DURKOPP ADLER 512-211-01, 532-211-01 Service Instructions Manual

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512-211-01
532-211-01
Service Instructions
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IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE
All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, inclu-
ding extracts, is prohibited without the prior written approval of Dürkopp Adler AG. Copyright © Dürkopp Adler AG 2016
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Table of Contents
1 About this service manual.........................................................5
1.1 Scope of the service manual........................................................5
1.2 Representation conventions – symbols and characters............... 5
1.3 Other documents.......................................................................... 6
1.4 Liability..........................................................................................6
2 Safety information......................................................................7
2.1 Basic safety instructions............................................................... 7
2.2 Signal words and symbols used in warnings................................8
3 Work principles......................................................................... 11
3.1 Order of settings.........................................................................11
3.2 Cable routing..............................................................................11
3.3 Removing the covers..................................................................12
3.3.1 Access to the machine bottom section.......................................12
3.3.2 Removing and fitting the head cover.......................................... 13
3.3.3 Removing and fitting the arm cover............................................14
3.3.4 Removing and fitting the right-hand side cover.......................... 14
3.3.5 Removing and fitting the left-hand side cover ............................15
3.3.6 Removing and fitting the rear cover............................................16
3.3.7 Opening and closing the hook flap.............................................17
3.3.8 Removing and inserting the throat plate.....................................17
3.4 Surfaces on shafts......................................................................19
4 Adjusting the light barriers...................................................... 21
4.1 Light barrier sensor disks ...........................................................21
4.2 Adjusting the left and right switching flags..................................22
4.3 Thread clamp switching flag....................................................... 23
5 Adjusting the hook and needle bar......................................... 24
5.1 Adjusting the needle bar height.................................................. 24
5.2 Adjusting the loop stroke and needle guard...............................25
5.3 Adjusting the distance between the hook tip and needle ...........27
6 Adjusting the thread trimmer .................................................. 28
7 Adjusting the height of the fabric clamp lift...........................30
8 Adjusting the thread wiper ...................................................... 32
9 Adjusting the thread regulator................................................33
10 Adjusting the winder................................................................ 34
10.1 Setting the fill volume .................................................................34
10.2 Adjusting the winding tension..................................................... 35
11 Settings via software................................................................ 36
11.1 Control panel..............................................................................36
11.2 Switching on the sewing machine ..............................................37
11.3 Reference the machine ..............................................................37
11.4 Selecting a sewing pattern .........................................................38
11.5 Scaling axes ...............................................................................38
11.5.1 Scaling the X-axis.......................................................................38
11.5.2 Scaling the Y-axis.......................................................................38
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Table of Contents
11.5.3 Converting the buttonhole gap (class 532).................................39
11.5.4 Converting the backtack dimensions (class 512).......................39
11.6 Setting the speed........................................................................40
11.7 Checking the sewing pattern......................................................40
11.8 Changing the sewing pattern......................................................40
11.9 Winding.......................................................................................41
11.10 Sewing........................................................................................41
11.11 Counter.......................................................................................42
11.12 Interrupting sewing.....................................................................42
11.13 Protecting standard sewing patterns.......................................... 42
11.14 Storing sewing patterns..............................................................43
11.14.1Mapping memory buttons..........................................................43
11.14.2Sewing with memory buttons.....................................................44
11.14.3Deleting the memory button assignments .................................44
11.15 Storing sewing pattern sequences .............................................44
11.16 Processing sewing pattern sequences....................................... 45
11.17 Deleting sewing pattern sequences............................................45
11.18 Stopping sewing.........................................................................46
11.19 Editing parameters in the memory..............................................46
11.19.1Editing parameters in level M1 ..................................................46
11.19.2Editing parameters in level M2 ..................................................47
11.20 Resetting parameters to factory settings.................................... 47
11.21 Editing sewing patterns externally.............................................. 48
11.22 Working with a USB stick ...........................................................49
11.23 Error messages..........................................................................51
11.24 Loading software via a USB stick...............................................54
11.24.1Loading the main program.........................................................54
11.24.2Loading sewing patterns............................................................54
11.24.3Setting parameter U085 (class 532)..........................................55
11.24.4Checking the software version...................................................55
12 Service settings via software.................................................. 56
12.1 Basic software operation............................................................56
12.2 Accessing the technician level....................................................57
12.2.1 Editing parameters in level 1......................................................57
12.2.2 Editing parameters in level 2......................................................58
12.3 Setting the blade position...........................................................58
12.4 Loading software via a USB stick...............................................61
12.4.1 Loading the main program..........................................................61
12.4.2 Loading sewing patterns.............................................................61
12.4.3 Setting parameter U085 (class 532)...........................................62
12.4.4 Checking the software version ...................................................62
13 Maintenance..............................................................................63
13.1 Cleaning .....................................................................................63
13.2 Lubrication..................................................................................64
13.2.1 Checking the oil level..................................................................65
13.2.2 Lubricating with grease...............................................................67
13.3 Adjusting the lubrication for the hook .........................................69
14 Appendix ...................................................................................71
14.1 Software error messages ...........................................................71
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14.2 Circuit diagram ...........................................................................73
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Table of Contents
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About this service manual
1.
2.

1 About this service manual

This manual for the 512/532 sewing machines has been compiled with the utmost care. It contains information and notes in order to make long-term and reliable operation possible.

1.1 Scope of the service manual

This manual describes the setting and maintenance work for sewing ma­chines 512/532. It applies to all submodels. The intended use and set-up is described in the operating manual.

1.2 Representation conventions – symbols and characters

Various information in this manual is represented or highlighted by the fol­lowing characters in order to facilitate easy and quick understanding:
Correct setting
Indicates proper setting.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Steps to be performed when operating the machine (sewing and equipping)
Steps to be performed for servicing, maintenance, and installation
Steps to be performed via the software control panel
The individual steps are numbered:
1. First step
2. Second step The sequence of the steps must always be followed.
Lists are identified by bullet points.
Result of performing an operation
Change to the machine or in the display.
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Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating possibilities.
Observe order
Specifies the work to be performed before or after a setting.
References
 Reference to another section in the manual.
Safety Important warnings for the machine operator are specially designated.
Since safety is of particular importance, hazard symbols, levels of danger and their signal words are described separately in 3 Safety information.
About this service manual
Orientation If the figure is unclear, indications of "right" and "left" are always from the
operator's point of view.

1.3 Other documents

This equipment includes components from other manufacturers. Each manufacturer has performed a hazard assessment for these purchased parts and confirmed their design compliance with applicable European and national regulations. The proper use of these components is descri­bed in each manufacturer's manual.

1.4 Liability

All information in this operating manual was compiled with consideration to the state of the art, and applicable standards and regulations.
The manufacturer cannot be held liable for damages resulting from:
• Breakage and transport damages
• Failure to observe operating manual
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
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Safety information

2 Safety information

This section contains basic information for your safety. Read the information carefully before setting up, programming, maintain­ing or operating the machine.
Make sure to follow the information included in this section. Failure to do so can result in serious injury and damage to the machine.

2.1 Basic safety instructions

Only authorized personnel should use the machine. Anyone working on the machine should read the operating manual first.
The machine should only be used in accordance with the manual. The operating manual should be available at the machine 's location at all
times. Observe the generally applicable safety and accident prevention regula-
tions and the legal regulations concerning industrial safety and environ­mental protection.
If you are using parts from other suppliers, please also observe the safety instructions and the operating manual provided by the respective manu­facturer.
All warnings on the machine must always be in legible condition and may not be removed. Missing or damaged labels should be replaced immedi­ately.
In the following situations, the machine must be disconnected from the power supply using the main switch or by disconnecting the power plug:
Threading
Replacing the needle or other sewing tools
Leaving the workplace
Performing service work, maintenance work and repairs Check the machine during use for any externally visible damage. Stop
working as soon as you notice any changes to the machine. Report any changes to your supervisor. A damaged machine should no longer be used.
Machines or machine parts that have reached the end of their service life must not continue to be used. They have to be disposed of correctly and in accordance with the applicable statutory provisions.
Only qualified specialists may set up the machine. Anyone setting up the machine must have read the set-up instructions first.
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Safety information
Only qualified specialists may perform maintenance work and repairs. Anyone maintaining or adjusting the machine must have rea d the service manual first.
Safety equipment should not be removed or deactivated. If this cannot be avoided for a repair operation or service setting, the safety equipment must be refitted and put back into service immediately afterwards.
Only qualified electrical specialists may perform work on electrical equip­ment.
The power cable must have a plug authorized for the country in which the machine is being used. The power plug may only be connected to the power cable by a qualified specialist.
Work on live components and equipment is prohibited. Exceptions are defined in the specifications in DIN VDE 0105.
Only use original spare parts from the manufacturer. Missing or faulty spare parts could impair safety and damage the machine.

2.2 Signal words and symbols used in warnings

Warnings in the text are distinguished by color bars. The color scheme is oriented towards the severity of the danger. Signal words indicate the d e­gree of risk:
Signal words Signal words and the endangerment that they describe:
Signal word Endangerment
DANGER Will result in serious injury or death.
WARNING Can result in serious injury or death.
CAUTION Can result in minor or moderate injury.
NOTICE Can result in property damage.
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Safety information
Symbols The following symbols indicate the type of risk to personnel:
Symbol Type of danger
General risk
Risk of electric shock
Risk of puncturing
Risk of crushing
Examples Examples of the layout of the warnings in the text:
DANGER
Type and source of risk
Consequences of non-observance Measures for avoiding the risk
This is what a warning looks like for a hazard that will result in serious injury or even death if not com­plied with.
WARNING
Type and source of risk
Consequences of non-observance Measures for avoiding the risk
This is what a warning looks like for a hazard that could result in serious injury or even death if not complied with.
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Safety information
CAUTION
Type and source of risk
Consequences of non-observance Measures for avoiding the risk
This is what a warning looks like for a hazard that could result in moderate or minor injury if the warn­ing is not complied with.
CAUTION
Type and source of risk
Measures for avoiding the risk
This is what a warning looks like for a hazard that could result in environmental damage if not com­plied with.
NOTICE
Type and source of danger!
Consequences of non-compliance. Measures for avoiding the danger.
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Work principles

3 Work principles

3.1 Order of settings

Observe order Always adhere to the specified sequence for the individual setting steps.
Always observe all notes marked with a in the margin on prerequisites and follow-up settings.
NOTICE
Property damage may occur!
Machine damage possible due to incorrect order. Always adhere to the working order specified in this manual.
Binding the cable
together

3.2 Cable routing

Ensure that all cables in the machine are laid in such a way that moving parts are not impaired in their ability to function correctly.
1. Lay excessively long cables neatly in proper cable snakes.
2. Tie the snakes together using a cable tie. If possible, bind the snakes to fixed parts.
The cables must be fixed firmly in place.
3. Cut off any protruding part of the cable tie.
NOTICE
Property damage may occur!
Machine damage and malfunctions can be caused by laying the cables incorrectly.
Excess cabling may obstruct moving machine parts in their ability to function correctly. This will affect the sewing function and may cause damage. Lay excess cabling as described above.
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Work principles

3.3 Removing the covers

NOTICE
Property damage may occur!
Machine damage and malfunctions can be caused by laying the cables incorrectly.
Excess cabling may obstruct moving machine parts in their ability to function correctly. This will affect the sewing function and may cause damage. Lay excess cabling as described above.
WARNING
Risk of injury from moving parts!
Crushing possible. Switch the sewing machine off before you remove
the covers or refit them.
In many types of setting work, you will have to remove the machine covers first in order to access the components.
Described here is how to remove the individual covers and how to reattach them. Just the cover that needs to be removed is then specified in the text for that particular type of setting work.

3.3.1 Access to the machine bottom section

In order to access the components at the machine bottom section, you must first tilt the machine upper section to the left.
Fig. 1: Tilting the machine upper section to the left and setting it upright
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(1) - Machine upper section
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Work principles
Tilting the machine upper section to the left
1. Tilt the machine upper section (1) to the left as far as possible.
Setting the machine upper section upright
1. Set the upper machine section (1) upright.

3.3.2 Removing and fitting the head cover

Fig. 2: Removing and fitting the head cover
(1) - Screw (2) - Eye guard
Removing the head cover
1. Unscrew the eye guard (2).
2. Loosen both screws (1).
3. Remove the head cover (3).
Fitting the head cover
1. Fit the head cover (3).
2. Tighten both screws (1).
3. Tighten the eye guard (2).
(3) - Head cover
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3.3.3 Removing and fitting the arm cover

Fig. 3: Removing and fitting the arm cover
Work principles
(1) - Screw (2) - Arm cover
Removing the arm cover
1. Loosen all 6 screws (1).
2. Remove the arm cover (2).
Fitting the arm cover
1. Fit the arm cover (2).
2. Tighten all 6 screws (1) firmly in place.

3.3.4 Removing and fitting the right-hand side cover

Fig. 4: Removing and fitting the right-hand side cover
(1) - Screw (2) - Right-hand side cover
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Work principles
Removing the right-hand side cover
1. Loosen both screws (1).
2. Remove the right-hand side cover (2).
Fitting the right-hand side cover
1. Fit the right-hand side cover(2).
2. Tighten both screws (1).

3.3.5 Removing and fitting the left-hand side cover

Fig. 5: Removing and fitting the left-hand side cover
(1) - Screw (2) - Left-hand side cover
Removing the left-hand side cover
1. Loosen all 3 screws (1).
2. Remove the left-hand side cover (2).
Fitting the left-hand side cover
1. Fit the left-hand side cover (2).
2. Tighten all 3 screws (1) firmly in place.
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3.3.6 Removing and fitting the rear cover

Fig. 6: Removing and fitting the rear cover
(1) - Screw (2) - Rear cover
Work principles
Removing the rear cover
1. Loosen all 4 screws (1) on the rear cover (2).
2. Remove the rear cover (2).
Fitting the rear cover
1. Fit the rear cover (2).
2. Tighten all 4 screws (1) on the rear cover (2) firmly in place.
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Work principles

3.3.7 Opening and closing the hook flap

Fig. 7: Opening and closing the hook flap
(1) - Hook flap
Opening the hook flap
1. Fold down the hook flap (1).
Closing the hook flap
1. Fold up the hook flap (1).

3.3.8 Removing and inserting the throat plate

Fig. 8: Removing and inserting the throat plate (1)
(1) - Springs of the fabric clamp (2) - Clamp feet
(3) - Screw (4) - Work surface
Removing the throat plate
1. Remove both springs of the fabric clamp (1).
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2. Raise both clamp feet (2).
⑤⑥
3. Loosen the screw (3) for the work surface (4).
4. Remove the work surface (4).
Fig. 9: Removing and inserting the throat plate (2)
Work principles
(5) - Thread puller blade connecting rod (6) - Screw
5. Open the hook flap (S. 17).
6. Loosen the screw (6).
7. Unhinge the thread puller blade connecting rod (5).
Fig. 10: Removing and inserting the throat plate (3)
(7) - Throat plate (8) - Screw
8. Loosen all 4 screws (8).
9. Remove the throat plate (7) upwards.
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Work principles
2
1
Inserting the throat plate
Fig. 11: Removing and inserting the throat plate (4)
(9) - Connecting rod pin for needle thread clamp
1. Insert the throat plate (7) from above. When doing this make sure that the hole in the needle thread clamp, which is located underneath the throat plate, and the connecting rod pin of the needle thread clamp (9) are mounted.
2. Mount the thread puller blade connecting rod (5) and make sure that the connecting rod grips properly.
3. Tighten all 4 screws (8) of the throat plate firmly in place.
4. Tighten the screw (6).
5. Close the hook flap (S. 17).
6. Fit the work surface (4).
7. Tighten the screw (3) for the work surface (4) firmly in place.
8. Mount both springs of the fabric clamp (1).

3.4 Surfaces on shafts

Fig. 12: Surfaces on shafts
(1) - Surface (2) - Shaft
Some shafts have flat surfaces at those points where the components are screwed on. This strengthens the connection and setting work is made ea­sier.
Always make sure that the whole screw is seated completely on the sur­face.
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Work principles
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Adjusting the light barriers

4 Adjusting the light barriers

4.1 Light barrier sensor disks

The light barrier sensor disks are used as a reference for positioning by the control unit.
WARNING
Risk of injury from moving parts!
Crushing possible. Switch the sewing machine off before adjusting the
light barriers.
Checking the correct setting
The 180° disk points to the front and its lower edge is precisely lined
up with the light barriers slots.
Faults caused by an incorrect setting
• Damage to fabric, wrinkling
• Incorrect needle position, needle jams in the hole
• Incorrect transport times
• Incorrect thread cutting
• Poor sewing results
Cover
• Remove rear cover (S. 16).
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Adjusting the light barriers
Fig. 13: Light barrier sensor disks
o
(1) - Thread trimmer se nsor disk (2) - Thread wiper and fabric clamp sensor
disk

4.2 Adjusting the left and right switching flags

The switching flags are used as reference by the control unit for the posi­tion of the clamps in an X and Y-direction.
Checking the correct setting
The clamps are centered in both an X and Y-direction.
Faults caused by an incorrect setting
• Damage to the needle
• Incorrect needle position
Cover
• Remove the right-hand side cover (S. 14).
• Remove the left-hand side cover (S. 15).
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Adjusting the light barriers
Fig. 14: Adjusting the right switching flag
(1) - Screw (2) - Switching flag, right
Fig. 15: Adjusting the left switching flag
(1) - Screw (2) - Switching flag, left
Adjusting steps
1. Loosen the screw (1).
2. Adjust the switching flag (2) accordingly.
3. Set the zero point via the control unit.
4. Tighten the screw (1).
5. Reference the machine.

4.3 Thread clamp switching flag

The thread clamp switching flag is used as reference by the control unit for the thread clamp. The switching flag is located underneath the throat plate to the right and is factory set.
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Adjusting the hook and needle bar
512 532

5 Adjusting the hook and needle bar

The following 3 settings must be coordinated:
• Height of the needle bar
• Loop stroke position and needle guard
• Hook clearance to the needle

5.1 Adjusting the needle bar height

WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the height of the needle bar.
The needle bar has 4 marker lines which serve as an adjusting aid. The top two lines are valid for class 512, while the bottom two lines are valid for class 532.
Cover
• Remove the head cover ( S. 13).
Fig. 16: Adjusting the needle bar height
(1) - Screw (2) - Needle bar
Adjusting steps
(3) - Marker line for class 512 (4) - Marker line for class 532
1. Use the handwheel to set the needle bar at its lowest position.
2. Loosen the screw (1).
3. Adjust the height of the needle bar (2) so that the applicable upper marker line (3/4) is aligned with the needle bar bush. When doing this make sure that the needle bar (2) is not twisted.
4. Tighten the screw (1).
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Adjusting the hook and needle bar

5.2 Adjusting the loop stroke and needle guard

Loop stroke
The loop stroke is the path length from the lower dead center of the need- le bar to the position where the hook is in the loop stroke position.
Fig. 17: Loop stroke
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the loop stroke and needle guard.
(1) - Center line of the needle (2) - Hook tip
Checking the correct setting
When the machine is in the loop stroke position, the hook tip should be located exactly on the center line of the needle. The needle must be aligned so that the surface of the groove is parallel to the running direction of the hook tip. The hook tip should be located in the lower third of the groove.
Faults caused by an incorrect setting
• Damage to the hook
• Damage to the needle
• Missing stitches
• Thread breakage
Order
Prerequisite:
• A straight and undamaged needle must be inserted (Operating
manual, Section 4.7 Changing needles).
(3) - Groove
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Adjusting the hook and needle bar
512 532
①⑤
②③
Cover
• Open the hook flap ( S. 17).
Fig. 18: Adjusting the loop stroke and needle guard
(1) - Hook tip (2) - Hook (3) - Driver (4) - Screw
(5) - Needle (6) - Marker line for class 512 (7) - Marker line for class 532
Adjusting steps
1. Use the handwheel to adjust the needle bar so that the corresponding marker line (6/7) is aligned with the needle bar bush.
2. Loosen the screw (4).
3. Remove the cover ring. When doing this make sure that the hook (2) does not work loose and fall.
4. Twist the driver (3) accordingly.
5. Shift the driver (3) axially so that the needle (5) rests against the driver tip and is easily pushed aside.
6. Insert the cover ring.
7. Tighten the screw (4).
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Adjusting the hook and needle bar
①③

5.3 Adjusting the distance between the hook tip and needle

Cover
• Open the hook flap ( S. 17).
Fig. 19: Adjusting the distance between the hook tip and needle
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the distance between the hook tip and needle.
(1) - Screw (2) - Eccentric (3) - Eccentric safety screw (4) - Needle
(5) - Hook tip (6) - Tip of the hook path bearing (7) - Hook path bearing
Checking the correct setting
The hook tip (5) must be as close as possible to the groove of the needle, without touching it. The tip of the hook path bearing (6) should have a gap of 7.5 mm to the right side of the needle.
Adjusting steps
1. Loosen the screw (1).
2. Loosen the safety screw (3) of the eccentric.
3. Adjust the hook path bearing (7) axially with the eccentric (2):
Eccentric to the left: reduce distance.
Eccentric to the right: increase distance.
4. Twist the hook path bearing (7) in such a way that it has a clearance of 7.5 mm to the right-hand side.
5. Tighten the safety screw (3) of the eccentric.
6. Tighten the screw (1).
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Adjusting the thread trimmer

6 Adjusting the thread trimmer

For the thread trimmer to work correctly, you must set the thread puller blade and the counter blade.
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the blades.
Faults caused by an incorrect setting
• Threads are not cut
• Threads are cut too long
Cover
• Remove the throat plate ( S. 17).
Fig. 20: Adjusting the blades
(1) - Needle guide (2) - Thread trimmer lever (3) - Screw for thread trimmer lever
(4) - Counter blade screw (5) - Counter blade
Adjusting steps
1. Loosen the screw (3).
2. Set a distance of 18.5 mm between the front of the throat plate and the thread trimmer lever (5).
3. Tighten the screw (3).
4. Loosen the counter blade screws (4).
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Adjusting the thread trimmer
5. Move the counter blade and set a distance of 0.5 mm between the needle guide (1) and the counter blade (5).
6. Tighten the counter blade screws (4).
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Adjusting the height of the fabric clamp lift

7 Adjusting the height of the fabric clamp lift

WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the fabric clamp lift.
The following maximum heights apply when adjusting the fabric clamp lift:
• Max. height for class 512: 15 mm
• Max. height for class 532:
• 13 mm (Standard button clamp)
• 7 mm (Universal button clamp without shank shaper)
• 5 mm (Universal button clamp with shank shaper)
Cover
1. Remove the arm cover ( S. 14).
Fig. 21: Adjusting the height of the fabric clamp lift
(1) - Screw
Adjusting steps
1. Loosen the screw (1).
2. Adjust the height by turning the fabric clamp lift on the shaft. When doing this observe the values for the maximum height.
3. Tighten the screw (1).
Order
After changing the height of the fabric clamp lift always check the setting of the thread wiper as well.
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Adjusting the height of the fabric clamp lift
Adjusting the fabric clamping feet (class 512)
Faults caused by an incorrect setting
• The two fabric clamping feet do not raise and lower synchronously.
Fig. 22: Adjusting the fabric clampi n g fe e t
(1) - Screw
Adjusting steps
1. Loosen the screws (1).
2. Align the fabric clamping feet synchronously.
3. Tighten the screws (1).
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8 Adjusting the thread wiper

1.5 mm 23-25 mm
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the thread wiper.
Fig. 23: Adjusting the thread wiper
Adjusting the thread wiper
(1) - Screw
Adjusting steps
1. Loosen the screw (1).
2. Adjust the thread wiper. When doing this observe the minimum distance of 1.5 mm to the needle and the distance range of 23 to 25 mm when pivoting. When using a thin needle set the distance at 23 mm.
3. Tighten the screw (1).
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Adjusting the thread regulator

9 Adjusting the thread regulator

The thread regulator determines the needle thread quantity to be guided around the hook. The required thread quantity depends on the thickness of the material to be sewn, thread strength, and stitch length.
Larger thread quantity for
• thick material
• high thread strengths
• large stitch lengths
Lower thread quantity for
• thin material
• low thread strengths
• small stitch lengths
Checking the correct setting
1. Open the hook flap (S. 17) and observe the thread running around the hook:
The needle thread loop runs without surplus and without jumping
around the largest hook diameter.
Faults caused by an incorrect setting
• Poor sewing results
Fig. 24: Adjusting the thread regulator
1
2
(1) - Thread regulator (2) - Fastening screw
Adjusting steps
1. Turn the handwhee l and observe the run of the thread around the hook.
2. Loosen the fastening screw (2).
3. Move the thread regulator (1):
Larger thread quantity: Turn the regulator counterclockwise
Lower thread quantity: Turn the regulator clockwise
4. Tighten the fastening screw (2).
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Adjusting the winder
1
2
3
4

10 Adjusting the winder

10.1 Setting the fill volume

Correct setting
1. Wind onto an empty bobbin ( Operating manual, Section 4.4).
Winding stops automatically when the bobbin is filled to approx.
0.5 mm below the bobbin edge.
NOTICE
Property damage may occou!
When operated without sewing material the sewing feet and bobbin case in the hook can be damaged.
Enable the winding mode (Operating manual, Section 5.8 Winding) and remove the bobbin case from the hook to perform a test winding process.
Fig. 25: Setting the winder fill volume
(1) - Adjusting screw (2) - Clamping screw
Adjusting steps
Rough adjustment
1. Loosen the clamping screw (2).
2. Align the actuating lever (4):
Smaller fill quantity: Push towards bobbin.
Larger fill quantity: Push away from bobbin.
3. Tighten the clamping screw (2).
(3) - Thread guide plate (4) - Actuating lever
Fine adjustment
4. Loosen the adjusting screw (1).
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Adjusting the winder
5. Move the thread guide plate (3):
Smaller fill quantity: Push towards bobbin.
Larger fill quantity: Push away from bobbin.
6. Tighten the adjusting screw (1).

10.2 Adjusting the winding tension

Correct setting
The correct winding tension depends on the anti-friction properties and thickness of the thread.
Faults caused by an incorrect setting
• Wrinkled seams
• Poor sewing results
Fig. 26: Adjusting the winding tension
(1) - Adjusting knob
Adjusting steps
1. Turn the adjusting knob (2):
Greater tension: Turn clockwise
Less tension: Turn counterclockwise
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11 Settings via software

⑦⑧

11.1 Control panel

Fig. 27: Control panel
Settings via software
Control panel buttons:
Button / LED Pos. Function
(1) USB button with LED
Saves/loads a sewing pattern to/from a USB stick.
(2) Needle thread clamp button with LED
Fixes needle thread during the first stitch. LED on = needle thread clamp on LED off = needle thread clamp off
(3) Memory button
Processes the memory functions.
(4) Reset button
Deletes an error and restores settings.
(5) Ready button with LED
Change between programming and sewing mode. LED on = sewing mode LED off = programming mode
(6) Error LED
LED on = error
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Button / LED Pos. Function
(7) Program display
Displays parameters.
(8) +/- Program buttons
Changes parameters and navigates forwards/backwards.
(9) Function display
Displays values of selected functions/programmes.
(10) +/- Function buttons
Changes values of functions/programmes.
(11) Selection button
Selects various functions. The corresponding function LED illuminates.
(12) Sewing pattern memory buttons
Saves sewing patterns.

11.2 Switching on the sewing machine

1. Set main switch to ON.
The sewing pattern last sewn is loaded and the sewing pattern num-
ber is shown in the Program display.

11.3 Reference the machine

1. Press the Ready button.
The LED in the button illuminates.
2. Press the Ready button.
The LED in the button switches off.
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11.4 Selecting a sewing pattern

NOTICE
Property damage may occur!
Damage to the needle if the sewing pattern size does not match the clamping foot.
Check the clamping foot, adjust if necessary.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the +/- Function buttons until the desired sewing pattern number appears in the Function display.

11.5 Scaling axes

Important
Changes to the axes are only valid temporarily. For permanent changes and the ability to move the sewing pattern, see chapter storing sewing pat­terns (S. 43).

11.5.1 Scaling the X-axis

1. Press the Selection button until the X-axis LED illuminates.
2. Press the +/- Function buttons until the value for the X-axis is reached. 100 % corresponds to the specified dimensions for the selected sewing pattern.

11.5.2 Scaling the Y-axis

1. Press the Selection button until the Y-axis LED illuminates.
2. Press the +/- Function buttons until the value for the Y-axis is reached. 100 % corresponds to the specified dimensions for the selected sewing pattern.
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11.5.3 Converting the buttonhole gap (class 532)

The buttonhole gap is preset to 3.4 mm (3.4 mm = 100 %). The buttonhole gap can be adjusted by changing the percentage value.
Buttonhole gap [mm]
1 29 2,9 85 4,8 141 1,1 32 3 88 4,9 144 1,2 35 3,1 91 5 147 1,3 38 3,2 94 5,1 150 1,4 41 3,3 97 5,2 153 1,5 44 3,4 100 5,3 156 1,6 47 3,5 103 5,4 159 1,7 50 3,6 106 5,5 162 1,8 53 3,7 109 5,6 165 1,9 56 3,8 112 5,7 168
2 59 3,9 115 5,8 171 2,1 62 4 118 5,9 174 2,2 65 4,1 121 6 176 2,3 68 4,2 124 6,1 179
Value [%]
Buttonhole gap [mm]
Value [%]
Buttonhole gap [mm]
Value [%]
2,4 71 4,3 126 6,2 182 2,5 74 4,4 129 6,3 185 2,6 76 4,5 132 6,4 188 2,7 79 4,6 135 6,5 191 2,8 82 4,7 138

11.5.4 Converting the backtack dimensions (class 512)

To convert the preset dimensions to the desired dimensions, apply the fol­lowing formula:
Value to be set = (100 % : preset dimension) * desired value
Example
Preset dimension in X-direction = 16 mm Desired value in X-direction = 10 mm
Value to be set = (100 % :
16 mm) * 10 mm = 62.5 %
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1 1.6 Setting the speed

Important
Changes to the speed are only valid temporarily. For permanent changes see chapter storing sewing patterns (S. 43).
1. Press the Selection button until the Speed LED illuminates.
2. Press the +/- Function buttons until the desired speed is reached.

11.7 Checking the sewing pattern

1. Press the Selection button until the Sewing pattern shape LED illu­minates.
The Program display shows the current sewing pattern shape.
2. Press the Ready button to confirm the sewing pattern.
The LED in the Ready button illuminates.
3. Press the foot pedal forwards.
The clamp is lowered.
4. Press the +/- Function buttons to sew 1 stitch each.
The Function display shows the current number of stitches.
5. Press the Reset button.
The clamp is raised.
6. Press the Selection button until the Sewing pattern shape LED illu­minates.

11.8 Changing the sewing pattern

1. Press the Selection button until the No. Pattern LED illuminates.
2. Press the +/- Function buttons until the desired sewing pattern number appears in the Function display.
3. Press the Ready button.
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11.9 Winding

Prerequisite:
• Needle removed.
• Needle thread not threaded.
1. Press the Ready button.
The LED in the button illuminates.
2. Press the Ready button.
The LED in the button switches off.
3. Press the Selection button until the Wind LED illuminates.
4. Press the Ready button.
The LED in the button illuminates, the clamp is lowered.
5. Press the pedal forwards.
Winding starts.
6. To stop winding, briefly press the pedal completely forwards.
7. Press the Ready button.
The LED in the button switches off, the clamp is raised.

1 1 .10Sewing

Prerequisite:
• The machine is in the sewing mode, the LED in the Ready button is illu-
minated.
• Needle fitted.
• Needle thread threaded.
• Sewing pattern selected.
1. Insert the material.
2. Press the foot pedal forwards to the first position.
The clamp is lowered.
If the pedal is released, the clamp is raised.
3. Briefly press the foot pedal completely forwards.
The sewing process starts. At the end of sewing the clamp is auto-
matically raised.
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Settings via software

11.11Counter

The counter can be used as a unit counter (parame ter number U020) or as an automatic stop counter (parameter number U076).
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the Selection button until the Counter LED illuminates.
2. Press the Reset button to set the counter to 0.
3. Press the +/- Function buttons to set the cycle count. Each sewing end decrements the counter by 1. After reaching the number of cycles, a message appears in the display.
4. Insert a new bobbin.
5. Press the Reset button.
The counter is reset.

11.12Interrupting sewing

1. Press the Reset button or press the pedal back.
The sewing process is interrupted; the display shows error message
E-50.
2. To continue sewing, press the Reset button or press the pedal for­wards.

11.13Protecting standard sewing patterns

Standard sewing patterns can be protected so that they are no longer dis­played.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the Memory and P1 buttons in quick succession.
The Program display shows the sewing pattern number; the Func-
tion display shows 0 or 1:
0 = sewing pattern is displayed. 1 = sewing pattern is protected.
2. Press the +/- Program buttons to select another sewing pattern.
3. Press the Ready button to confirm the sewing pattern.
4. Press the +/- Function buttons to change between 0 and 1.
5. Press the Ready button to confirm the value.
6. Press the Memory button.
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11.14Storing sewing patterns

Standard sewing patterns can be stored on the sewing pattern memory buttons P1 to P5; 50 memory slots are available for this. The memory slots are accessed using the +/- Function buttons; memory slots up to 25 can also be accessed using the sewing pattern memory but­tons and combinations thereof.
Shortcuts for sewing pattern memory buttons
Memory slot no. Shortcut
P1 P1 P8 P1 + P4 P15 P4 + P5 P22 P2 + P3 + P4 P2 P2 P9 P1 + P5 P16 P1 + P2 + P3 P23 P2 + P3 + P5 P3 P3 P10 P2 + P3 P17 P1 + P2 + P4 P24 P2 + P4 + P5 P4 P4 P11 P2 + P4 P18 P1 + P2 + P5 P25 P3 + P4 + P5 P5 P5 P12 P2 + P5 P19 P1 + P3 + P4 P6 P1 + P2 P13 P3 + P4 P20 P1 + P3 + P5 P7 P1 + P3 P14 P3 + P5 P21 P1 + P4 + P5
Memory slot no. Shortcut
Memory slot no.
Shortcut
Memory slot no.
Shortcut

11.14.1Mapping memory buttons

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the Memory and P2 buttons simultaneously.
2. Press the +/- Program buttons to select a memory slot.
3. Press the Ready button to confirm the memory slot.
4. Select the sewing pattern (S. 38).
5. Scale the axes (S. 38).
6. Set the speed (S. 40).
7. Moving the position of the sewing pattern:
• Press the Selection button until the X-axis LED flashes.
• Press the +/- Function button and set the values: -5/+5.
• Press the Selection button until the Y-axis LED flashes.
• Press the +/- Function button and set the values: -4 /+4.
8. Press the Ready button to confirm the settings.
9. Press the Memory button to quit the memory mode.
10. Check the sewing pattern (S. 40).
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11.14.2Sewing with memory buttons

1. Press the sewing pattern memory button/button combination.
2. Press the Ready button.
3. Check the sewing pattern.
4. Sew.

11.14.3Deleting the memory button assignments

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the Memory and P2 buttons simultaneously.
2. Press the +/- Program buttons to select a memory slot.
3. Press the Ready button to confirm the memory slot.
4. Press the Reset button to delete the memory assignment.
5. Press the Ready button to confirm the deletion.
6. Press the Memory button to quit the memory mode.

1 1.15Storing sewing pattern sequences

Besides the sewing patterns in memory slots P1 ~ P50, the automatic se­wing machine also lets you use memory slots C01 ~ C25.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the Memory and P3 buttons simultaneously.
2. Press the +/- Program buttons to select a memory slot (C01 ~ C25).
3. Press the Ready button to save the sewing pattern sequence.
4. Press the +/- Function buttons to select the 1st sewing pattern.
5. Press the +/- Program buttons to select the 2nd sewing pattern.
6. Press the +/- Function buttons to select the 3rd sewing pattern.
7. Press the +/- Program buttons to select the 4th sewing pattern, etc.
8. Press the Ready button to confirm the sewing pattern sequence.
The Program display shows the memory slot; the Function display
shows the number of sewing patterns.
9. Press the Memory button to quit the memory mode.
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11.16Processing sewing pattern sequences

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the +/- Function buttons to select a sewing pattern sequence.
2. Press the Ready button to confirm the sewing pattern sequence.
The Program display shows the sewing pattern sequence, e.g.
<1.1>; The Function display shows the sewing pattern number.
3. Briefly press the pedal completely forwards.
The sewing pattern is sewn. After completing sewing, the Program
display shows the further sewing pattern sequence, e.g. <1.2>; the Function display shows the next sewing pattern number, etc.
4. To change between sewing patterns in a sequence, press the +/- Program buttons and select the sewing pattern.

11.17Deleting sewing pattern sequences

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press the Memory and P3 buttons simultaneously.
2. Press the +/- Program buttons to select a sewing pattern sequence (C01 ~ C25).
3. Press the Ready button to confirm the sewing pattern sequence.
4. Press the Reset button to delete the sewing pattern sequence.
5. Press the Ready button to confirm the deletion.
6. Press the Memory button to quit the memory mode.
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11.18Stopping sewing

VORSICHT
Risk of injury from sharp and moving parts!
Puncture or crushing possible. Do not place your hand below the raised clamp.
1. Press the Ready button.
The LED in the button illuminates. The control unit is in the sewing
mode.
2. Set main switch to OFF.
Note If the automatic sewing machine is switched off without pressing the Rea-
dy button, any modified values will not be saved.

11.19Editing parameters in the memory

11.19.1Editing parameters in level M1

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 3 seconds.
The controller beeps 1x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the parameter values.
2. Press the +/- Program buttons to select other parameters.
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates.
4. Press the +/- Function buttons to change values.
5. Press the Reset button to reset a changed value.
6. Press the Ready button to save a change.
The LED in the button switches off.
7. Press the Memory button.
The LED in the button switches off.
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11.19.2Editing parameters in level M2

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the values.
2. Press the +/- Program buttons to select other parameters.
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates.
4. Press the +/- Function buttons to change values.
5. Press the Reset button to reset a changed value.
6. Press the Ready button to save a change.
The LED in the button switches off.
7. Press the Memory button.
The LED in the button switches off.

11.20Resetting parameters to factory settings

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The LED in the button illuminates.
2. Select parameter number U098 by using the +/- Program buttons.
3. Press the Ready button.
4. Enter the function value 1 by using the +/- Function buttons.
5. Press the Selection button.
The controller beeps 1x. If the controller beeps 3x, the reset was
unsuccessful.
6. Set parameter U085 for class 532.
Setting parameter U085 (class 532)
After resetting the parameters to the factory setting, parameter U085 must be set for the button sewing machine.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
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1. Press and hold the Memory button for 6 seconds.
The LED in the button illuminates.
2. Select parameter number U085 by using the +/- Program buttons.
3. Press the Ready button.
4. Enter the function value 1 by using the +/- Function buttons.
Press the Selection button.

11.21Editing sewing patterns externally

NOTICE
Property damage may occur!
Damage to the clamp if the sewing field size does not match the clamping feet.
Check the clamping foot, adjust if necessary.
Sewing patterns can be created and edited externally on a PC, e.g. using MS Excel or a text editor.
Each row represents a stitch coordinate in an X and Y-direction. The ma­ximum size of a sewing pattern is 400 x 300 x 1/10 mm.
Negative values or comma separated values should not be entered. The operator does not have to perform any calculations to center the se-
wing pattern. The machine automatically centers the sewing pattern in the middle of the sewing field. To subsequently move the sewing pattern, see chapter storing sewing patterns (S. 43).
Fig. 28: Example of stitch coordinates in MS Excel or a text editor
(1) - Starting point/first stitch (2) - End point/last stitch
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Fig. 29: Example of a sewing pattern
(1) - Starting point/first stitch (2) - End point/last stitch
1. Enter the stitch coordinates in MS Excel or a text editor. The coordinates are accurate to a precision of 0.1 mm and are sepa­rated by a comma.
Important
In the text editor, the last row of coordinates must be terminated with a break so that the cursor is positioned in the next free row.
2. Saving a file:
• File name: HSR2000 ~ HSR2099
• File format: .CSV
3. Save the file to a USB stick.
Information
It is also possible to create sewing patterns with DA-CAD 5000 and sa ve them as a CSV file.

1 1.22Working with a USB stick

Up to 10 of your own sewing patterns can be saved to the controller via aUSB stick.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Insert the USB stick into the USB port on the controller.
The controller beeps briefly.
2. Press the USB button.
3. The LED in the button illuminates; the Program display shows para­meter number U01.
4. Press the +/- Program buttons and select a memory slot (U01 ~ U10).
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Settings via software
5. Press the Ready button.
The Function display shows values 1 to 4:
• 1: Load a sewing pattern from a USB stick.
• 2: Load a sewing pattern onto a USB stick.
• 3: Delete a sewing pattern on the controller.
• 4: Edit a sewing pattern.
Saving a sewing pattern from a USB stick onto the controller: Value 1
1. Press the +/- Function buttons to set value 1.
2. Press the Selection button and select the sewing pattern file (HSR2000.csv ~ HSR2099.csv).
3. Press the Selection button to load a sewing pattern from the USB stick.
The Function display shows the value ok; the controller beeps,
the sewing pattern is saved.
4. Press the Reset button 2x.
Saving a sewing pattern from the controller to the USB stick: Value 2
1. Press the +/- Function buttons to set value 2.
2. Press the Selection button to save the sewing pattern to the USB stick (HSW2001.scv = U01 ~ HSW2010.scv = U10).
3. Press the Selection button to confirm you want to save it.
The Function display shows the value ok; the controller beeps,
the sewing pattern is saved.
4. Press the Reset button 2x.
Deleting a sewing pattern on the controller: Value 3
1. Press the +/- Function buttons to set value 3.
2. Press the Selection button.
3. Press the Reset button to confirm the deletion.
The Function display shows "----".
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Editing a sewing pattern / contour test: Value 4
Fig. 30: Editing a sewing pattern
1. Press the +/- Function buttons to set value 4.
2. Press the Selection button.
The Program display shows a 1 for the first stitch; the Function dis-
play shows the value for the X-axis; the X-axis LED illuminates.
3. Press the +/- Function buttons to set the coordinates of the 1st stitch for the X-axis.
4. Press the Selection button.
The Y-axis LED illuminates; the Function display shows the value
for the Y-axis.
5. Press the +/- Function buttons to set the coordinates of the 1st stitch for the Y-axis.
6. Press the +/- Program buttons to select the next stitch.
7. Repeat steps 3 to 5 for all additional stitches.
8. Press the Ready button to save the edited sewing pattern.
9. Press the Reset button.
The LED in the button switches off.
10. Press the USB button.
The LED in the button switches off.

11.23Error messages

If an error occurs, the Error LED illuminates.
Error Description Possible cause Remedy
E 8 Error table data Unable to read the table
data
E 1 0 Error sewing
pattern number
The selected sewing pat­tern is not saved in ROM or is set to non-readable. The sewing pattern is "0"
Save the table data again.
Press the Reset button to confirm the sewing pat­tern number.
E 3 0 Error needle
bar position top
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The needle bar is not at the top position
Check the connections. Turn the needle bar to the top dead center posi­tion.
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Settings via software
Error Description Possible cause Remedy
E 4 0 Error sewing
field
E 4 2 Error scaling Sewing length is beyond
E 4 5 Error sewing
pattern data
E 5 0 Pause Reset button pressed while
E 3 0 2 Error machine
head
E 3 0 5 Error thread
trimmer position
E 3 0 6 Error thread
catcher position
E 3 3 2 Error clamp foot
position
E 5 0 1 Data read error Data not available or saved
Sewing field exceeded Press the Reset button.
10 mm
Sewing pattern data cannot be applied
sewing. Sewing machine stopped.
Machine head has moved. F old back machine head.
Thread trimmer blade not at home position
Thread catcher not at home position
Clamp foot not at home position
in the wrong format
Check X/Y scaling. Press the Reset button.
Check sewing pattern and X/Y scaling.
Press the Reset button. Check ROM.
Press the Reset button. Actuate the thread trim­mer. Restart the sewing pro­cess.
Set main switch to OFF. Check sensor.
Set main switch to OFF. Check sensor.
Set main switch to OFF. Check sensor.
Save the data to a USB stick again.
E 5 0 2 USB read error MOT file error Save the data to a USB
stick again.
E 5 0 3 SUM read error CHECKSUM data error in
MOT file
E 5 0 4 End block error No end block in the MOT
file
E 5 0 5 USB read error USB stick not found Set main switch to OFF.
E 5 0 6 USB read error Unable to read U01 ~ U10. Set ma in switch to OFF.
E 5 0 7 Read error own
sewing patterns
E 5 0 8 File error own
sewing patterns
E 5 0 9 File error own
sewing patterns
E 5 1 0 File error own
sewing patterns
U01 ~ U10 read error Download the data again.
U01 ~ U10 read error Check file type.
U01 ~ U10 read error Check file type.
U01 ~ U10 read error Check file type.
Save the CHECKSUM file to a USB stick again.
Save the end block file to a USB stick again.
Set main switch to ON. Reinsert USB stick.
Set main switch to ON. Reinsert USB stick.
Save data to USB again.
E 5 1 1 USB write error File with the same name
already exists
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Delete or rename file.
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Settings via software
Error Description Possible cause Remedy
E 5 1 2 USB read error Data cannot be loaded
from USB stick
E 5 1 3 USB write error Data cannot be copied to
USB stick.
E 5 5 0 Data write error Flash memory transfer
error
E 5 5 1 Internal process
error
E770375Motor signal
error
E 7 3 6 Motor rotation
error
E 7 3 7 Error Z phase Z signal no long er changes Check motor / encoder. E 7 3 8 Error Z phase Z signal inaccurate /
E 9 0 7 Error search X-
axis
Software error Set main switch to OFF.
Encoder / motor has no signal
Motor stops after some time / encoder has no sig­nal
encoder has no signal X-axis sensor does not res-
pond
Check USB stick. Reinsert USB stick.
Check USB stick. Reinsert USB stick.
Set main switch to OFF. Repeat process. Replace the mainboard.
Repeat process. Replace the mainboard. Update software.
Check motor / encoder.
Check motor / encoder.
Check motor / encoder.
Set main switch to OFF. Check sensor.
E 9 0 8 Error search Y-
axis
E 9 1 0 Error clamp foot
search
E 9 1 1 Error clamp foot
motor
E 9 1 2 Internal error - Notify DA Service E 9 1 3 Error thread
catcher search
E 9 1 4 Error thread
catcher motor
Y-axis sensor does not res­pond
Clamp foot sensor does not respond
Clamp foot motor does not operate correctly
Thread catcher sensor does not respond
Thread catcher motor does not operate correctly
Set main switch to OFF. Check sensor.
Set main switch to OFF. Check sensor.
Set main switch to OFF. Check motor and connection.
Set main switch to OFF. Check sensor.
Set main switch to OFF. Check motor and connection.
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Settings via software

11.24Loading software via a USB stick

NOTICE
Property damage may occur!
Damage to the machine as a result of interrupting the copying process.
Never remove the USB stick during the copying process. Only remove the USB stick after observing the specified time period.
If a new version of the software becomes available, it can be downloaded from www.duerkopp-adler.com and loaded onto a USB stick.
Important
The following files must be saved to the USB stick:
• FUYSTS.BT
• LEEYSTS.BT1
• BT1mot
• BT1PAT

11.24.1Loading the main program

1. Switch on the controller.
2. Insert the USB stick.
3. Press the USB button and wait approx. 3 seconds.
4. Press the Memory button.
5. Press the +/- Function buttons to set value 5 in the Function display.
6. Press the Selection button.
The process for downloading to the controller starts.
Important
If a value is no longer shown in the Function display, the download pro­cess is complete. Now wait at least 25 seconds, otherwise it could corrupt the controller!
7. Switch off the controller.
8. Remove the USB stick.

11.24.2Loading sewing patterns

1. Switch on the controller.
The current software version is briefly displayed.
2. Insert the USB stick.
3. Press the USB button and wait approx. 3 seconds.
4. Press the Memory button.
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Settings via software
5. Press the P5 button.
The process for downloading to the controller starts. This will take
approx. 4 minutes.
6. Press the Reset button.
7. Remove the USB stick.
The software transfer is complete.

11.24.3Setting parameter U085 (class 532)

After installing new software, parameter U085 must be set for the button sewing machine.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The LED in the button illuminates.
2. Select parameter number U085 by using the +/- Program buttons.
3. Press the Ready button.
4. Enter the function value 1 by using the +/- Function buttons.
5. Press the Selection button.

11.24.4Checking the software version

1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
2. Press the +/- Program buttons and select parameter U097.
3. Press the Ready button.
The current software versions are displayed:
• M X.XX = Main program
• P X.XX = Control panel
• T X.XX = Servo motors
• A X.XX = Sewing patterns
4. Press the +/- Function buttons and check the respective software ver­sion.
5. Press the Ready button.
6. Press the Memory button.
The LED in the button switches off.
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Service settings via software
⑦⑧

12 Service settings via software

This chapter describes service settings such as
The basic configuration of the machine
Test functions for individual elements of the machine
Calibration functions
Presets for programs and functions
Information regarding changes to the stitch length, thread tension, curve support, etc. as well as instructions for accessing and creating sewing programs can be found in the operating manual (Operating manual, Section 5 Settings via software).

12.1 Basic software operation

The software is controlled via the control panel.
Fig. 31: Control panel
Control panel buttons:
Button / LED Pos. Function
(1) USB button with LED
Saves/loads a sewing pattern to/from a USB stick.
(2) Needle thread clamp button with LED
Fixes needle thread during the first stitch. LED on = needle thread clamp on LED off = needle thread clamp off
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Service settings via software
Button / LED Pos. Function
(3) Memory button
Processes the memory functions.
(4) Reset button
Deletes an error and restores settings.
(5) Ready button with LED
Change between programming and sewing mode. LED on = sewing mode LED off = programming mode
(6) Error LED
LED on = error
(7) Program display
Displays parameters.
(8) +/- Program buttons
Changes parameters and navigates forwards/backwards.
(9) Function display
Displays values of selected functions/programmes.
(10) +/- Function buttons
Changes values of functions/programmes.
(11) Selection button
Selects various functions. The corresponding function LED illuminates.
(12) Sewing pattern memory buttons
Saves sewing patterns.

12.2 Accessing the technician level

All of the settings in the service area are performed at the technician level.

12.2.1 Editing parameters in level 1

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 3 seconds.
The controller beeps 1x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the parameter values.
2. Press the +/- Program buttons to select other parameters.
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Service settings via software
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates.
4. Press the +/- Function buttons to change values.
5. Press the Reset button to reset a changed value.
6. Press the Ready button to save a change.
The LED in the button switches off.
7. Press the Memory button.
The LED in the button switches off.

12.2.2 Editing parameters in level 2

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the values.
2. Press the +/- Program buttons to select other parameters.
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates.
4. Press the +/- Function buttons to change values.
5. Press the Reset button to reset a changed value.
6. Press the Ready button to save a change.
The LED in the button switches off.
7. Press the Memory button.
The LED in the button switches off.

12.3 Setting the blade position

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the values.
2. Press the +/- Program buttons and select parameter U099.
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A
B
C
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates. The Program display shows
"°°20".
4. Press button P1.
The thread trimmer sensor disk travels to position.
Fig. 32: Setting the blade position
5. Check to see if the hole of the thread puller blade and the needle g uide of the throat plate are aligned:
Fig. 33: Checking the hole of the thread puller blade
Case A: The setting is wrong; the thread puller blade overlaps the
counter blade: Adjust blade sensor upwards.
Case B: The setting is wrong; the thread puller blade overlaps the
needle guide: Adjust blade sensor downwards.
Case C: The setting is correct.
6. Press button P1.
The thread trimmer sensor disk travels to position again.
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Service settings via software
7. Check once again to see if the hole of the thread puller blade and the needle guide of the throat plate are accurately aligned.
8. Press the Ready button to save the change.
The LED in the button switches off.
9. Press the Memory button.
The LED in the button switches off.
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Service settings via software

12.4 Loading software via a USB stick

NOTICE
Property damage may occur!
Damage to the machine as a result of interrupting the copying process.
Never remove the USB stick during the copying process. Only remove the USB stick after observing the specified time period.
If a new version of the software becomes available, it can be downloaded from www.duerkopp-adler.com and loaded onto a USB stick.
Important
The following files must be saved to the USB stick:
• FUYSTS.BT
• LEEYSTS.BT1
• BT1mot
• BT1PAT

12.4.1 Loading the main program

1. Switch on the controller.
2. Insert the USB stick.
3. Press the USB button and wait approx. 3 seconds.
4. Press the Memory button.
5. Press the +/- Function buttons to set value 5 in the Function display.
6. Press the Selection button.
The process for downloading to the controller starts.
Important
If a value is no longer shown in the Function display, the download pro­cess is complete. Now wait at least 25 seconds, otherwise it could corrupt the controller!
7. Switch off the controller.
8. Remove the USB stick.

12.4.2 Loading sewing patterns

1. Switch on the controller.
The current software version is briefly displayed.
2. Insert the USB stick.
3. Press the USB button and wait approx. 3 seconds.
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Service settings via software
4. Press the Memory button.
5. Press the P5 button.
The process for downloading to the controller starts. This will take
approx. 4 minutes.
6. Press the Reset button.
7. Remove the USB stick.
The software transfer is complete.

12.4.3 Setting parameter U085 (class 532)

After installing new software, parameter U085 must be set for the button sewing machine.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The LED in the button illuminates.
2. Select parameter number U085 by using the +/- Program buttons.
3. Press the Ready button.
4. Enter the function value 1 by using the +/- Function buttons.
5. Press the Selection button.

12.4.4 Checking the software version

1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
2. Press the +/- Program buttons and select parameter U097.
3. Press the Ready button.
The current software versions are displayed:
• M X.XX = Main program
• P X.XX = Control panel
• T X.XX = Servo motors
• A X.XX = Sewing patterns
4. Press the +/- Function buttons and check the respective software ver­sion.
5. Press the Ready button.
6. Press the Memory button.
The LED in the button switches off.
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Maintenance

13 Maintenance

This chapter describes maintenance work that needs to be carried out on a regular basis to extend the service life of the machine and achieve the desired seam quality.
Work to be carried out Operating hours
8 40 160 1000
Removing lint and thread remnants Clearing the fan screen at the control box Refilling oil Lubricating the sewing automat

13.1 Cleaning

WARNING
Risk of injury from flying particles!
Flying particles can enter eyes, causing injury. Wear safety goggles.
Hold the compressed air gun so that the particles do not fly close to people. Make sure no particles fly into the oil sump.
Lint and thread remnants should be removed after every 8 hours of ope­ration using a compressed air gun or a brush. When sewing very fluffy ma­terial, the machine should be cleaned more frequently.
A clean sewing machine provides protection from faults.
Points that need to be cleaned particularly thoroughly:
• Area under the throat plate (1)
• Area around the hook (2)
• Bobbin housing and interior
• Thread cutter
• Area around the needle
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Fig. 34: Cleaning and checking
(1) - Underside of throat plate (2) - Hook
Maintenance

13.2 Lubrication

WARNING
Risk of injuries due to contact with oil!
Contact with oil can cause irritation, rashes, allergies or skin injuries.
ALWAYS avoid long-term contact with oil. ALWAYS thoroughly wash the affected areas if
contact with oil occurs.
CAUTION
Risk of environmental damage from old oil!
Incorrect handling of old oil can result in severe environmental damage.
ALWAYS observe the legally prescribed regulations for handling and disposal of mineral oil.
Take care to ensure that oil is NEVER spilled.
For lubricating the sewing automat, use only lubrication oil DA-10 or oil of equivalent quality with the following specifications:
• Viscosity at 40°C: 10 mm²/s
• Flash point: 150° C
DA-10 can be obtained from DÜRKOPP ADLER AG sales offices using
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Maintenance
the following part number:
• 250 ml container: 9047 000011
• 1 liter container: 9047 000012
• 2 liter container: 9047 000013
• 5 liter container: 9047 000014
The special grease for lubricating the machine components is provided in the accessory pack. It can also be obtained from DÜRKOPP ADLER AG sales offices using the following part number:
• 9047 098004

13.2.1 Checking the oil level

Checking the oil leven of the hook
The sewing automat is equipped with a oil-wick lubrication system. The hook is supplied from the oil reservoir (1).
Fig. 35: Refilling oil
(1) - Oil reservoir (2) - Oil filler opening
The oil level in the oil reservoir (1) must not drop below the lower red mar­king or be above the upper red marking.
1. Fill oil through the oil filler opening (2) up to the upper red marking.
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Maintenance
Checking the oil level of the gear
Fig. 36: Refilling oil
(3) - Oil filler opening (4) - Screw
1. Unscrew the screw (4) from the oil filler opening at the back of the machine.
2. Fill oil through the oil filler opening (3).
For lubricating the gear maximum 110 ml are necessary.
Fig. 37: Refilling oil
(5) - Oil gauge glass
When oil splashes at the oil gauge glass during operation enough oil
is filled in.
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Maintenance

13.2.2 Lubricating with grease

Allowing the machine to operate at peak efficiency requires that its moving parts be lubricated sufficiently.
Lubrication points on the rear of the machine
Abb. 38: Lubrication (1)
(1) - Cam disk (2) - Fleece
1. Apply an adequate amount of grease to the fleece (2) to lubrica te the outer side of the cam disk (1).
2. Apply a small amount of grease to the joints (3) to ensure they remain flexible.
Abb. 39: Lubrication (2)
(4) - Roller (5) - Guide groove
(3) - Joints
(6) - Joints
3. Apply a small amount of grease to the inner guide groove (5) and the roller (4) from the outside.
4. Apply a small amount of grease to the joints (6).
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Lubrication points on the machine head
Abb. 40: Lubrication (3)
Maintenance
(7) - Thread lever guide (8) - Groove
1. Apply grease to cross head backside (9) and the connectors (10).
2. Lubricate the groove (8).
3. Lubricate the thread lever guide (7).
(9) - Cross head backside (10) - Connectors
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Maintenance

13.3 Adjusting the lubrication for the hook

Abb. 41: Adjusting the lubrication for the hook
(1) - Screw
Adjusting steps
1. Loosen and remove the screw (1).
The lubricating screw is located underneath the screw. The lubrica-
ting screw presses against the oil wick of the hook lubricator.
2. Adjusting the lubricating screw:
Loosening the screw: Increases lubrication for the hook
Tightening the screw: Reduces lubrication for the hook
3. Insert and tighten the screw (1).
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Appendix

14 Appendix

14.1 Software error messages

The remedial measures are to be processed in the order specified.
Error Meaning Possible cause
E 8 Error table data Unable to read the table
data
E 1 0 Error sewing pattern
number
E 3 0 Error needle bar
position top
E 4 0 Error sewing field Sewing field exceeded • Press the Reset button.
E 4 2 Error scaling Sewing length is below
E 4 5 Error sewing pattern
data
E 5 0 Pause Reset button pressed while
E 3 0 2 Error machine he ad Machine head has moved. • Fold back machine head.
The selected sewing pat­tern is not saved in ROM or is set to non-readable. The sewing pattern is "0"
The needle bar is not at the top position
10 mm Sewing pattern data cannot
be applied
sewing. Sewing machine stopped.
Remedial measures Process in the order specified!
• Save the table data again.
• Press the Reset button to confirm the sewing pattern number.
• Check the connections.
• Turn the needle bar to the top dead center position.
• Check X/Y scaling.
• Press the Reset button.
• Check sewing pattern and X/Y scaling.
• Press the Reset button.
• Check ROM.
• Press the Reset button.
• Actuate the thread trimmer.
• Restart the sewing process.
E 3 0 5 Error thread trimmer
position
E 3 0 6 Error thread catcher
position
E 3 3 2 Error clamp foot
position
E 5 0 1 Data read error Data not available or in the
E 5 0 2 USB read error MOT file error • Save the data to a USB stick again. E 5 0 3 SUM read error CHECKSUM data error in
E 5 0 4 End bloc k error No end block in the MOT
E 5 0 5 USB read error USB stick not found • Set main switch to OFF.
E 5 0 6 USB read error Unable to read U01 ~ U10. • Set main switch to OFF.
Thread trimmer blade not at home position
Thread catcher not at home position
Clamp foot not at home position
wrong format
MOT file
file
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Save the data to a USB stick again.
• Save the CHECKSUM file to a USB stick again.
• Save the end block file to a USB stick again.
• Set main switch to ON.
• Reinsert USB stick.
• Set main switch to ON.
• Reinsert USB stick.
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Appendix
Error Meaning Possible cause
E 5 0 7 Read error own
sewing patterns
E 5 0 8 File error own
sewing patterns
E 5 0 9 File error own
sewing patterns
E 5 1 0 File error own
sewing patterns
E 5 1 1 USB write error File with the same name
E 5 1 2 USB read error Data cannot be loaded
E 5 1 3 USB write error Data cann o t be copied to
E 5 5 0 Data write error Flash memory transfer
E 5 5 1 Internal process
error
U01 ~ U10 read error • Download the data again.
U01 ~ U10 read error • Check file type.
U01 ~ U10 read error • Check file type.
U01 ~ U10 read error • Check file type.
already exists
from USB stick
USB stick.
error
Softwar error • Set main switch to OFF.
Remedial measures Process in the order specified!
• Save data to USB again.
• Delete or rename file.
• Check USB stick.
• Reinsert USB stick.
• Check USB stick.
• Reinsert USB stick.
• Set main switch to OFF.
• Repeat process.
• Replace the mainboard.
• Repeat process.
• Replace the mainboard.
• Update software.
E770375Motor signal error Encoder / motor has no sig-
nal
E 7 3 6 Motor rotation error Motor stops / encoder has
no signal E 7 3 7 Error Z phase Z signal no longer changes • Check motor / encoder. E 7 3 8 Error Z phase Z signal inaccurate /
encoder has no signal E 9 0 7 Error search X-axis X-axis sensor does not res-
pond E 9 0 8 Error search Y-axis Y-axis sensor does not res-
pond E 9 1 0 Error clamp foot
search
E 9 1 1 Error clamp foot
motor E 9 1 2 Internal error - • Notify DA Service E 9 1 3 Error thread catcher
search E 9 1 4 Error thread catcher
motor
Clamp foot sensor does not respond
Clamp foot motor does not operate corrrectly
Thread catcher sensor does not respond
Thread catcher motor does not operate corrrectly
• Check motor / encoder.
• Check motor / encoder.
• Check motor / encoder.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check motor and connection.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check motor and connection.
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Appendix

14.2 Circuit diagram

Circuit diagram - Sheet 1
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Circuit diagram - Sheet 2
Appendix
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Appendix
Circuit diagram - Sheet 3
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Circuit diagram - Sheet 4
Appendix
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Appendix
Circuit diagram - Sheet 5
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Appendix
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DÜRKOPP ADLER AG
Potsdamer Straße 190 33719 Bielefeld GERMANY Phone +49 (0) 521 / 925-00 E-mail service@duerkopp-adler.com www.duerkopp-adler.com
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Service Instructions - 0791 512641 EN - 00.0 - 06/2016
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