Correct setting
The thread is wound evenly over the entire height of the bobbin.
The thread runs in a straight line without kinds from the joint through the
thread guide to the bobbin.
Figure 44: Setting the winding form of the bobbin winder
1
2
3
4
Adjusting steps
1. Release the knurled nut (4).
2. Turn the guide bolt (1) with a standard screwdriver:
• Set the joint deeper: Turn clockwise
• Set the joint higher: Turn anticlockwise
Important: Do not turn the adjusting knob (2) while doing this.
3. Tighten the knurled nut (4).
17.3 Setting the winding tension
Correct setting
The correct winding tension depends on the anti-friction capability and
thickness of the thread.
Malfunctions in case of incorrect settings.
• Wrinkled seams
• Poor sewing results
Adjusting steps
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 54
1. Turn the adjusting knob (2):
• Greater tension: Turn clockwise
• Less tension: Turn anticlockwise
Page 57
Service settings via software
(1) - Number keys
(2) - ESC key
(3) - OK key
(4) - Arrow keys /
(5) - Arrow keys /
M
6WHSSHU
3RVLWLRQ
'HIDXOW3URJUDP
001-999
3
0DFKLQHFRQILJ
8VHUFRQILJ
6HUYLFH
3
257LFN
1
2
(1) - Active entry in a menu list
(2) - Active entry in a value field
18 Service settings via software
This chapter describes service settings, such as
• the basic machine config uration.
• Test functions for individual machine components
• Calibration functions
• Presets for programs and functions
Changes to the stitch length, thread tension, curve support, etc., as well
as calling and creating sewing programs are described in the Operating
instructions ( Operating instructions Chap 9 Operating the controls and
programming).
18.1 Basic software operation
The software is controlled via the control panel.
Figure 45: Display and control panel for software
1
Active entry high-
lighted
2
4
3
4
5
5
Displaying and selecting
The display shows the menu items of value fields that you can select.
The active entry is always highlighted (brighter).
Figure 46: Active menu entries and value fields
Moving with the
arrow keys
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 55
The arrow keys let you move from entry to entry:
•
/
in a list of menu items
•
/
adjacently in value fields
Page 58
Service settings via software
080
3
10 2
1
0
3
*
****
&RGH
Back to menu level
Back with Pressing takes you to the previous menu level.
Cancelling
a menu with
Entering values
with numeric
keys or
incorrect values
Confirming
Cancelling a val-
ESC
/
Entering
with
ue entry
with
ESC
Cancelling in menu lists
If you press
ESC
in a menu list, you are taken to the user level.
Changing values
In active fields you can enter a value with the number keys or change it
/
step by step with
.
If you have entered a value that is not within the preset value range, the
software automatically applies the limit value from the value range that is
closest to your input.
Pressing
OK
In a menu list, this opens the select menu item.
OK
applies the active entry:
Cancelling processing of values
If you press
ESC
when editing a value field, this cancels the entry without
applying your changes.
18.2 Accessing technician level
All settings in the service area are performed at technical level.
Pedal inactive The pedal is inactive in technician mode
For safety reasons, the pedal is inactive in technician mode. Although you
can test the pedal inputs in the
Multitest
not activated by pressing the pedal.
Figure 47: Input field for technician code
Accessing technician level
P
1. Press the
key and S key at the same time.
The display shows the input mask for the code.
2. Enter the technician code 25483 with the numeric keys.
After each keypress with a number, the input cursor automatically
moves to the next position. For safety reasons, the figures are not
displayed. A 0 is displayed at the entry point, and an asterisk at all
other points. You can press
/
to move from one entry point to
another.
menu, the sewing motor is
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 56
Page 59
Service settings via software
Directly after entering the code, the display shows the 4 menu items for
technician level:
• Default Program
Presets for new programs to be created
• Machine config.
Start and end tack, thread trimmer, speeds, stop positions, sewing foot
lifting
• User config.
Audible signal between program steps, left pedal function, program
cancel with pedal, change between right and left sleeve
• Service
Test functions for solenoids and drives, calibration of transport, sewing
feet and thread tension, reset functions
Access after an error message
After some error messages it may be impossible to access menus or programs. Even after switching the machine off and back on, the machine
boots with an error message and does not continue into the programs.
For this case, there is the option of sending the machine to technician
mode directly on booting, in order to perform
of issuing a
Reset all
Multitest
to restore the factory defaults.
diagnostics or
Operating steps
1. Switch off the machine at the main switch.
F
2. Hold down the
The machine boots and the display shows the input mask for the
code.
3. Enter the technician code 25483 ( Chap. 18.2, p. 56).
Only the two submenus
•
Multitest
•
Reset all
key and switch on the machine at the main switch.
Multitest
: Tests for error diagnostics ( p. 63)
: Reset the machine to the factory defaults ( p. 72)
and
Reset
are available.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 57
Page 60
Service settings via software
6WLWFKOHQ
2.6
001-999
3
&XUYH
2
)RRW3UHVV
9
PP
7KU7HQV
40
18.3 Menu items at technician level
Default
program
18.3.1 Menu item
default program
In this menu item you can define the default values when a new program
is created.
Select values that can be kept in as many programs as possible depending on the sewing requirements; this makes it easier to create new programs.
Figure 48: Parameters in the menu item default program
Parameters in the menu item
Icon Entry Meaning Permissible value range
Stitchlen. Stitch length 1.0 – 5.5 mm 2.5
Curve C urve support 0 – 6 2
Foot Press. Sewing foot pressure 1 – 15 9
Default program
Default
value
Thr. Tens. Thread tension 1–99 40
Fullness Working in fullness -6 – 16 0
Alternate Alternating:
The sewing foot is
lifted by this height for
every stitch
Start Tack Start tack 0 = No tack
Start Tack End tack 0 = No tack
Thread
Trim
Teach Side Sleeve side to be pro-
Action Action
Thread trimmer 0 = Thread trimmer off
grammed first
program-
after
ming the 1st sleeve
side, to create the
2nd sleeve side
0 – 2.5 mm 0
1 = Tack on
1 = Tack on
1 = Thread trimmer on
R = Start with right sleeve
L = Start with left sleeve
•
nothing
•
mirror
teach
•
sleeve side, also program the 2nd
sleeve side
•
ask
sleeve side, the selection mask for
nothing
,
appears
= mirror sleeve side
= After programming the 1st
= After programming the 1st
mirror
or
teach
side
sleeve
2nd
no
=
mirror
0
0
1
R
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 58
Page 61
Service settings via software
n
Submenus in
Machine
config.
18.3.2 Menu item
Machine config
This menu lets you define the basic settings for the machine that apply in
all programs.
The menu item has the submenus:
• Start Tack - Settings for the start tack
• End Tack - Settings for the end tack
• Thread Trim - Settings for the thread trimmer
• Speed - Start, positioning and maximum speed
• Stop Positions - Sets the stop positions
• Foot - Sets sewing foot lifting
Submenu
Start Tack
This submenu lets you determine how to sew the start tack.
Figure 49: Parameters in the submenu Start Tack
n
5HSHWLWLRQV
W&KDQJH
6WLWFKHV
6WLWFKHV
2
0
3
3
Start Tack Parameters in the submenu
Icon Entry Meaning
Repetitions Number of repetitions in the tack 1 – 10 2
t Changes Wait time when switching between for-
ward and reverse stitch
Stitches Numb er of forward stitches in the tack 1 – 50 3
Stitches Number of reverse stitches in the tack 1 – 50 3
Speed Speed for sewing the tack 50 – 2000 1000
Submenu
End Tack
Start Tack
End Tack This submenu is identical to the submenu
tings are made for the end tack. ( Section Submenu Start Tack, p.
59)
Permissible
value range
0–5000 0
Start Tack
Default
value
. The same set-
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 59
Page 62
Service settings via software
6SHHG
180
7KU7HQV
10
7XUQ%DFN
1
n
0D[6SHHG
4000
3RV6SHHG
400
6RIW6SHHG
500
16WLWFKHV
1
PD[
n
n
Submenu
Thread Trim
In this submenu you can define settings for thread trimming.
Figure 50: Parameters in the submenu Thread Trim
Thread Trim Parameters in the submenu
Icon Entry Meaning Permissible value range
Speed Speed for thread trimming 50 – 250 180
Thr. Tens. Thread tension for thread
trimming
Turn Back After trimming, the machine
automatically turns back to
a position where the needle
is slightly higher.
Thread Trim
1 – 99 The bigger the value, the
shorter the thread is trimmed
0 = No automatic turn back
1 = Automatic turn back
Default
value
10
1
Submenu
Speed
In this submenu, you can determine the speed for certain situations.
Figure 51: Parameters in the submenu Speed
Speed Parameters in the submenu
Icon Entry Meaning Permissible value range
Speed Maximum speed when the pedal
is fully depressed
Pos.
Speed
Soft Speed Speed for softstart stitches 10 – 1000 500
N Stitches Number of softstart stitches 1 – 10 1
Speed for positioning 10 – 700 400
Speed
Default
value
100 – 4000 4000
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 60
Page 63
Service settings via software
6WRS,GOH
35
6WRS7RS
0
6WRS%RWWRP
130
)/$W6WRS
0
)/$IWHU7ULP
0
)/KHLJKW
30
Stop
Positions
Submenu
Stop Positions
This menu item lets you define the needle position on stopping.
The position is given in degrees. The needle position at top dead centre is
0°. The other handwheel positions are derived from this. 360° is a complete turn of the handwheel.
Figure 52: Parameters in the submenu Stop Positions
Parameters in the submenu
Icon Entry Meaning
StopIdle° Handwheel setting after thread trimming and
turning back
StopTop° Handwheel setting for top stop position of
the needle on stopping in the seam
StopBottom° Handwheel setting for bottom stop position of
the needle on stopping in the seam
Stop Positions
Permissible
value range
0° – 359° 35°
0° – 15° 0°
0° – 359° 130°
Default
value
Submenu
Foot
In this submenu you can define settings for sewing foot lifting.
Figure 53: Parameters in the submenu Foot
Foot Parameters in the submenu
Icon Entry Meaning Permissible value range
FL AtStop Foot lifting on stop during sew-
ing
FL AfterTrim
FL height Height of lifted foot 0 – 999 30
Sewing foot lifting after thread
trimming
Foot
0 = No sewing foot lifting
1 = Sewing foot lifting
0 = No sewing foot lifting
1 = Sewing foot lifting
Default
value
0
0
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 61
Page 64
Service settings via software
)RUZDUG6RXQG
1
$XWR)RUZ6LGH
1
3HGDO$ERUW
1
0RGH3HGDO
1
18.3.3 Menu item
User config
In this menu you can define more settings for the machine.
Figure 54: Parameters in the menu item User config
User config. Parameters in the submenu
Icon Entry Meaning Permissible value range
Forward
Sound
AutoForwSide
Pedal
Abort
Mode
Pedal
Audible signal on
transition between
program steps
Automatic change
between right/left
during sewing
Program cancel with
main pedal
Function of the
optional additional
pedal
User config
0 = Signal off
1 = Signal on
0 = No automatic change
1 = Automatic change
0 = No cancel with main pedal
1 = Cancel with main pedal
0 = Additional pedal no function
1 = Change in fullness
2= Change in curve support
Default
value
1
1
1
1
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 62
Page 65
Service settings via software
0XOWLWHVW
520
0
&DOLEUDWLRQ
5HVHW
Submenus in
Service
Menu structure
Service
18.3.4 Menu item
Service
In this menu you can perform function tests, calibrate the machine or re set
to the factory defaults.
Figure 55: Submenus in the menu item Service
The menu item has the submenus:
• Multitest - Test functions for solenoids and drives
• Calibration - Calibrate transport, feet, thread tension
• Reset - Reset all programs or parameters to the factory defaults
The submenus have additional subitems:
Menu item Submenu Subitem
Test output
Test PWM
Submenu
Multitest
Test Input
Test Auto Input
Test Sew. Motor
Test S tep.Motor
Feed sync.
Foot Calib.
Thread Calib.
Reset programs
Reset all
Service
Submenu
Multitest
Calibration
Reset
Multitest
In this submenu you can use the software to test if specific solenoids,
drives or inputs are functional.
Figure 56: Subitems in the submenu Multitest
+
520
0
7HVW,QSXW
7HVW$XWR,QSXW
–
7HVW6HZ0RWRU
7HVW6WHS0RWRU
Subitem
Test output
Do not select this menu item. The menu item has no assignment on this
machine.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 63
Page 66
Service settings via software
3:0
9DOXH
PWM
2
2))
3:0
9DOXH
PWM
4
Test PWM Subitem
In this subitem you can test the solenoids for the thread trimmer and
thread tensioner.
Use
/
in the
• 2 = Thread trimmer solenoid
• 4= Thread tensioning solenoid
Test steps thread trimmer solenoid
Figure 57: Display in subitem Test PWM - Thread trimmer solenoid
1. Press OK.
The display for
2. Monitor the thread trimmer and check whether the thread trimmer really
is triggered when you press
mer, p. 23)
Test PWM
PWM
field to select the element you want to test:
Value
changes between ON and
OK
. ( Chap. 9 Adjusting the thread trim-
OFF
.
Test steps thread tensioning solenoid
Figure 58: Display in subitem Test PWM - Thread tensioner solenoid
1. Press OK.
The display shows a field for entering a % value.
2. Thread on up to the thread lever. ( Operating instructions Chap. 8.1
Threading the needle thread)
3. Press
/
to change the value in the % field.
4. Pull the loose end of the thread and monitor whether the thread tension
increases or is reduced in line with the change in the % field.
Important: The values shown in the % field do not correspond to the
calibrated thread tension values( Section Subitem Thread Calib,
p. 69), but only give you some orientation as to the extent to which the
tension increases or drops.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 64
Page 67
Service settings via software
+
–
,QSXW
9DOXH
5
21
Test Input
Subitem
Figure 59: Display in subitem Test Input
Test Input
Test steps
1. Use
in the
Input
field to select the element you want to test:
/
2. Actuate the element as described in the Test method column (see table
later on).
3. Monitor the display.
If the element is functional, the display for
ON
and
OFF
.
Input Element Test method
1 T ilt sensor Tilt the machine back and return to upright
position
2 – 4 not used
-----
Value
changes between
5 Main pedal input A
6 Main pedal input B
7 Main pedal input C
8 Main pedal input D
9* Knee switch in switch position 1* Press the knee switch
10* Knee switch in switch position 2* Press the knee switch
* It is sufficient to test the knee switch in one of the two switch positions.
11 – 12 not used
13 Mode pedal input A
14 Mode pedal input B
15 Mode pedal input C
16 Mode pedal input D
90 Reference sensor disk for sewing
motor
Depress the pedal to various positions.
-----
Depress the pedal to various positions.
Turn the handwheel
State change at top and bottom dead centre of needle.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 65
Page 68
Service settings via software
+
–
,QSXW
9DOXH
AUTO
M
6HZLQJ0RWRU
6SHHG
350
Test
Auto Input
Test
Sew. Motor
Subitem
Figure 60: Display in subitem Test Auto Input
In this subitem you can perform the same tests as in
Test Auto Input
Test Input
, with-
out needing to select the element beforehand in the display.
Test steps
1. Actuate the element as described in the Test method column( p. 65).
The display shows the last element to be changed for
element is functional, the display for
OFF
.
Subitem
Figure 61: Display in subitem Test Sew. Motor
Test Sew. Motor
Value
changes between ON and
Input
. If the
This subitem tests the sewing motor.
Test steps
OK
1. Press
.
The machine is referenced.
2. For
3. Press
Speed
OK
.
press / to enter a speed in steps of 50.
The motor runs at the set speed.
To quit:
1. Press
ESC
.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 66
Page 69
Service settings via software
Test
Step Motor
Subitem
Figure 62: Display in Subitem Test Step Motor
Test Step Motor
M
6WHSSHU
3RVLWLRQ
2
2))
This subitem tests the step motors for the sewing feet and transport belts.
Test steps
1. Press
2. Press
3. Press
in the
OK
.
/
to test the motor in question.
Stepper
field to select the motor you want to test:
/
If the motor is working correctly, the behavior shown in the table can
be observed.
Stepper
no.
Motor Behavior for functional motor
1 Upper drive for both transport
belts
The belts move.
Test also in-
cludes the encod-
ers
2 Height of right top transport foot The height changes.
3 Height of left top transport foot The height changes.
4 Lower drive for both transport
belts
The belts move.
Notes for the step motor encoders
There is no separate test for the step motor encoders. They are tested
along with the step motors. If the results for the step motors are OK, the
encoders are functional.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 67
Page 70
Service settings via software
Submenu Cali-
bration
Submenu
In this submenu you can sync the transport and sewing feed, or calibrate
thread tension.
Feed sync. Subitem
In this subitem you can set the synchronous run of the top and bottom
transports.
Check the correct setting
1. Switch off the machine at the main switch.
2. Removing the needle ( Operating instructions Chap. 8.7).
3. Switch on the machine at the main switch.
4. Switch to manual mode ( Operating instructions Chap. 9.4 Manual
5. Press
6. Press
7. Press the numeric key 0 as the fullness.
8. Place 2 identical sheets of cardboard on top of one another on the fabric
9. Press the pedal and observe the cardboard being fed:
Calibration
Feed sync.
mode).
/
to select the parameter
to set 0 as the curve support value.
support.
Both pieces must stay aligned.
Curve support
.
If the pieces of cardboard are not aligned, you must synchronize the top
and bottom transport in
Figure 63: Synchronizing the top and bottom transport
&$/
Feed sync.
+/-
)HHG6\QF
)RRW&DOLE
in technician level.
2
7KUHDG&DOLE
Synchronization steps
1. Access technical level ( Chap. 18.2, p. 56).
2. Select the menu item
3. Select the submenu
4. Select the subitem
An input box with a numeric value appears on the right.
5. Change the value in this field by pressing
• Increase top transport: Increase value
• Reduce top transport: Reduce value
6. Repeat the test with the pieces of cardboard.
7. Repeat steps 1 to 6 if needed.
Service
Calibration.
Feed sync.
by pressing OK.
/
:
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 68
Page 71
Service settings via software
)HHG6\QF
2
&$/
)RRW&DOLE
7KUHDG&DOLE
F
Foot Calib. Subitem
Figure 64: Display in subitem Foot Calib
The control unit must know the top and bottom positions of the sewing
feet. The top position is sent on switching on the machine.
The bottom position is determined by calibrating in this subitem.
Order
Always calibrate the sewing feet after changing settings on the sewing foot
gear( Chap. 14 Checking the sewing foot lifting gear, p. 43).
Calibration steps
1. Access the subitem
2. Press OK.
The machine is calibrated automatically: both sewing feet move up
and down once. This completes the calibration.
Foot Calib
&$/ &$/
)HHG6\QF
)RRW&DOLE
7KUHDG&DOLE
Foot Calib.
2
Thread Calib. Subitem
Figure 65: Display in subitem Thread Calib
In this subitem you can calibrate the thread tensioner.
You need an external tension measuring device for calibration.
Only calibrate thread tension once
The thread tension only needs to be calibrated once. Even after a complete reset ( Section Submenu Reset, p. 72) and after loading new
software, ( Section Installing software with a dongle, p. 73) the values
are kept.
The thread tension only needs to be calibrated after changing the control
unit.
Thread Calib
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 69
Page 72
Service settings via software
F = 300g
3
F
ė
(1) - Adjusting nut (2) - Tensioning washers
(3) - Grub screw
Calibration points
You must set the calibration points 3 – 1 one after another:
• Point 3 - maximum tension (300 g)
• Point 2 - medium tension (150 g)
• Point 1 - minimum tension (5 g)
Calibration steps
1. Set calibration point 3
1. Thread on up to the thread lever ( Operating instructions Chap. 8.1
Threading the needle thread)
2. After the thread lever, thread into the measuring device.
3. Press
Figure 66: Calibration point 3
/
to select calibration point 3
4. Press OK.
Figure 67: Calibrating the thread tension - setting calibration point 3
1
3
2
5. Fully release the grub screw (3) at the centre of the thread tensioner.
6. Turn in the adjusting nut (1) as far as possible without pressing the
tensioning washers (2) against each other.
7. Slowly turn the adjusting (1) nut out and monitor the display on the
tension measuring device.
8. At the point where the measuring device shows a value of 300 g: tighten
the grub screw (3) without changing the position of the adjusting nut (1).
9. Press
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 70
OK
.
Page 73
Service settings via software
2. Set calibration point 2
1. Press
2. Press
/
to select calibration point 2
OK
.
3. Change the thread tension with
150 g.
OK
4. Press
.
3. Set calibration point 1
1. Press
2. Press
/
to select calibration point 1
OK
.
3. Change the thread tension with
5g.
OK
4. Press
.
/
until the measuring device reads
/
until the measuring device reads
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 71
Page 74
Service settings via software
5HVHWSURJUDPV
001-999
Res
3
5HVHWDOO
Submenu
Reset
Reset
programs
Submenu
Figure 68: Submenu Reset
In this submenu you, you can reset programs or parameters to the factory
defaults. For safety reasons, you are first prompted to enter the technician
password.
Call
Reset
1. Press
The display shows the input mask for the password.
2. Enter the technician code 25483 with the numeric keys ( Chap. 18.2
Accessing technician level, p. 56).
You are in the
desired subitem.
Subitem
In this subitem, you first delete all your own programs. On ly the standard
programs are kept, and they are reset to their factory defaults.
Reset
with password
/
to select the
Reset
Reset
submenu and can press / to access the
Reset programs
submenu.
If you want to do this:
1. Press to select
2. Press
All of your own programs are deleted. Only the standard programs
are kept, and they are reset to their factory defaults.
Reset all Subitem
In this submenu you reset all programs or parameters to the factory defaults.
Only the calibration values for thread tension and the sewing feet are kept.
If you want to do this:
1. Press to select
2. Press
All programs and parameters (except for the calibration values for
thread tension and the sewing feet) are reset to the factory defaults.
/
OK
.
Reset all
/
OK
.
Reset programs
Reset all
.
.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 72
Page 75
Service settings via software
1
2
(1) - Connector for dongle (2) - Main switch
233000
A01
2012-02-15
650
V00.54
2012-07-02
233000
A01
2012-02-15
1
2
(1) - Firmware version
(2) - Software version
18.4 Installing software with a dongle
When a new software version becomes available, you can download it
from www.duerkopp-adler.com and use a dongle to install it. All machine
settings are kept.
Dongle transmission only for software
Not for copying
programs
You can only use the dongle to transfer software. Sewing programs cannot be copied from one machine to another - neither with a dong le nor using a USB stick - instead they must be created again on the machine (
Operating instructions Chap. 9.7 Editing mode and 9.8 Programming
mode).
Figure 69: Installing software with a dongle
Transfer steps
1. Switch off the machine at the main switch (2).
2. Insert the dongle into the connector (1) on the rear of the control unit.
3. Switch on the machine at the main switch (2).
The machine boots and automatically starts to transfer the software.
During this process the display only shows the firmware version for the
control panel on the left. Once the transfer has been completed, the
display additionally shows the machine software version on the right.
The machine is referenced.
Figure 70: Firmware and software version display
4. Remove the dongle.
This completes the software transfer. The machine is ready for sew-
ing.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 73
Page 76
Service settings via software
.H\V2.
Behavior in case of a missing software version display
In some cases the machine fails to display the software version on the
right side of the display despite completing the transfer.
If no software version appears after 2 minutes:
1. Switch off the machine at the main switch.
2. Remove the dongle.
3. Switch on the machine at the main switch.
Once the transfer has been completed, the display additionally
shows the machine software version on the right. The machine is
referenced.
The machine is ready for sewing.
18.5 Checking the key functionality at the control panel
Test steps
1. Switch off the machine at the main switch.
ESC
2. Hold down the
The display shows the following:
Figure 71: Screen for testing keys on the control panel
key and switch on the machine at the main switch.
3UHVVNH\V
3. Press all the keys in the control panel except
If a key is functional, the corresponding field in the display is filled
and lit. If the key is not functional the field stays empty.
ESC
4. Finally, press the
• If all keys are functional:
The display shows the following status message:
Figure 72: Status message for fully functional keys
5.Press OK.
key.
ESC
in any order.
• If one or more keys are not functional:
Keys
...
The display shows the following status message:
NOT
OK!
The control panel must be replaced.
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 74
Page 77
Maintenance work
Environmental damage due to lubricating grease
Lubricating grease is a hazardous material and must not enter
the drains or the ground. Collect residual lubricants carefully
and dispose of them and of greased machine parts in line with
legal requirements.
Observe all of the lubricant manufacturer's safety and environmental instructions.
Environmental
1
2
(1) - Joints on the gearbox:
(2) - Needle bar
19 Maintenance work
19.1 Lubrication
Once a year, you must lubricate the following areas of the machine head
with grease:
• Joints on the gearbox:
• Needle bar
Figure 73: Lubricating the joints on the machine head
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 75
Page 78
Maintenance work
Damage to paint due to solvent-based cleaning agents
Solvent-based cleaning agents will damage the machine's paint
Only use solvent-free substances to clean the machine.
Attention
19.2 Cleaning
Sewing dust and residual thread must be removed every 8 operating
hours with a compressed air gun or a brush.
Areas requiring particular cleaning:
• Hook
• Needle plate
• Handwheel screen
This cleaning work is described in the Operating instructions ( Operat-
ing instructions Chap. 10 Maintenance).
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 76
Page 79
Appendix
20 Appendix
20.1 Software error messages
Perform the remedies in the stated order.
Error Meaning Possible causes
1051 Sewing motor timeout • Cable to sewing motor refer-
ence switch defective
• Reference switch defective
1052 Sewing motor overcur-
rent
1053 Mains voltage too high • Mains voltage too high • Check mains voltage
1055 Sewing motor overload • Sewing motor not running
1056 Sewing motor excess
temperature
1058 Sewing motor speed
above set value
1062 Sewing motor IDMA
auto-increment
• Sewing motor cable defective
• Sewing motor defective
• Control unit defective
freely or blocked
• Sewing motor defective
• Control unit defective
• Sewing motor not running
freely
• Sewing motor defective
• Control unit defective
• Reference sensor defective
• Sewing motor defective
• Fault • Switch machine off and back on.
Remedies
Perform in the stated order!
• Replace cable
• Replace reference switch (9815 935006)
• Replace sewing motor cable
• Replace sewing motor
• Replace control unit (9850 650002)
• Resolve obstruction/blockage
• Replace sewing motor
• Replace control unit (9850 650002)
• Resolve obstruction
• Replace sewing motor
• Replace control unit (9850 650002)
• Replace reference sensor (9815 935006 or
0911 490140)
• Replace sewing motor
1302 Sewing motor power
fault
1342
1344
1410 Sewing motor: Thread
1411 Sewing motor: Thread
1412 Sewing motor: Stop
1420 Sewing motor power
Sewing motor fault • Internal fault • Switch machine off and back on.
cutting speed not
reached
cutting position not
reached
position not reached
after turning back
fault
• Sewing motor blocked
• Encoder cable not connected
or defective
• Encoder defective
• Encoder defective
• Sewing motor defective
• Thread cutting position not
reached
• Stop position not reached after
turning back
• Sewing motor blocked
• Encoder cable not connected
or defective
• Encoder defective
• Resolve blockage
• Check/replace encoder cable
• Replace sewing motor
• Perform software update
• Contact DA Service
• Switch machine off and back on.
• Replace encoder
• Replace sewing motor
• Contact DA Service
• Switch machine off and back on.
• Perform software update
• Contact DA Service
• Switch machine off and back on.
• Perform software update
• Contact DA Service
• Resolve blockage
• Check/replace encoder cable
• Replace sewing motor
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 77
Page 80
Appendix
Error Meaning Possible causes
1421 Sewing motor timeout • Cable to sewing motor refer-
ence switch defective
• Reference switch defective
1430 Sewing motor:
Positioning speed not
reached
1431 Sewing motor: Stop
position
1450 Internal sewing motor
fault
1498
1499
21 .. .. Step motor X-axis: belt
22 .. .. Step motor Y-axis: right
Internal sewing motor
fault
top transport
foot
• Encoder defective
• Sewing motor defective
• Stop position not reached or
exceeded
• Internal sewing motor fault • Switch machine off and back on.
• Internal sewing motor fault • Switch machine off and back on.
• •
• •
Remedies
Perform in the stated order!
• Replace cable
• Replace reference switch (9815 935006)
• Switch machine off and back on.
• Replace encoder
• Replace sewing motor
• Contact DA Service
• Positioning speed not reached
• Perform software update
• Perform software update
• Replace control unit (9850 650002)
• Contact DA Service
• Perform software update
• Replace control unit (9850 650002)
• Contact DA Service
23 .. .. Step motor Z-axis: left
foot
.. .. 02 Step motor power fault • Step motor not running freely or
.. .. 03 Step motor step loss • Not running freely mechani-
.. .. 52 Step motor overcurrent • • Replace step motor
.. .. 53 Step motor overvoltage • Mains voltage too high • Checking mains voltage
.. .. 55 Step motor overload • Step motor not runni ng freely or
.. .. 56 Step motor excess tem-
perature
• •
• Resolve obstruction/blockage
blocked
• Encoder cable not connected
or defective
• Step motor cable not connected
or defective
• Encoder defective
• Step motor defective
cally, or blockage
blocked
• Step motor defective
• Control unit defective
• Step motor not running freely
• Step motor defective
• Control unit defective
• Check/replace encoder cable
• Replace encoder
• If the step motor is not energized:
• Check/replace step motor cable
• Replace step motor
• Resolve obstruction/blockage
• Replace control unit (9850 650002)
• Resolve obstruction/blockage
• Replace step motor
• Replace control unit (9850 650002)
• Resolve obstruction
• Replace step motor
• Replace control unit (9850 650002)
.. .. 62 Step motor IDMA auto-
increment
2551 Communication with
additional control
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 78
• Fault • Switch machine off and back on.
• Signal from additional control
does not exist
• Check/replace cable to additional control
• Replace additional control (9850 650001)
• Replace control unit (9850 650002)
Page 81
Appendix
Error Meaning Possible causes
3100
3103
3107 Control unit: Excess
4202 Communication with
4440
4459
6000
6299
6351
6354
6400
6999
Machine voltage error • Short-term mains voltage drop • Check mains voltage and stabilise if needed
• Air vents blocked
temperature
memory card
Control panel OP3000 • Fault • Switch machine off and back on.
Driver error • Internal fault • Switch machine off and back on.
Error I²C • Control unit defective • Replace control unit (9850 650002)
Driver error • Internal fault • Switch machine off and back on.
• Ventilation grating soiled
• Ambient temperature too high
• Access to memory card in controller not possible
Remedies
Perform in the stated order!
• Check air vents
• Clean ventilation grating
• Allow control unit to cool down
• Format/replace memory card
• Perform software update
• Replace control panel (9850 001069)
• Perform software update
• Contact DA Service
• Perform software update
• Contact DA Service
7551
7559
7651
7659
8151
8161
8251
8258
91 10 Communication with
9210 Thread tensioner: Ini-
Communication with
control panel interface
Communication with
control panel interface
IDMA error • Internal fault
Error on ADSP boot or
boot
foot pedal
tialization error
• Internal fault
• Cable fault
• Cable to control panel defective
• Internal fault
• Cable fault
• Cable to control panel defective
• Fault
• Control unit defective
• Internal fault
• Fault
• Foot pedal not in idle position
• Setpoint generator defective
• Plug 120t not plugged in to
DAC3 or X502 on PCB, or
defective
• Cable 120t-L021A defective
• Distributor board defective
• Switch machine off and back on.
• Switch off interference source
• Perform software update
• Replace cable
• Contact DA Service
• Switch machine off and back on.
• Switch off interference source
• Perform software update
• Replace cable
• Contact DA Service
• Switch machine off and back on.
• Perform software update
• Replace control unit (9850 650002)
• Contact DA Service
• Switch machine off and back on.
• Perform software update
• Contact DA Service
• Do not depress the pedal while booting the
machine
• Replace setpoint generator (9800 330012)
• Check plug and cable and replace as needed
• Replace distributor board (9850 650000)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 79
Page 82
Appendix
Error Meaning Possible causes
9220 Communication with
electrical thread tensioner
• Thread tensioning solenoid
defective
• Plug from distributor board to
thread tensioner solenoid not
plugged in or defective, or
cable defective
• Plug 140t not plugged in to
DAC3 or X503 on PCB, or
defective, or cable X140t-L023
defective
• Distributor board defective
Remedies
Perform in the stated order!
• Check cables and plugs from solenoid to distributor board and from distributor board to
control unit and replace as needed
• Replace thread tensioner (0650 110094)
• Replace distributor board (9850 650000)
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 80
Page 83
Kl.650 mit DAC3
M1.1
A1
M1
M
Obertransport direkt
M
M
Nähfuß rechts
M
M
Nähfuß links
M
Blatt
1 / 7
Steuerung, Nähmotor, Schrittmotore
0027/10
control, sewing motor, stepping motors
987654321
A
B
C
D
E
F
G
H
Steuerung k DAC III, Variante 1
9850 001224
Encoder k 9850 281002
X300b
X622
X621
Encoder Nähmotor
Gestell
X20
X620
Nähmotor
Nähmotor
X300t
X631
M2.1
Encoder X-Achse
Blatt /2.F1
Blatt /6.B8
X630
M2
X30
Schrittmotor X-Achse
Leitung k
X301b
230V
+10% -20%
50/60Hz
X641
M3.1
Encoder Y-Achse
X0
Blatt /5.G2
Netzstecker
X640
X40
M3
Schrittmotor Y-Achse
X301t
Q0
Hauptschalter
X651
M4.1
Encoder Z-Achse
X650
X50
M3
Schrittmotor Z-Achse
Blatt /2.B1
F400
Netz
F404
Bauschaltplan
9890 650001 B
Änd.
Datum
Datum
Bearb.
Geprüft
NormName
2011-04-11
Isaak
abc Teilefamilie
Freigabe01.0 2012-07-24 Cz
01
control DAC III, variant 1
En (SD)
X300b
encoder cpl.
01
+5V_ADSP
(9pol.)
1
gews
1
gn
GND
2
grbn
2
bn
SIG_3A
3
gngn
3
gr
ws
1
SIG_1B
44
br
2
encoder sewing motor
SIG_1A
5
wsge
5
ws
gn
3
frame
SIG_2B
66
ge
4
01
SIG_2A
7
bn
7
gr
5
SIG_3B
88
NC
9
gr
9
ge
Schirm
9870 650003 L024
(SD)
X20
gr
W
(4pol.)
1
sw1
U
V
2
sw2
W
sw1
ws
U
sewing motor
U
3
sw3
V
sw3
br
V
sewing motor
PE
4
gnge
W
sw2
ge
Schirm
01
gnge
01
9870 650002 L015
9870 650004 L034
En (X)
X300t
gr
gr
+5V_ADSP
(9pol.)
1
gn
NC
2
SIG_X_1A
3
bn
SIG_X_2A
4
ge
ws
1
Encoder X-Achse
encoder X-axis
encoder X-axis
IDX_X_A
5
bn
2
GND
6
ws
9870 650002 L011
sheet
9870 650002 L014
sheet
gn
3
SIG_X_1B
7
100nF
ge
4
SIG_X_2B
8
100nF
IDX_X_B
9
Schirm
(X)
X30
9870 650004 L028
ws
rt
1
Schrittmotor X-Achse
stepping motor X-axis
bn
bl
2
PH_X_A1
(5pol.)
1
gr
rs
3
PH_X_A2
2
rs
gr
4
stepping motor X-axis
PH_X_B1
3
gn
ge
5
PH_X_B2
4
ge
gn
6
PE
5
bl
bn
7
rt
ws
8
Schirm
9870 001020
En (Y)
X301b
9870 650004 L029
+5V_ADSP
(9pol.)
1
gn
NC
2
SIG_Y_1A
3
bn
SIG_Y_2A
4
ge
ws
1
Encoder Y-Achse
encoder Y-axis
encoder Y-axis
IDX_Y_A
5
bn
2
GND
6
ws
gn
3
L1NPE
SIG_Y_1B
7
100nF
ge
4
SIG_Y_2B
8
100nF
IDX_Y_B
9
bn
bl
gnge
sheet
Schirm
mains plug
(Y)
X40
01
9870 650004 L030
ws
rt
1
bn
bl
2
PH_Y_A1
(5pol.)
1
gr
rs
3
Schrittmotor Y-Achse
stepping motor Y-axis
PH_Y_A2
2
rs
gr
4
stepping motor Y-axis
PH_Y_B1
3
gn
ge
5
PH_Y_B2
4
ge
gn
6
PE
5
bl
bn
7
rt
ws
8
Schirm
bn
bl
bnblgnge
En (Z)
X301t
9870 650004 L031
+5V_ADSP
(9pol.)
1
gn
NC
2
T1L1
T2L2
SIG_Z_1A
3
bn
mains switch
PE
SIG_Z_2A
4
ge
ws
1
Encoder Z-Achse
encoder Z-axis
encoder Z-axis
IDX_Z_A
5
bn
2
GND
6
ws
gn
3
SIG_Z_1B
7
100nF
ge
4
SIG_Z_2B
8
100nF
IDX_Z_B
9
Schirm
bn
bl
gnge
bn
bl
gnge
(Z)
X50
01
9870 650004 L032
ws
rt
1
bn
bl
2
PH_Z_A1
(5pol.)
1
gr
rs
3
Schrittmotor Y-Achse
stepping motor Y-axis
PH_Z_A2
2
rs
gr
4
stepping motor Z-axis
PH_Z_B1
3
gn
ge
5
PH_Z_B2
4
ge
gn
6
PE
5
bl
bn
7
rt
ws
8
Schirm
9870 650001 L003
sheet
FF6,3A
9870 650004 L033
power
FF6,3A
Appendix
20.2 Circuit diagram
Circuit diagram - Sheet 1
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 81
Page 84
Appendix
Kl.650 mit DAC3
Die Zeichnung wurde grundlegend überarbeitet.
M
+
Stichlänge
+ +
Blatt
2 / 7
Zusatzsteuerung 4.Schrittmotor
0027/10
supplementary control 4.stepping motor
987654321
A
B
C
D
E
F
G
H
Blatt /1.A4
Blatt /6.F8
Blatt /1.A9
Hinweise für Umschaltung auf andere
Netzspannung beachten !
Steuerung K 9850 650001
X407
X401 ST1
Spannung [V]
A - C
D - E
A2
A
F1
17,5
ST3
X403
B
NTC
190
C
D
C
0V
200
B
D
Schrittmotor-Modul 9850 001185
210
A
D
D
87V
220
C
E
E
0V
230
B
E
+-
240
A
E
-
F2
120V
ST5 X405
F3
X660
M5
V
Blatt /3.E2
9850 001185
Bauschaltplan
9890 650001 B
A2
Z1
A2.2
T1
A2.1
Änd.
Datum
Datum
Bearb.
Geprüft
NormName
2011-04-11
Isaak
abc Teilefamilie
Freigabe01.0 2012-07-24 Cz
9870 650002 L010
9870 650002 L011
sheet
9870 650002 L012
sheet
9870 650001 L003
sheet
observe the information on changeover
to other main voltages !
control box
9890 650002 B
gngegngegr
gngegr
gngegr
gnge
bnbn
blbl
9870 650001 L005
wsbngn
ge
9870 650001 L006
9870 650001 L004
1
234
01
PE
PH_A1
PH_A2
PH_B1
PH_B2
T2A
bnbn
1
bn
bnbn
2
02
stepping motor module
gr
bl
gr
rt
bl
blbl
3
T2A
swsw
4
+24V
+24V
Enable
DIR
Boost
Step
Fehler
GND
GND
GND
1
Molex 10pol. 2R122
33
44
55
66
77
88
99
10 10
wsbngngegrrsbl
T2,5A
rt
9870 650001 L002
bl
100k 100K
ge
1
Schrittmotor W-Achse
stepping motor W-axis
330µF
2
bn
3
4
5
330µF
gn
6
7
ws
8
330µF
~~
+
-
gr
1µF
9870 650001 L001
sheet
gr
N'U'
LOAD
UN
PE
LINE
ST1ST3ST5
1
ON
2345678910
Circuit diagram - Sheet 2
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 82
Page 85
Kl.650 mit DAC3
A1
A4
A5
Blatt
3 / 7
Stepper, I/O, Bedienfeld, Tastenleiste
0027/10
stepper, I/O, control panel, keyboard
987654321
A
B
C
D
E
F
G
H
Steuerung k DAC III, Variante 1
9850 650002
Stepper 3-4 SignaleStepper 1-2 SignaleDiag-Schnittstelle
X100t
X100b
X110
Blatt /2.E8
Kodierung
Ein-/Ausgänge 9-16Ein-/Ausgänge 1-8
X120t
X120b
Blatt /6.F3
Blatt /6.D3
Blatt /5.C2
Blatt /5.B2
Blatt /6.B3
PWMRef.-SignaleCAN-SchnittstelleBDE-Schnittstelle
X140t
X140b
X150t
X150b
Blatt /5.D2
Blatt /5.F2
TastenleisteBedienfeldsicherer Halt
X160
X170
X201
X410
X420
Bedienfeld OP3000
9850 001069
Bedienfeld OP7000
9850 001088
Bauschaltplan
9890 650001 B
Änd.
Datum
Datum
Bearb.
Geprüft
NormName
2011-04-11
Isaak
abc Teilefamilie
Freigabe01.0 2012-07-24 Cz
control DAC III, variant 1
stepper 3-4 signalsstepper 1-2 signalstest interface
SM 3-4
X100t
SM 1-2
X100b
Dongle
X110
+24V_1
SM3 DIR
SM3 CLK
SM3 REF
SM4 EN
SM4 BST
SM4 RDY
+24V_1
SM3 EN
SM3 BST
SM3 RDY
GND
SM4 DIR
SM4 CLK
SM4 REF
+24V_1
SM1 DIR
SM1 CLK
SM1 REF
SM2 EN
SM2 BST
SM2 RDY
+24V_1
SM1 EN
SM1 BST
SM1 RDY
GND
SM2 DIR
SM2 CLK
SM2 REF
+5V
MRST
MTST
CLK
GND
T4IN
5V Opto
Anode
GND Opto
(15pol.)
123456789
101112
131415
(15pol.)
123456789
1011121314
15
(9pol.)
1
2345678
9
ws
gn
gr
bn
ge
rs
bl
01
9870 650001 L001
sheet
coding
I/O 9-16I/O 1-8
IO 9-16
X120t
IO 1-8
X120b
+24V_1
IN_9
IN_11
IN_13
IN_15
U_CONST
IN_ANA_2
+24V_1
OUT_9
OUT_11
OUT_13
OUT_15
GND
GND
IN_10
IN_12
IN_14
IN_16
GND
IN_ANA_4
+24V_1
OUT_10
OUT_12
OUT_14
OUT_16
+24V_1
IN_1
IN_3
IN_5
IN_7
I_CONST
IN_ANA_1
+24V_1
OUT_1
OUT_3
OUT_5
OUT_7
GND
GND
IN_2
IN_4
IN_6
IN_8
GND
IN_ANA_3
+24V_1
OUT_2
OUT_4
OUT_6
OUT_8
(25pol.)
123456789
101112131415161718192021222324
25
(25pol.)
123456789
1011121314
1516171819202122232425
ge
bn(rt)
gn
gr
bn
ws
gn
ge
gr
bn
ws
gn
ge
bn
gn
ws
ws
gn
bn
ge
01
01
01
01
01
9870 650003 L021C
sheet
9870 650003 L021B
sheet
9870 650003 L021A
sheet
9870 650003 L020A
sheet
9870 650003 L020B
sheet
Knieschalter
Zusatzpedal
Input_2
Input _1
Hauptpedal
PWMref. signalsCAN interfacePDA-interface
PWM
X140t
REF
X140b
CAN
X150t
Data
X150b
+24V_2
GND
PWM_1
PWM_2
PWM_3
PWM_4
+24V_2
GND
+24V_1
GND
REF_NM
REF_X
REF_Y
REF_Z
+5V_ADSP
GND
GND
CANL
GNDNCGND
GND
CANH
NC
+24V_1
RXD TTL
RS485 D-
CTS TTL
RTS TTL
GND
TXD TTL
RS485 D+
+5V
+24V_1
7
(8pol.)
1
2
34567
8
(8pol.)
1234567
8
(9pol.)
123
4
56789
(9pol.)
1234568
9
01
ws
bngnge
gn
ws
bn
01
01
9870 650003 L023
sheet
9870 650003 L022
sheet
keypadcontrol panelsafety stop
Keypad
X160
Panel
X170
DATAT-
LOADT+
DATAA-
LOADA+
GND
DATAT+
CLKT-
DATAA+
CLKA-
GND
+24V_1
CLKT+
LOADT-
CLKA+
LOADA-
GND
GND
BOOT
/XSTOPBF
RxDBF-
TxDBF+
GND
+24V_1
GND
/RESIN_2
/RESTERM
RxDBF+
TxDBF-
GND
+24V_1
+24V_1
IN_SH
(15pol.)
123456789
1011121314
15
(15pol.)
123456789
1011121314
15
(2pol.)
1
2
gn
ws
gr
rt
rs
bl
ge
bn
Schirm
bn
bn
Leitung k
9870 650006
ws
bngnge
gr
rs
bl
rt
sw
vi
Schirm
Stecker k
9850 001208
Leitung k
9870 650005
01
01
wsbngngegrrsblrtSchirm
wsbngngegrrsbl
rtswvi
Schirm
01
(9pol.)
123456789
01
1
(15pol.)
234567891011121314
15
Rx+
Rx-
Tx-
Tx+
GND
Boot
Boot
Reset
+24V
control panel
GND
BOOT
RS422 /OUT
RS422 IN
GND SIG
24V
/RES_DAC3
/RESET IN
RS422 OUT
RS422 /IN
control panel
Appendix
Circuit diagram - Sheet 3
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 83
Page 86
Circuit diagram - Sheet 4
Kl.650 mit DAC3
A1 A1A1
Blatt
4 / 7
Steuerung, Anschlußplan
0027/10
control, connection diagram
987654321
A
B
C
D
E
F
G
H
Steuerung k
DAC III, Variante 1 + CF-Karte
9850 001224
NC
NC
T6,3AF401
T6,3A
T6,3A
F402
F403
Bauschaltplan
9890 650001 B
Änd.
Datum
Datum
Bearb.
Geprüft
NormName
2011-04-11
Isaak
abc Teilefamilie
Freigabe01.0 2012-07-24 Cz
PWM
X140t
En (Z)
X301t
En (X)
X300t
CAN
X150t
IO 9-16
X120t
SM 3-4
X100t
Power
F404
Fuse
FF6,3A
REF
X140b
En (Y)
X301b
En (SD)
X300b
Panel
X170
Keypad
X160
Data
X150b
IO 1-8
X120b
Dongle
X110
SM 1-2
X100b
Save
Stop
X201
Fuse
FF6,3A
F400
9870 650003 L022
9870 650003 L023
9870 650004 L030
9870 650004 L032
9870 650003 L024
9870 650004 L028
9870 650005
9850 650006
9870 650003 L020B
9870 650003 L020A
9870 650003 L021A
9870 650003 L021B
9870 650003 L021C
9870 650001 L001
control
DAC III, variant 1+CF-card
(SD)
X20
(X)
X30
(Y)
X40
(Z)
X50
(SD)
X20
(X)
X30
(Y)
X40
(Z)
X50
9870 650004 L034
9870 650004 L029
9870 650004 L031
9870 650004 L033
8
1
2
1
4
1
8
1
5
1
Jumper
5
1
5
1
Appendix
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 84
Page 87
Appendix
Kl.650 mit DAC3
A3
A6
Blatt
5 / 7
Ein-/Ausgänge, Nähkopf
0027/10
inputs/outputs, sewing head
987654321
A
B
C
D
E
F
G
H
Blatt /3.E4
Blatt /3.C4
Blatt /3.B6
Blatt /3.D6
Blatt /1.A6
X1X501
X502 X2
X3X503
X4X504
T2
Leiterplatte k 9850 650000
F4
9850 001083
+-
X10 X510
X511X11
X6 X506
X7 X507
X508X8
X509X9
X5 X505
X522
X521
X520
Ref. Nähmotor
S100
Y102
Fadenabschneider-Magnet
Y104
Fadenspannungsmagnet
LED-Leuchte 9850 650003
Bauschaltplan
9890 650001 B
Änd.
Datum
Datum
Bearb.
Geprüft
NormName
2011-04-11
Isaak
abc Teilefamilie
Freigabe01.0 2012-07-24 Cz
X120b
X120t
X140t
X140b
9870 650003 L020A
sheet
9870 650003 L021A
sheet
9870 650003 L023
sheet
9870 650003 L022
sheet
sheet
01
01
01
01
wsbngn
ge
wsbngn
wsbngn
ge
wsbngn
Molex C-Grid 7pol.
1234567
Molex C-Grid
12345
6
Phoenix Combicon 5pol.
12345
Molex C-Grid 5pol.
12345
IN:
190-240V
50/60Hz
10VA
01
PCB
+24V_1
GND
IN_ANA_4
+24V_1
GND
IN_1
IN_4
+24V_2
GND
PWM_2
PWM_4
+5V_ADSP
GND
REF_NM
OUT:
LED1: 24V/70mA
LED2: 400mA
3W
9850 650000 S
Kippsensor
Stromsensor
+24V_1
LED 1
ws
bn
GND
IN_4
+24V_1
GND
+24V_2
+24V_2
PWM_2
PWM_4
+5V_ADSP
GND
REF_NM
Molex C-Grid
1
Greiferdeckel / Hook Cover
2
3
LED-LeuchteMolex Micro-Fit
1
2
2,8 FL
FS2,8 FL
Molex C-Grid 4pol.
123
4
1
2
ws
bn
bn
bl
bn
bl
ws
bn
gn
9870 650004 L035
9870 650004 L036
ws
bn
1
2
wsbngn
+5V
GND
REF_NM
(3pol.)
1
ref. sewing motor
2
3
0281 350154
Trimmer Magnet
9820 110035
Thread Tension Magnet
01
01
01
LED-light
Circuit diagram - Sheet 5
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 85
Page 88
Appendix
Kl.650 mit DAC3
Blatt
6 / 7
Ein-/Ausgänge, Gestell
0027/10
inputs/outputs, frame
987654321
A
B
C
D
E
F
G
H
Zusatzausstattung
Z
Blatt /3.F4
Blatt /3.C4
Blatt /3.B4
X430
X440
X450
Z
Pedal Drehzahl
9800 330012
Pedal Mehrweite
9800 330012
Knieschalter 9880 002004
A7
A9
A8
Blatt /2.G1
Blatt /1.B4
Bauschaltplan
9890 650001 B
Änd.
Datum
Datum
Bearb.
Geprüft
NormName
2011-04-11
Isaak
abc Teilefamilie
Freigabe01.0 2012-07-24 Cz
optional equipment
9870 650003 L020B
sheet
9870 650003 L021B
sheet
9870 650003 L021C
sheet
01
01
01
ws
bngngegrSchirm
ws
bn
gn
gegrSchirm
ws (sw)
bn (rt)gnge
(9pol.)
123456789
(9pol.)
123456789
RJ11 / 6P4C
11
22
334455
66
ws (sw)
bn (rt)gnge
+24V_1
C IN_7
B IN_6
D IN_8
A IN_5
Schirm
+24V_1
C IN_15
B IN_14
D IN_16
A IN_13
Schirm
01
pedal speed
pedal fullness
Knee switch
9880 002004
9870 650002 L013
01
9870 650002 L012
sheet
9870 650002 L014
sheet
Circuit diagram - Sheet 6
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 86
Page 89
Appendix
Kl.650 mit DAC3
Die Zeichnung wurde neu hinzugefügt.
T41
A41
T2
siehe Hauptschalter Blatt 1
Q0
A2
A1
Blatt
7 / 7
2. Nähleuchte (optional)
0027/10
2. sewing light (optional)
987654321
A
B
C
D
E
F
G
H
Z
Hinweis für Umschaltung auf
andere Netzspannungen beachten
Z
T3
H
Z
230V
+10% -20%
50/60Hz
Netzstecker
X0
Netzteil LED-Nähleuchte
X499
X498
Z
Q0
Hauptschalter
Z
Z
Zusatzsteuerung
Hauptsteuerung DAC3
Bauschaltplan
9890 650001 B
Änd.
Datum
Datum
Bearb.
Geprüft
NormName
2011-04-11
Isaak
abc Teilefamilie
Freigabe01.0 2012-07-24 Cz
1x220V
=Zusatzausstattung
Optional equipment
Observe the information on changeover
to other mainvoltages
11
12
0
1x230V
1x240V
11
12
0
M0,16/250G
(798 460121)
bei 220V Netz
798 500088
bn
25VA
220-240V
0
11V
12V
bn
I
12V/20W
Nähleuchte
III
bl
bl
01
mains plug
L1NPE
bn
bl
gnge
Power-supply LED-sewing light
bl
bn
bl
bn
bnblgnge
bn
bl
T1L1
T2L2
mains switch
PE
Leitung k
9870 745159
Leitung k
9870 650019
bn
bl
gnge
bn
bl
gnge
supplementary control
main control DAC3
Circuit diagram - Sheet 7
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 87
Page 90
Appendix
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 88
Page 91
Page 92
DÜRKOPP ADLER AG
Potsdamer Straße 190
33719 Bielefeld
GERMANY
Phone
+49 (0) 521 / 925-00
E-mail marketing@duerkopp-adler.com
www.duerkopp-adler.com
·
·
Subject to design changes · Printed in Germany · © Dürkopp Adler AG · Service Instructions 0791 650641 · 00.0 EN · 09/2012
Loading...