DURKOPP ADLER 540 - 100, Operating Instructions Manual

Page 1: ...allation 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 1 2 3 Ausgabe Edition 04 2006 Printed in Federal Republic of Germany Teile Nr Part No 0791 540001 ...

Page 2: ...540 100 Manual complete Contents Operating Instructions Installation Instructions Service Instructions Interconnection diagram 9890 540001 B Software version A04 1 B04 1 ...

Page 3: ... 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 pe...

Page 4: ...ion 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 technician...

Page 5: ...ondensed stitches 10 4 1 6 Submenu for entering machine times 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 Submenu for setting date and time 11 4 3 Submenu for test functions 12 4 3 1 Submenu Multitest 12 4 3 1 1 Submenu output test 13 4 3 1 2 Submenu input test 13 4 3 1 3 Submenu automatic input test 14 4 3 1 4 Submenu se...

Page 6: ...he sewing basket 28 9 3 Alignment of the sewing basket as to the throat plate 29 9 4 Reference position of the sewing basket 30 10 Bobbin thread scissors 10 1 Setting of the closing path 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 Alignment of the scissors block 35 11 4 Sci...

Page 7: ... 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 p...

Page 8: ... actuating the cursor keys ñ and 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 Select the line with the value to be altered with the cursor keys ñ and ò Actuate the OK...

Page 9: ...meter 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 com...

Page 10: ...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 stitche...

Page 11: ...e submenu for the configuration of the control elements T3 Service Selection of the submenu for test functions 4 1 Submenu Machine configuration No Parameter name Symbol Range Description T1 1 Parameter Selection of the submenu for parameter setting T1 2 Soft start Selection of the submenu for soft start setting T1 3 Equipment Selection of the submenu for equipment definition T1 4 Thread monitor S...

Page 12: ...efore the lip there with the lip tension switched on T1 1 8 Lip tension after the seam beginning 0 10 Number of stitches after the seam beginning after which the lip tension is switched on Only valid for taper bars 4 1 2 Submenu for soft start setting No Parameter name Symbol Range Description T1 2 1 Number of stitches 0 10 Number of stitches of the soft start T1 2 2 Speed 200 max sewing speed acc...

Page 13: ...ng basket remains in its position Step the pedal forward 2nd step The sewing cycle is started After the sewing cycle the automate runs in reference position and the sewing basket is lifted The material can be taken out The automate is ready for a new sewing cycle Method C The buttonhole is continued to be sewn from the recognized point of thread breakage After switching the automate on again the s...

Page 14: ...of condensed stitches T1 5 2 Stitch length X 0 3 2 0 mm Enter the stitch distance of the condensed stitches in direction X T1 5 3 Stitch length Y 0 0 0 8 mm Enter the stitch distance of the condensed stitches in direction Y T1 5 4 Position last stitch 4 4 Enter the position of the last knotting stitch according to fig 1 Lip there Lip back Fig 1 10 ...

Page 15: ...T2 3 Locking P on off Switch the keyboard blocking for the P key on or off If the key blocking is switched on no buttonhole programs can be established or altered T2 4 Push button on off Select the push button instead of the foot pedal or in addition to the foot pedal 4 2 1 Submenu for selecting the menu language You can choose among the following languages German English Default setting Parameter...

Page 16: ...le Select the submenu Memo dongle 4 3 1 Submenu Multitest No Parameter name Symbol Description T3 1 1 Outputs Select the submenu Output test T3 1 2 Inputs Select the submenu Input test T3 1 3 Auto input Select the submenu of the automatic input test T3 1 4 Sewing motor Select the submenu Sewing motor test T3 1 5 Step motor Select the submenu Step motor test T3 1 6 RAM Select the submenu RAM test T...

Page 17: ...t lifts Y2 Scissors cylinder Y3 Lip tension Y4 Knife cylinder Caution Danger of injury Do not reach into the running machine when checking the output elements 4 3 1 2 Submenu Input test Select the input to be tested with the cursor keysñ and ò The switching state of the input and its alterations are indicated Inputs Function S1 Push button optional S2 Pedal step 1 2 forwards S4 Pedal step 2 forwar...

Page 18: ... Symbol Range Description T3 1 4 1 X axis 50 50 With the cursor keys ï and ð the step motor is moved in the corresponding direction by 5 ticks each T3 1 4 2 Y axis 50 50 With the cursor keys ñ and ò the step motor is moved in the corresponding direction by 5 ticks each Press the ESC key in order to quit the menu item again The step motor is referenced anew 4 4 1 6 Submenu RAM test When selected th...

Page 19: ...on Confirmation Reset to default the buttonhole geometry and the machine parameters 4 4 3 Submenu Memo dongle The dongle can be inserted into the socket x110 test interface of the control DAC III or pulled off again when the automate is running No Parameter name Symbol Description T3 5 1 Dongle content It is automatically recognized whether a data or machine software dongle has been plugged in The...

Page 20: ... Description T3 5 2 1 Machine data After a confirmation all machine data are loaded All global parameters except Reference switch position x y cage length and width knife length calibration values thread tension All buttonhole data All sequences Free contours automatically the first two free contours on the dongle Selection of the further 14 free contours via menu item Free contours T3 5 2 4 T3 5 ...

Page 21: ...is saved All buttonhole data All sequences Free contours are not saved T3 5 3 3 Individual buttonholes The 50 buttonhole program locations of the machine are displayed With the cursor keys ñ and ò the buttonhole program to be saved is selected The designation of the buttonhole program is composed of upper bartack cutting length lower bartack e g B26 0C for upper bartack B round tack cutting length...

Page 22: ... it has to be formatted on this class anew ATTENTION A machine dongle can be formatted too The software is deleted in the course of this Through formatting the machine dongle becomes a data dongle Enter the name of the data dongle 14 characters max Press the OK key in the submenu Formatting Select the point to be edited with the cursor keys ï and ð Select the character with the cursor keys ñ and ò...

Page 23: ...crew 2 Insert the knife in the knife slot press it against the knife holder and displace the knife holder until the knife is in the centre of the slot Tighten screw 2 and mount the knife Knife height adjustment Loosen screw 1 Set the knife height in such a way that the knife remains in the knife slot for a depth of 0 2 mm during the cutting open Tighten screw 1 ATTENTION When adjusting the height ...

Page 24: ...witching on the knife no loud sound should be heard Setting Loosen counternut 1 Screw out screw 2 completely then screw in screw 2 with two rotations If necessary make a fine adjustment of screw 2 corresponding to the instructions Tighten counternut 1 20 1 2 ...

Page 25: ... screw 3 again Attention After correcting the needle position check the distance between hook and needle chapter 6 4 and adjust it if required 6 2 Reference position of the needle bar Standard proximity switch The distance between the proximity switch 6 and the switching edge 7 should amount 0 7 mm Functional check Select the input 17 in the Multitest Input test On recognition of the switching edg...

Page 26: ...ent positions when the machine is switched off Needle bar in the centre of the needle hole reference position Bolt 10 abuts on the right flank of the slotted hole Needle bar in the furthest right entry point with a throw width of 6 mm Bolt 10 abuts on the left flank of the slotted hole Let the machine move to the initial position e g immediately after switching on Loosen the screws 11 Shift the sh...

Page 27: ...it Setting Pull out the locking pin 1 Loosen the screws 2 Insert the locking pin 1 in the drill hole 3 Thick end for 2 2 mm throw width Thin end for 2 mm throw width Turn the needle to the bottom dead centre The next notch in the direction of rotation is the looping stroke position The bolt of the needle bar linkage must be at the right flank of the slotted hole of the adjusting sheet Bend the nee...

Page 28: ...just above the eye of the needle Setting Dismount the throat plate Bring the machine in looping stroke position Check the needle bar height according to the instructions and correct after loosening the screw 4 if required Tighten screw 4 again Note Do not turn the needle bar when altering the needle bar height 24 4 ...

Page 29: ...needle protection with a butt end soft tool according to the instructions 6 7 Alignment of the bobbin case holder Standard The holder should be at the same level as the bottom part of the bobbin case Line C D The back surfaces of the holder and the bottom part of the bobbin case should be at the same level A B Setting Align the height of the holder 2 with an appropriate bending tool according to t...

Page 30: ...tions Tighten screws 3 and 4 again 8 Thread tension plate 8 1 Thread puller setting Standard Caused by the pulling of the needle thread the first stitch of the buttonhole is sewn without thread tension Thus it is avoided that the bobbin thread in the thread rest is pulled up at the first stitch Setting Loosen the screws 4 Adjust the thread puller 5 to the left more thread pulled to the right less ...

Page 31: ... Loosen screw 1 Turn ring 2 for altering the tension Turn case 3 for altering the spring travel Spring travel 2 3 mm Tighten screw 1 again Setting of the thread regulator Loosen screw 4 The distance 5 inner flanks of the thread regulator should be set to 5 mm Tighten screw 4 Note To obtain an optimal thread take up with thick material the regulator should be shifted to the rear The optimal positio...

Page 32: ... pin 3 according to the instructions Increase the stroke turn the threaded pin in clockwise direction Reduce the stroke turn the threaded pin counter clockwise Tighten counternut 2 and screws 1 again Lift and check the cage 9 2 Lifting Lowering speed of the sewing basket Turn the throttling screw 4 for adjusting the lifting speed Turn the throttling screw 5 for adjusting the lowering speed higher ...

Page 33: ...the needle hole The guide roller of the cloth presser block should run centrally in the guide groove of the guide lever of the sewing basket Setting Reduce the sewing basket pressure Unscrew the sheet 6 Loosen threaded pins 7 and 9 Shift the guide lever of the cage 8 according to the instructions Tighten threaded pins 7 and 9 Screw the sheet 6 on again 29 3 6 8 7 9 ...

Page 34: ...h the pedal backwards The sewing basket is lifted and the machine performs a reference run Push the pedal backwards The sewing basket is lowered Check the distance and correct it if necessary 10 Bobbin thread scissors The support plate 3 must be close and movable without clearance Insert or remove discs 4 of 0 1 mm if necessary The thread puller 5 has to be aligned in such a way that it is at the ...

Page 35: ...uired turn the eccentric 8 after loosening the screw 9 Attention Take care that there is enough clearance between the thread puller and the cover of the hook path when the bobbin thread scissors is open Hint For checking the clearance between the thread puller and the cover of the hook path the machine should be slowly moved via the handwheel If necessary the thread puller can be adjusted after lo...

Page 36: ...rd The spring sheet of the thread rest must be adjusted in such a way that the thread is held in the thread rest with a very low holding force Setting Turn the threaded pin 7 in the support plate in order to change the holding force of the clamping sheet 32 7 ...

Page 37: ...The bolt of the movable part of the scissors runs against a quare and opens the scissors The needle thread is released The scissors is in its left end position now Catch position The open scissors swivels in three stitches before the last stitch knotting stitch Cutting and clamping When the machine has come to a standstill the cage lifting is started The main thread tension opens The needle thread...

Page 38: ...hread clamping plate must be sufficient to hold the thread safely The cutting edges of both scissors parts must be sharp enough to cut the thread accurately Dismount check and mount the scissors Switch the main switch off Unhook the spring 1 Loosen the locking pin 2 Pull out the axle 3 and remove the needle thread scissors Dismount the needle thread scissors and check according to the instructions...

Page 39: ...ing head edge 3 and 4 mm throw width For 6 mm equipment turned by 1 counter clockwise Setting Unscrew the regulating screw for the sewing basket pressure Loosen the threaded pins 1 and adjust the scissors block according to the instructions ATTENTION By turning the scissors block the position of the cage as to the needle hole is changed Correct the cage position according to chapter 9 3 if require...

Page 40: ...Notes 36 ...

Page 41: ...dge of the sewing basket Standard throw width 6 mm When the sewing basket is lowered the edge of the bottom part of the scissors should have a distance of 0 0 3 mm from the left edge of the sewing basket Setting Turn the locking pin 1 according to the instructions Check the height of the needle thread scissors according to chapter 11 6 Height adjustment and correct if required 37 3 1 ...

Page 42: ...il pin 3 lifts the scissors Tighten threaded pin 2 11 6 Scissors swivelled out Standard When swivelled out the front edge of the scissors should be at the same level as the inner edge of the cage Setting Switch the machine off Swivel the scissors out according to the instructions Loosen the threaded pin 4 Twist the block 6 until it abuts against the stop 7 Tighten the threaded pin 4 38 4 5 3 2 7 4...

Page 43: ...n the needle hole Loosen threaded pin 4 and shift the holding block until the spacing is set 11 8 Opening the scissors Standard The scissors should open as early as without touching the needle Setting Position the needle in the left entry point Loosen the screw 1 and swivel in the stop 2 until the opening scissors just does no longer touch the needle Tighten the screw 1 39 3 1 2 1 3 1 5 mm ...

Page 44: ... to move the needle upwards and bring it out of the range of the closing scissors Shift the closing block on the bar until it abuts on the bolt of the movable part of the scissors Tighten the threaded pin 2 again Attention The movement of the closing block must be limited by the cloth presser bar By no means the scissors must limit this movement 11 10 Setting the time for opening the scissors Stan...

Page 45: ...nning of the buttonhole may be possible 12 Machine stop position Standard After the sewing cycle the thread lever should be in the upper dead center Correction Switch the machine off Move the thread lever to the upper dead center by turning the handwheel Loosen screw 4 and turn the 180 disc in such a way that it stands centrally on the reference switch 3 Tighten the screw again Switch the machine ...

Page 46: ... As the bobbin winder is connected to the power supply with cables lift the cover carefully so that the cables are not damaged Loosen screw 1 and turn the block according to the instructions Tighten screw 1 again Should the winding process stop too early in spite of optimum setting the feeler 2 must be aligned correspondingly 42 1 2 ...

Page 47: ... out the solenoid valve unit Pull off the cables underneath the solenoid valve unit An individual valve block can be exchanged after loosening the screws 5 Put the plugs underneath the solenoid valve unit in again Reinsert the solenoid valve unit and tighten screws 2 Fix the plug 6 in the holder again Put the hoses on again ATTENTION Before switching on the solenoid valve for the knife cylinder th...

Page 48: ... loosening the screw 4 For larger equipment the spring 4 at the cage guide lever has to be displaced a drill hole further Re establish the sewing basket pressure ATTENTION The new cage size has to be entered in the control For this purpose select the menu items T1 3 1 to T1 3 5 Submenu for determining the equipment chapter 4 1 3 and enter the values of the new equipment 44 3 4 5 ...

Page 49: ...ng the motor Tighten screws 1 Mount the belt protection and handwheel Stretching of the long drive and hook shaft belt Unscrew the belt tightener 3 Loosen screw 2 Press the upper belt pulley unit to the right with the belt tightener 3 Tighten screw 2 Screw the belt tightener 3 on again Mount the belt protection and handwheel Hint Check the hook setting and readjust it if necessary chapter Hook and...