DURKOPP ADLER 650-16 Operating Instructions Manual
650-16
Operating Instructions
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE
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Property of Dürkopp Adler AG and protected by copyrig
of these contents, including extracts, is prohibited without the prior
written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG 2016
ht. Any reuse
Table of Contents
1 About these instructions.................................. ..................................5
1.1 For whom are these instructions intended? ..........................................5
1.2 Representation conventions – symbols and characters........................5
1.3 Other documents............ ..................................... ..................................7
1.4 Liability ..................................................................................................7
2 Safety....................................................................................................9
2.1 Basic safety instructions........................................................................9
2.2 Signal words and symbols used in warnings.......................................10
3 Machine description..........................................................................15
3.1 Overview of machine components ......................................................15
3.2 Declaration of Confor mi ty....................................................................16
3.3 Proper use............................................... ..................................... .......16
4 Operation ...........................................................................................19
4.1 Preparing the machine for operation...................................................19
4.2 Switching on and off the machine .......................................................19
4.3 Changing the needle ...........................................................................20
4.4 Threading the needle thread....................................... ........................23
4.5 Winding the hook thread .....................................................................25
4.6 Replacing the hook thread bobbin.......................................................26
4.7 Thread tension .................. ... .................................... ... ........................27
4.7.1 Setting the needle thread tension........................................................28
4.7.2 Setting the hook thread tension...........................................................29
4.8 Setting the needle thread regulator.....................................................31
4.9 Raising the presser feet ......................................................................32
4.10 Knee switch.........................................................................................34
4.11 Sewing.................................................................................................34
5 Control with the OP3000 control panel ...........................................37
5.1 OP3000 control panel..........................................................................37
5.2 Switching on the machine ...................................................................38
5.3 Control operating modes.....................................................................39
5.4 Manual mode.......................................................................................40
5.4.1 Quick access function (softkey menu).................................................42
5.4.2 Menu for other settings........................................................................43
5.4.3 Sewing process...................................................................................44
5.5 Automatic mode ..................................................................................45
5.5.1 Before starting sewing......................................................................... 46
5.5.2 Sewing.................................................................................................47
5.5.3 Canceling the program........................................................................49
5.6 Quick programming.............................................................................49
5.6.1 Creating a program by keyboard input................................................52
Operating Instructions 650-16 - 02.0 - 08/2016 1
Table of Contents
5.6.2 Creating a program by sewing the seam (Teach-In)...........................53
5.7 Edit mode............................................................................................54
5.7.1 Changing further parameters for the current step ...............................55
5.7.2 Changing further parameters for the selected program ......................56
5.8 Programming mode.............................................................................58
5.8.1 Creating a program .............................................................................58
5.8.2 Copying the program............... .. ... ..................................... .. ... .............60
5.8.3 Deleting a program............ .................................... ... ...........................61
5.8.4 Mirroring the program ..........................................................................62
6 Control with the OP7000 control panel ...........................................63
6.1 OP7000 control panel..........................................................................63
6.2 Switching on the machine ...................................................................64
6.3 Control operating modes.....................................................................64
6.4 General operation................................................................................65
6.4.1 Inputting numeric values.....................................................................65
6.4.2 Entering text........................................................................................67
6.5 Manual mode MAN..............................................................................69
6.5.1 Parameters that can be set in MAN mode ..........................................70
6.5.2 Sewing process...................................................................................73
6.6 Automatic mode AUTO .......................................................................74
6.6.1 AUTO parameters that can be set.......................................................75
6.6.2 Sewing process...................................................................................81
6.7 Programming mode.............................................................................83
6.7.1 Editing existing programs (EDIT) ........................................................84
6.7.2 Creating a new program (PROGRAMMING).......................................90
6.7.3 Copying the seam program.................................................................99
6.7.4 Deleting the seam program.................................................................99
6.7.5 Length correction (LENGTH CORRECTION)....................................100
6.8 Service mode SERVICE.................................................... ................101
7 Maintenance.....................................................................................103
7.1 Cleaning ............................................................................................104
7.2 Lubricating.........................................................................................106
7.3 Parts list.............................................. ... .................................... ........108
8 Setup ................................................................................................109
8.1 Check the scope of delivery..............................................................109
8.2 Removing the transport locks ............................................................109
8.3 Assembling the frame........................................................................110
8.4 Pre-assembling the table top.............................................................111
8.6 Attaching the table top and pedals to the frame................................113
8.7 Setting the working height.................................................................115
8.8 Inserting the machine upper part.......................................................117
8.9 Electrical connection .........................................................................118
2 Operating Instructions 650-16 - 02.0 - 08/2016
Table of Contents
8.9.1 Connecting the mains power supply .................................................119
8.9.2 Connecting the cables to the upper part ...........................................120
8.9.3 Connecting the cables for the additional control ...............................121
8.9.4 Connecting the setpoint transducers to the control ...........................122
8.9.5 Connecting the equipotential bonding for the upper part ..................123
8.9.6 Connecting the equipotential bonding for the control ........................124
8.9.7 Connecting the equipotential bonding for the additional control........125
8.9.8 Connecting the equipotential bonding for the sewing head motor ....126
8.9.9 Connecting the equipotential bonding for the knee switch ................127
8.9.10 Connecting the equipotential bonding for the setpoint transducers ..128
8.9.11 Connecting the knee switch ..............................................................129
8.9.12 Connecting the control panel.............................................................130
8.9.13 Connecting the LED sewing light ......................................................131
8.9.14 Connect the additional sewing light (Waldmann) (optional)..............131
8.10 Sewing test........................................................................................132
9 Decommissioning ...........................................................................133
10 Disposal ...........................................................................................135
11 Troubleshooting..............................................................................137
11.1 Customer service ..............................................................................137
11.2 Errors in sewing process...................................................................138
12 Technical Data.................................................................................141
13 Appendix..........................................................................................143
Operating Instructions 650-16 - 02.0 - 08/2016 3
Table of Contents
4 Operating Instructions 650-16 - 02.0 - 08/2016
About these instructions
1 About these instructions
These instructions have been prepared with utmost care.
They contain information and notes intended to ensure long-term
and reliable operation.
Should you notice any discrepancies or if you have improvement
req
Customer Service ( p. 137).
Consider the instructions part of th
place where they are readily avai l able.
1.1 For whom are these instructions intended?
These instructions are intended for:
Service Instructions are supplied separately.
With regard to minimum qualification
be met by personnel, please also follow the chapter Safety
( p. 9).
uests, then we would be glad to receive your feedback through
e product and store them in a
• Operators:
This group is familiar with the machine and has access
to the instructions. Specifical
( p. 19) is important for the operators.
• Specialists:
This group has the appropriate technical training for
performing maintenance or repairing malfunctions.
pecifically, the chapter Setup ( p. 109) is important
S
for specialists.
ly, chapter Operation
and other requirements to
1.2 Representation conventions – symbols and characters
Various information in these instructions is represented or highlighted by the following characters in order to facilitate easy and
quick understanding:
Proper setting
Specifies proper setting.
Operating Instructions 650-16 - 02.0 - 08/2016 5
About these instructions
1
st
2
nd
etc.
•
Disturbances
Specifies the disturbances that can occur due to an incorrect
setting.
Cover
Specifies which covers must be re
moved in order to access the
components to be set.
Steps to be performed when operating the machine
(sewing and equipping)
Steps to be performed for service, maintenance, and
stallation
in
Steps to be performed via the software control panel
The individual steps are numbered:
First step
Second step
The steps must always be followed in the specified order.
Lists are marked by bullet points.
Result of performing an operation
Change to the machine or on the display/control panel.
Important
Special attention must be paid to
this point when performing a step.
Information
Additional information, e.g. on alternative operating options.
Order
Specifies the work to be performed before or after a setting.
6 Operating Instructions 650-16 - 02.0 - 08/2016
About these instructions
References
Reference to another section in these instructions.
Safety Important warnings for the machine users are specially designa-
ted. Since safety is of particular importance, hazard symbols,
evels of danger and their signal words are described separately
l
in the chapter Safety ( p. 9).
Orientation If no other clear location information is used in a figure, indications
right or left are always from the operator's point of view.
of
1.3 Other documents
The machine 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
nents is described in each manufacturer's instructions.
compo
1.4 Liability
All information and notes in these instructions have been compiled
in accordance with the latest technology and the applicable standards and regulations.
Dürkopp Adler cannot be held liable for any damage resulting
from:
• Breakage and damage during transport
• Failure to observe these instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved parts
Operating Instructions 650-16 - 02.0 - 08/2016 7
About these instructions
Transport
Dürkopp Adler cannot be held liable for breakage and transport
amages. Inspect the delivery immediately upon receiving it.
d
Report any damage to the last transport manager. This applies
even if the packaging is undamaged.
Leave machines, equipment and packaging material in the condition in which they were found when the damage was discovered.
his will ensure any claims against the transport company.
T
Report all other complaints to Dürkopp Adler immediately after
ceiving the product.
re
8 Operating Instructions 650-16 - 02.0 - 08/2016
Safety
2 Safety
This chapter contains basic information for your safety. Read the
instructions carefully before setting up or operating the machine.
Always follow the information included in the safety instructions.
Failure to do so can result in serious injury and property damage.
2.1 Basic safety instructions
The machine may only be used as described in these instructions.
The instructions should be available at
all times.
Work on live components and equipme
are defined in the DIN VDE 0105.
For the following work, switch off the
or disconnect the power plug:
• Replacing the needle or other sewing tools
• Leaving the workstation
• Performing maintenance work and repairs
• Threading
Missing or faulty spare parts could impair safety and damage the
ine. Only use original parts from the manufacturer.
mach
the machine's location at
nt is prohibited. Exceptions
machine at the main switch
Transport Use a sturdy lifting carriage or forklift truck for transporting the
machine. Raise the machine max. 20 mm and secure it to prevent
from slipping off.
it
Setup The power cable must have a plug that is authorized for use in
the country in which the machine is being used. The power plug
may only be assembled to the power cable by qualified specialists.
Obligations
of the operator
Operating Instructions 650-16 - 02.0 - 08/2016 9
Follow the country-specific safety and accident prevention regulations and the legal regulations conce
the protection of the environment.
rning industrial safety and
Safety
All the warnings and safety signs on the machine must always be
in legible condition. Do not remove!
Missing or damaged warnings and safety signs must be replaced
immediately.
Requirements to
met by the
be
personnel
Only qualified specialists may:
• set up the machine
• carry out maintenance work and repairs
• carry out work on electrical equipment
Only authorized persons may work on th
e machine and they must
first have understood these instructions.
Operation Inspect the machine while in use for any externally visible damage.
orking if you notice any changes to the machine. Report any
Stop w
changes to your supervisor. Do not use a damaged machine any
further.
Safety
equipment
Safety equipment should not be removed or deactivated. If it is
ssential to remove or deactivate safety equipment for a repair
e
operation, it must be assembled and put back into service immediately afterward.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color
scheme based on the severity of the danger. Signal words indicate
the severity of the danger.
Signal words Signal words and the hazard they describe:
Signal word Meaning
DANGER (with hazard symbol)
If ignored, fatal or serious injury will result
WARNING (with hazard symbol)
10 Operating Instructions 650-16 - 02.0 - 08/2016
If ignored, fatal or serious injury can result
Safety
CAUTION (with hazard symbol)
If ignored, moderate or minor injury can result
CAUTION (with hazard symbol)
If ignored, environmental damage can result
NOTICE (without hazard symbol)
If ignored, property damage can result
Symbols The following symbols indicate the type of danger to personnel:
Symbol Type of danger
General
Electric shock
Puncture
Crushing
Environmental damage
Operating Instructions 650-16 - 02.0 - 08/2016 11
Examples Examples of the layout of warnings in the text:
DANGER
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that will result
in serious injury or even death if ignored.
WARNING
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that could
result in serious or even fatal injury if ignored.
Safety
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
is is what a warning looks like for a hazard that could
Th
result in moderate or minor injury if the warning is ignored.
12 Operating Instructions 650-16 - 02.0 - 08/2016
Safety
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that could
result in property damage if ignored.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
is is what a warning looks like for a hazard that could
Th
result in environmental damage if ignored.
Operating Instructions 650-16 - 02.0 - 08/2016 13
Safety
14 Operating Instructions 650-16 - 02.0 - 08/2016
Machine description
①
④
②
⑤
③⑥
⑨
⑦
⑩
⑧
(1) - Plate
(2) - Drawe
(3) - Frame
(4) - Additional pedal
(5) - Pedal
(6) - Knee switch
(7) - Control
(8) - Control panel
(9) - Machine
(10)- Thread reel holder
3 Machine description
3.1 Overview of machine components
Fig. 1: Overviwe of machine components
Operating Instructions 650-16 - 02.0 - 08/2016 15
Machine description
3.2 Declaration of Conformity
The machine complies with European regulations ensuring health,
safety, and environmental protection as specified in the declaration of conformity or in the declaration of incorporation.
3.3 Proper use
The machine is intended only for use with dry sewing material.
The sewing material must not contain any hard objects.
The needle thicknesses permissible for the machine are listed in
echnical Data ( p. 141) chapter.
the T
The seam must be completed with a thread that satisfies the
uirements of the specific application at hand.
req
The machine is intended for industrial use.
The machine may only be set up and operated in dry conditions on
-maintained premises. If the machine is operated on premises
well
that are not dry and well-maintained, then further measures may
be required which must be compatible with DIN EN 60204-3 1.
Only authorized persons may work on the machine.
Dürkopp Adler cannot be held liable for damages resulting from
mproper use.
i
16 Operating Instructions 650-16 - 02.0 - 08/2016
Machine description
WARNING
Risk of injury from live, moving and cutting
p
arts as well as from sharp parts!
Improper use can result in electric shock,
ing, cutting and punctures.
crush
Follow all instructions provided.
NOTICE
Property damage from non-observance!
Improper use can result in material damage at the machine.
Follow all instructions provided.
Operating Instructions 650-16 - 02.0 - 08/2016 17
Machine description
18 Operating Instructions 650-16 - 02.0 - 08/2016
Operation
4 Operation
4.1 Preparing the machine for operation
WARNING
Risk of injury from moving parts, cutting and
sharp parts!
Crushing, cutting and punctures are possible.
If possible, make preparations only when the
machine is switched off.
Complete the following steps in preparation of sewing before
starting to work:
• Changing the needle
• Threading the needle thread
• Threading the looper thread
• Adjusting the thread tension
4.2 Switching on and off the machine
Fig. 2: Switching on and off the machine
Operating Instructions 650-16 - 02.0 - 08/2016 19
Switching on the machine
To switch on the machine:
1. Turn the main switch from position 0 to position I.
The machine switches on.
Switching off the machine
To switch off the machine:
1. Turn the main switch from position 0 to position I.
The machine switches off.
4.3 Changing the needle
CAUTION
Risk of injury from sharp parts!
Punctures possible.
Switch off the machine before changing the
needle.
Operation
20 Operating Instructions 650-16 - 02.0 - 08/2016
Operation
③
④
①
②
Fig. 3: Changing the needle
(1) - Needle bar
(2) - Srew
To change the needle:
1. Loosen the screw (2) and remove the needle.
2. Insert the new needle into the hole in the needle bar (1) until
it reaches the end stop.
Important
The groove (4) must face towards the hook tip (3).
3. Tighten the screw (2).
Order
After changing to a different needle thickness, always adjust the
clearance between the hook and the needle
( Service instructions).
(3) - Hook tip
(4) - Groove
Operating Instructions 650-16 - 02.0 - 08/2016 21
Operation
Disturbance
An incorrect hook distance can cause the following malfunctions:
• Changing to a thinner needle:
• Missing stitches
• Thread damage
• Changing to a thicker needle:
• Damage to the hook tip
• Damage to the needle
22 Operating Instructions 650-16 - 02.0 - 08/2016
Operation
4.4 Threading the needle thread
CAUTION
Risk of injuries from cutting parts!
Punctures possible.
Switch off the machine before threading the
needle thread.
Fig. 4: Threading the needle thread
To thread the needle thread:
1. Plug the thread reels on to the thread reel holders and feed
the needle and hook threads through the unwinding bracket.
Important
The unwinding bracket must be horizontal and be positioned
above the thread reels.
2. Thread the needle thread as shown above.
Operating Instructions 650-16 - 02.0 - 08/2016 23
Operation
Threads with high elasticity
Fig. 5: Threading the needle thread: Threads with high elasticity
To thread the needle thread when using threads with high elasticity:
1. Thread the needle thread as shwon above.
24 Operating Instructions 650-16 - 02.0 - 08/2016
Operation
①
②
③
4.5 Winding the hook thread
NOTICE
Property damage may occur!
Moving the bobbin without performing sewing can cause
damage to the presser foot and the bobbin case in the hook.
Activate bobbin mode if you wish to wind the hook thread
without performing sewing.
Fig. 6: Winding the hook thread
(1) - Winder flap
(2) - Bobbin
To wind the hook thread:
1. Fit the bobbin (2) on the bobbin shaft.
2. Thread the hook thread as shown in the following figure.
3. Wind the hook thread clockwise on to the bobbin core.
4. Swing the bobbin winder flap (1) against the bobbin.
5. Switch the main switch on.
6. Start sewing.
7. Once the bobbin is full, the winder switches off automatically
( Service instructions).
8. Pull off the bobbin, clamp the thread under the cutter (3) and
tear it off.
Operating Instructions 650-16 - 02.0 - 08/2016 25
(3) - Cutter
4.6 Replacing the hook thread bobbin
④⑤
⑥
⑦
①
③
②
CAUTION
Risk of injury from sharp and moving parts!
Cutting or crushing possible.
Switch off the machine before replacing the hook
thread bobbin.
Fig. 7: Replacing the hook thread bobbin
Operation
(1) - Bobbin housin g flap
(2) - Hook cover
(3) - Bobbin
(4) - Slot
(5) - Tension spring
(6) - Hole
(7) - Bobbin hous in g upper section
26 Operating Instructions 650-16 - 02.0 - 08/2016
Operation
To replace the hook thread bobin:
Removing an empty bobbin
1. Push the hook cover (2) downwards.
2. Move the needle to the up position.
3. Lift the bobbin housing flap (1).
4. Remove the bobbin housing upper section (7) with the
bobbin (3).
5. Remove the empty bobbin (3) from the bobbin housing upper
section (7).
Inserting a full bobbin
1. Insert the full bobbin (3) into the bobbin housing upper
section (7).
2. Feed the hook thread through the slot (4) under the tensioning
spring (5) into the hole (6).
3. Pull the hook thread approx. 5 cm out of the bobbin
housing (7).
4. The bobbin must rotate in the direction of the arrow when
pulling out the thread.
5. Insert the bobbin housing (7) again.
6. Push the hook cover (2) upwards.
4.7 Thread tension
Together with the bobbin thread tension, the needle thread tension
influences the seam pattern.
The needle thread tension is defined by the pre-tensioner, the
main tensioner and the additional tensioner.
Proper Setting
The main tension (1) should be set as low as possible.
The thread interlacing should be exactly in the middle of the
material being sewn.
With thin sewn material, excessive thread tension can lead to
undesired gathering and thread breakages.
Operating Instructions 650-16 - 02.0 - 08/2016 27
Fig. 8: Thread tension
DA150018_V52_XX
②
①
③
①
(1) - Identical needle thread and bobbin thre ad tension
(2) - Bobbin thread tension higher than needle thread tension
(3) - Needle thread tension higher than bobbin thread tension
4.7.1 Setting the needle thread tension
Fig. 9: Setting the needle thread tension
Operation
(1) - Main tensioner
To set the needle thread tension:
1. Set the main tensioner (1) via the control panel so that a even
stitch pattern is achieved.
When the thread is cut, the main tensioner (1) is opened
automatically.
28 Operating Instructions 650-16 - 02.0 - 08/2016
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