DURKOPP ADLER 540 - 100 User manual

Manual, complete

540 - 100

CNC double lockstitch buttonholer

Operating Instructions

Installation Instructions

Service Instructions

Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld

Phone + 49 (0) 5 21 / 9 25-00 • Fax + 49 (0) 5 21 / 9 25 24 35 • www.duerkopp-adler.com

Ausgabe / Edition: 04/2006 Printed in Federal Republic of Germany Teile-Nr./Part.-No.: 0791 540001

540 - 100

Manual, complete

Contents

Operating Instructions

Installation Instructions

Service Instructions

Interconnection-diagram

9890 540001 B

Software version

A04.1

B04.1

Foreword

This instruction manual is intended to help the user to become familiar

with the machine and take advantage of its application possibilities in

accordance with the recommendations.

The instruction manual contains important information on how to

operate the machine securely, properly and economically. Observation

of the instructions eliminates danger, reduces costs for repair and

down-times, and increases the reliability and life of the machine.

The instruction manual is intended to complement existing national

accident prevention and environment protection regulations.

The instruction manual must always be available at the

machine/sewing unit.

The instruction manual must be read and applied by any person that is

authorized to work on the machine/sewing unit. This means:

– Operation, including equipping, troubleshooting during the work

cycle, removing of fabric waste,

– Service (maintenance, inspection, repair and/or

– Transport.

The user also has to assure that only authorized personnel work on

the machine.

The user is obliged to check the machine at least once per shift for

apparent damages and to immediatly report any changes (including

the performance in service), which impair the safety.

The user company must ensure that the machine is only operated in

perfect working order.

Never remove or disable any safety devices.

If safety devices need to be removed for equipping, repairing or

maintaining, the safety devices must be

remounted directly after completion of the maintenance and repair

work.

Unauthorized modification of the machine rules out liability of the

manufacturer for damage resulting from this.

Observe all safety and danger recommendations on the machine/unit!

The yellow-and-black striped surfaces designate permanend danger

areas, eg danger of squashing, cutting, shearing or collision.

Besides the recommendations in this instruction manual also observe

the general safety and accident prevention regulations!

General safety instructions

The non-observance of the following safety instructions can cause

bodily injuries or damages to the machine.

1. The machine must only be commissioned in full knowledge of the

instruction book and operated by persons with appropriate

training.

2. Before putting into service also read the safety rules and

instructions of the motor supplier.

3. The machine must be used only for the purpose intended. Use of

the machine without the safety devices is not permitted. Observe

all the relevant safety regulations.

4. When gauge parts are exchanged (e.g. needle, presser foot,

needle plate, feed dog and bobbin) when threading, when the

workplace is left, and during service work, the machine must be

disconnected from the mains by switching off the master switch or

disconnecting the mains plug.

5. Daily servicing work must be carried out only by appropriately

trained persons.

6. Repairs, conversion and special maintenance work must only be

carried out by technicians or persons with appropriate training.

7. For service or repair work on pneumatic systems, disconnect the

machine from the compressed air supply system (max. 7-10 bar).

Before disconnecting, reduce the pressure of the maintenance

unit.

Exceptions to this are only adjustments and functions checks

made by appropriately trained technicians.

8. Work on the electrical equipment must be carried out only by

electricians or appropriately trained persons.

9. Work on parts and systems under electric current is not permitted,

except as specified in regulations DIN VDE 0105.

10. Conversion or changes to the machine must be authorized by us

and made only in adherence to all safety regulations.

11. For repairs, only replacement parts approved by us must be used.

12. Commissioning of the sewing head is prohibited until such time

as the entire sewing unit is found to comply with EC directives.

It is absolutely necessary to respect

the safety instructions marked by these signs.

Danger of bodily injuries !

Please note also the general safety instructions.

Index Page:

Part 3: Service Instructions Class 540-100

1. Elements of the control panel

1.1 Alteringparametervalues......................................... 4

1.1.1 Numericalvalues.............................................. 4

1.1.2 Selectionofaparameter.......................................... 4

2. Menu structure technician mode (overview)

2.1 Submenumachineconfiguration(overview).............................. 6

3. Calling up the technician mode and entering the code ..................... 7

4. Main menu of the technician mode

4.1 Submenumachineconfiguration..................................... 7

4.1.1 Submenuuser................................................ 8

4.1.2 Submenuforsoftstartsetting....................................... 8

4.1.3 Submenu for determining the equipment ................................ 8

4.1.4 Submenuforthreadmonitorconfiguration............................... 9

4.1.5 Submenu for the configuration of condensed stitches ........................ 10

4.1.6 Submenuforenteringmachinetimes.................................. 11

4.2 Submenu for the configuration of the operating elements ...................... 11

4.2.1 Submenu for selecting the menu language............................... 11

4.2.2 Submenuforsettingdateandtime ................................... 11

4.3 Submenufortestfunctions........................................ 12

4.3.1 SubmenuMultitest ............................................. 12

4.3.1.1 Submenuoutputtest............................................ 13

4.3.1.2 Submenu input test ............................................. 13

4.3.1.3 Submenu automatic input test ...................................... 14

4.3.1.4 Submenusewingmotortest........................................ 14

4.3.1.5 Submenustepmotortest ......................................... 14

4.4.1.6 SubmenuRAMtest............................................. 14

4.4.1.7 SubmenuEPROMtest........................................... 14

4.4.2 SubmenuDACIII.............................................. 15

4.4.3 Submenu memo-dongle .......................................... 15

4.4.3.1 Dongle contents ............................................... 15

4.4.3.2 Submenu loading .............................................. 16

4.4.3.3 Submenusaving .............................................. 17

4.4.3.4 Formatting.................................................. 18

5. Knife setting

5.1 Aligningtheknifeandadjustingtheknifeheight ........................... 19

5.2 Settingoftheknifeincisiondamper................................... 20

Index Page:

6. Hook and needle bar

6.1 Needle position ............................................... 21

6.2 Reference position of the needle bar .................................. 21

6.3 Setting the adjusting sheet ........................................ 22

6.4 Loop formation stroke position and distance between hook and needle ............. 23

6.5 Needle bar height .............................................. 24

6.6 Needle protection .............................................. 25

6.7 Alignment of the bobbin case holder................................... 25

7. Aligning the throat plate as to the needle .............................. 26

8. Thread tension plate

8.1 Threadpulleradjustment ......................................... 26

8.2 Thread controller spring and thread regulator ............................. 27

9. Sewing basket

9.1 Settingoftheclothpresserblock(liftingstroke) ........................... 28

9.2 Lifting / Lowering speed of the sewing basket ............................. 28

9.3 Alignmentofthesewingbasketastothethroatplate ........................ 29

9.4 Referencepositionofthesewingbasket................................ 30

10. Bobbin thread scissors

10.1 Settingoftheclosingpath......................................... 31

10.2 Adjusting the spring sheet of the thread rest.............................. 32

11. Needle thread scissors

11.1 Function sequence ............................................. 33

11.2 Removal and check of the needle thread scissors .......................... 34

11.3 Alignmentofthescissorsblock...................................... 35

11.4 Scissorsswivelledin............................................ 37

11.5 Heightadjustment.............................................. 38

11.6 Scissorsswivelledout........................................... 38

11.7 Distance to the needle ........................................... 39

11.8 Opening the scissors ............................................ 39

11.9 Settingoftheclosingpath......................................... 40

11.10 Setting the time for opening the scissors ................................ 40

12. Machine stop position .......................................... 41

13. Bobbin winder ............................................... 42

14. Solenoid valves .............................................. 43

15. Exchange of the sewing basket .................................... 44

16. Stretching the drive belts ........................................ 45

1. Elements of the control panel

Key Function

If no text field is activated:

–Change to the parent menu.

If a text field is activated:

–Change between the figures tenth, unit, ten etc.

–Change between the lines in the menus. The selected line is

always dark-shadowed.

If a text field is activated:

–Increase or reduce the value of the respective figure by one or

change between the parameters in case of functions with several

choices, e.g. between “Push button on“ and “Push button off“.

–Activate the text field. The value can be altered with the keys “ñ“

and “ò“.

If a text field is activated:

–The set value is taken over.

–You get back to the main menu from a submenu.

If a text field is activated:

–An input is aborted. The previous value remains unchanged.

–The control changes from the sewing mode to the programming

mode. The buttonhole parameters can be altered in this mode.

–The control changes from the sewing mode or programming mode

to the sequence programming mode.

–The control changes from the sewing mode to the technician mode.

This mode can only be activated by entering a code 25483.Inthis

operating state it is possible to set basic machine parameters and

to call up diagnosis and adjusting programs.

1.1 Altering parameter values

1.1.1 Numerical values

Numerical values can be altered as follows:

–Selectthelinewiththevaluetobealteredwiththecursorkeysñ

and ò.

–Actuate the OK key.

The cursor flashes under a digit of the numerical value.

–Change between the digits with the cursor keys ïand ð.

–Increase or reduce the value of the selected digit with the cursor

keys ñand ò.

In case of parameters which cannot optionally be altered another

possible parameter value is indicated by actuating the cursor keys

ñand ò.

–Actuate the OK key.

The set value is taken over.

–If the set value is not to be taken over, actuate the ESC key.

The initially set value is restored

1.1.2 Selection of a parameter

Some parameters allow to choose between several possibilities.

The parameter can be altered as follows:

–Selectthelinewiththevaluetobealteredwiththecursorkeysñ

and ò.

–Actuate the OK key.

–Change between the possibilities with the cursor keys ñand ò.

The selected parameter is displayed.

–Actuate the OK key. The set parameter or value is taken over.

–If the set parameter or value is not to be taken over, actuate the

ESC key.

The initially set parameter or value is restored.

2. Menu structure technician mode (overview)

Parameter

Soft start

Equipment

X- /Y- Correction Submenu: Machine configuration

Thread monitor

Condensed stitches

Subclasses

Times

Counter (totalizer) : Display Selection: German, English,

Italian, Parameter

Hour : Input

Minute: Input

Machine Language Day: Input

Set date/time Month: Input

User configuration Lock P: Selection Year: Input

Hand switch: Selection

Service

Output test

Input test

Auto input

Sewing motor test

Multitest Step motor test

Events RAM test

DAC III EPROM test

Data reset

Memo dongle Time/Date: Display

Temperature DAC III: Display

Interm. circuit voltage: Display

Buttonhole data

Machine compl.

Content

Save

Format

2.1 Submenu machine configuration (overview)

Max. speed: Input

Speed basting stitches: Input

Scissors is moved out: Input

n-stitches b. u. bartack/bartack tension on: Input

n-stitches b. l. bartack/bartack tension on: Input

n-stitches b. lip there/lip tension on: Input

n-stitches b. lip back/lip tension on: Input

n-stitches b. seam beginning/lip tension on: Input

Number of stitches: Input

Speed: Input

Cage length: Selection

Parameter Free cage length: Input

Soft start Cage width: Selection

Equipment Free cage width: Input

Thread monitor Knife length: Input

Condensed stitches Pressure monitor: Input

Times

Counter (totalizer)

Repair mode: Selection

Needle thread mon. on/off: Selection

Number of stitches: Input

Stitch length x: Input

Stitch length y: Input

Position last stitch: Input

Table of contents

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