DURKOPP ADLER 550-867 User manual

550-867

Service Instructions

Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents,

including extracts, is prohibited without the prior written approval of Dürkopp Adler AG.

IMPORTANT

READ CAREFULLY BEFORE USE

KEEP FOR FUTURE REFERENCE

Table of Contents

Service Instructions 550-867 - 00.0 - 12/2017 1

1 About these instructions.......................................................7

1.1 For whom are these instructions intended?.............................7

1.2 Representation conventions – symbols and characters ..........7

1.3 Other documents .....................................................................9

1.4 Liability.....................................................................................9

2 Safety ....................................................................................11

2.1 Basic safety instructions ........................................................11

2.2 Signal words and symbols used in warnings.........................12

3 Working basis ......................................................................15

3.1 Following the order of the settings.........................................15

3.2 Laying the cables...................................................................16

3.3 Flats on shafts........................................................................16

3.4 Setting the handwheel into position.......................................17

3.5 Locking the machine in place.................................................18

3.6 Tilting and erecting the machine head...................................20

3.7 Removing and assembling covers.........................................21

3.7.1 Removing and placing the arm cover ....................................21

3.7.2 Removing and placing the head cover...................................23

3.7.3 Removing and placing the rear cover ....................................24

3.7.4 Removing and placing the cover on the side.........................25

3.8 Removing and placing the handwheel...................................26

3.9 Opening and closing the hook cover......................................27

3.10 Disassembling and assembling the throat plate ....................29

3.11 Disassembling and assembling the feed dog ........................30

4 Setting the handwheel scale...............................................33

5 Positioning the arm shaft....................................................35

6 Toothed belt wheels ............................................................36

6.1 Positioning the upper toothed belt wheel...............................37

6.2 Positioning the lower toothed belt wheel................................38

7 Setting the mechanical stitch adjustment.........................39

8 Setting the eccentric for the forward and backward

stitches .................................................................................41

9 Presetting the step motor ...................................................42

10 Setting the feed dog ............................................................43

10.1 Setting the feed dog position .................................................43

10.1.1 Moving the feed dog ..............................................................44

10.1.2 Moving the feed dog carrier...................................................45

10.2 Setting the feed dog movement.............................................47

10.2.1 Setting the feed movement for the feed dog..........................48

10.2.2 Setting the stroke movement of the feed dog........................49

10.2.3 Setting the height of the feed dog at top dead center............51

10.2.4 Setting the compensating weight...........................................52

11 Setting transmission lever.................................................. 54

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2 Service Instructions 550-867 - 00.0 - 12/2017

12 Needle bar linkage...............................................................57

12.1 Aligning the needle bar linkage sideways..............................57

12.2 Aligning the needle bar linkage in the sewing direction .........59

13 Hook, loop stroke and needle bar height ..........................61

13.1 Setting the loop stroke position..............................................61

13.2 Setting the height of the needle bar.......................................63

13.3 Setting the needle guard........................................................66

13.4 Setting the distance between hook tip and needle ................68

14 Bobbin case lifter.................................................................70

14.1 Setting the lifting gap .............................................................70

14.2 Setting the timing for lifting.....................................................73

15 Sewing feet...........................................................................74

15.1 Setting the stroke of feeding foot and presser foot................74

15.2 Setting the stroke movement for the feeding foot..................75

15.3 Setting the sewing foot pressure............................................77

16 Sewing foot lift .....................................................................78

16.1 Setting the sewing foot lift mechanically................................78

16.2 Setting the height of the mechanically raised sewing feet.....80

16.3 Setting the height of the pneumatically raised sewing feet....82

17 Thread-guiding parts...........................................................84

17.1 Setting the needle thread regulator........................................84

17.2 Setting the needle thread tension spring ...............................85

17.3 Repairing the tensioning plate ...............................................87

17.4 Replacing the thread force sensor.........................................87

18 Short thread cutter...............................................................90

18.1 Locking latch for the thread-pulling knife ...............................91

18.2 Setting the thread-pulling knife ..............................................92

18.3 Setting the counter blade.......................................................96

18.4 Setting the cutoff position.......................................................98

19 Electrostatic discharge (ESD)...........................................100

20 Potentiometer in the machine arm...................................101

20.1 Basic setting without control panel V810/V820....................101

20.2 Basic setting with control panel V810 or V820.....................103

21 Connections of the circuit board......................................105

22 Setting the friction clutch..................................................107

23 Programming......................................................................109

23.1 Structure of the software......................................................109

23.1.1 Security levels (0-2).............................................................109

23.1.2 Start screen - preparing the machine for operation .............111

23.1.3 Main screen .........................................................................114

23.1.4 Register screen....................................................................116

23.1.5 Recurring elements..............................................................117

23.1.6 Input window........................................................................118

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23.2 Logging into the system.......................................................118

23.2.1 Logging in with the hand scanner........................................119

23.2.2 Logging in via software........................................................120

23.2.3 Logging in using the fingerprint scanner..............................122

23.3 Managing users ...................................................................123

23.3.1 Opening the user database..................................................124

23.3.2 Printing a copy of the access code......................................124

23.3.3 Opening the fingerprint database.........................................125

23.3.4 Storing a user photo.............................................................125

23.3.5 Creating a new user.............................................................127

23.3.6 Deleting users......................................................................133

23.3.7 Deleting the fingerprint database.........................................134

23.4 Seam record sets.................................................................135

23.4.1 Opening the Seam record sets display..........................136

23.4.2 Creating a new seam record set..........................................137

23.4.3 Editing a seam record set (Edit seam parameter

record)...............................................................................139

23.4.4 Copying a seam record set..................................................154

23.4.5 Deleting a seam record set..................................................155

23.4.6 Changing the thread (Change thread in

seam records)..................................................................157

23.4.7 Exporting a seam record set................................................158

23.4.8 Importing a seam record set................................................159

23.5 Database..............................................................................159

23.5.1 Opening the Database display...........................................159

23.5.2 Opening the protocol database............................................160

23.5.3 Printing a protocol file ..........................................................161

23.5.4 Copying a protocol file (Copy) .............................................161

23.5.5 Error codes (Help) ..............................................................162

23.5.6 Printing a copy of an end label (Lab. Copy)......................162

23.5.7 Thread tension (Thr. tens.)............................................163

23.6 Check...................................................................................164

23.6.1 Structure of the Checks display...........................................164

23.6.2 Opening the Checks display...............................................166

23.6.3 Creating a system backup (Backup system)....................166

23.6.4 Restoring data (Restore system)....................................168

23.6.5 Creating a backup of the protocol database

(Backup protoc. DB)......................................................169

23.6.6 Printing a barcode label (Print BC label)......................169

23.6.7 Data transfer........................................................................170

23.6.8 Copying Dump Files.............................................................170

23.6.9 Displaying connections........................................................171

23.6.10 Reducing the data volume of the protocol database

(Reduce protoc. DB)......................................................171

23.6.11 Setup....................................................................................172

23.6.12 Opening the thread database (Threads)............................181

23.6.13 Printing the protocol database (DB print).........................181

23.6.14 Opening the seam database (Show DB) .............................182

23.6.15 Opening the bobbin database (Bobbins) ...........................182

23.6.16 Needle database (Needle DB)...........................................183

23.6.17 Calibrating the step motor (SM-Cali) .................................185

23.6.18 Opening the calibration database (T.Tens.-Cali)...........186

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4 Service Instructions 550-867 - 00.0 - 12/2017

23.6.19 Calibrating the stitch length (SM)..........................................187

23.6.20 Checking input and output (I/O) .........................................189

23.6.21 Checking the scanners (Scanner)......................................190

23.6.22 Checking the sewing motor (Sew. Motor).........................191

23.6.23 Thread tension (Thread tens.)........................................192

23.6.24 Uninterrupted power supply (UPS).......................................194

23.7 Protocol printer.....................................................................195

23.8 Uninstalling the barcode printer drivers ...............................195

23.9 Calibrating the end label printer...........................................198

23.10 Barcodes..............................................................................198

23.10.1 Barcodes at a glance...........................................................198

23.10.2 Opening the Barcodes display.............................................199

23.10.3 Changing the barcode type..................................................201

23.10.4 Defining a barcode...............................................................202

23.10.5 Saving a barcode profile......................................................203

23.10.6 Loading a barcode profile ....................................................204

23.11 Setting batch mode..............................................................205

23.12 Setting multi barcodes .........................................................205

23.13 Preparing the end label (Label)..........................................206

23.13.1 Opening the End label display .............................................207

23.13.2 Defining the end label text ...................................................207

23.13.3 Positioning the text on the end label....................................208

23.13.4 Defining the format of the end label.....................................208

23.13.5 Positioning the end label barcode........................................209

23.13.6 Defining the font size ...........................................................210

23.13.7 Defining an end label barcode type .....................................210

23.13.8 Defining the content of the end label barcode .....................211

23.13.9 Saving an end label .............................................................213

23.13.10 Loading an end label............................................................213

23.13.11 Defining extended label printing...........................................214

23.14 Deleting a bobbin.................................................................216

23.15 Storage locations and automatic backups (Path+netw.)..218

23.15.1 Changing the storage location.............................................218

23.15.2 Setting an automatic backup of the protocol database........219

23.16 Thread database..................................................................220

23.16.1 Creating a new thread..........................................................221

23.16.2 Changing a thread ...............................................................222

23.16.3 Deleting a thread..................................................................223

23.17 Creating a teach-in file.........................................................223

23.18 Restarting the program (Reset)..........................................227

23.19 Exiting the program..............................................................228

23.20 Logging out of the system....................................................229

23.21 Additional program Label Creator .................................230

23.21.1 Preparing the end label (example).......................................231

23.21.2 Default settings....................................................................232

23.21.3 Adjusting the end label size.................................................233

23.21.4 Opening theToolbox .........................................................234

23.21.5 Inserting contents.................................................................235

23.21.6 Moving contents...................................................................236

23.21.7 Creating a barcode ..............................................................237

23.21.8 Adding an additional barcode ..............................................239

23.21.9 Creating standard text..........................................................239

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Service Instructions 550-867 - 00.0 - 12/2017 5

23.21.10 Creating variable text...........................................................240

23.21.11 Inserting a graphic ...............................................................241

23.21.12 Saving a label script file.......................................................242

23.21.13 Printing a test end label .......................................................243

23.22 Additional program SABSearch .........................................243

23.22.1 Performing a search (example)............................................244

23.22.2 Exiting SABSearch .............................................................247

24 Maintenance .......................................................................249

24.1 Cleaning...............................................................................250

24.2 Lubricating ...........................................................................252

24.2.1 Checking the lubrication of the machine head.....................252

24.2.2 Checking the hook lubrication..............................................254

24.3 Servicing the pneumatic system..........................................256

24.3.1 Setting the operating pressure.............................................256

24.3.2 Draining the water condensation .........................................257

24.3.3 Cleaning the filter element...................................................258

24.4 Parts list...............................................................................259

25 Decommissioning..............................................................261

25.1 Transporting the machine....................................................262

26 Disposal..............................................................................263

27 Troubleshooting.................................................................265

27.1 Customer Service ................................................................265

27.2 Messages of the software....................................................265

27.2.1 Information messages..........................................................266

27.2.2 Error messages....................................................................266

27.2.3 Editing error messages........................................................268

27.3 Errors in sewing process......................................................270

28 Technical data....................................................................271

28.1 Characteristics.....................................................................272

28.2 Technical features of the software.......................................273

28.3 Data recording .....................................................................274

29 Appendix.............................................................................275

Table of Contents

6 Service Instructions 550-867 - 00.0 - 12/2017

About these instructions

Service Instructions 550-867 - 00.0 - 12/2017 7

1 About these instructions

These instructions have been prepared with utmost care. They contain in-

formation and notes intended to ensure long-term and reliable operation.

Should you notice any discrepancies or if you have improvement requests,

then we would be glad to receive your feedback through Customer

Service ( p. 265).

Consider the instructions part of the product and store them in a place

where they are readily available.

1.1 For whom are these instructions intended?

These instructions are intended for specialists. This group has the

appropriate technical training for performing maintenance or repairing

malfunctions.

With regard to minimum qualification and other requirements to be met by

personnel, please also follow the chapter Safety ( p. 11).

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.

Disturbances

Specifies the disturbances that can occur from an incorrect setting.

Cover

Specifies which covers must be disassembled in order to access the com-

ponents to be set.

Steps to be performed when operating the machine (sewing and

equipping)

Steps to be performed for service, maintenance, and installation

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.

1.

2.

…

About these instructions

8 Service Instructions 550-867 - 00.0 - 12/2017

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.

References

 Reference to another section in these instructions.

Safety Important warnings for the user of the machine are specifically marked.

Since safety is of particular importance, hazard symbols, levels of

danger and their signal words are described separately in the chapter

Safety ( p. 11).

Location

information

If no other clear location information is used in a figure, indications of right

or left are always from the user's point of view.

•



About these instructions

Service Instructions 550-867 - 00.0 - 12/2017 9

1.3 Other documents

The machine includes components from other manufacturers. Each man-

ufacturer has performed a hazard assessment for these purchased parts

and confirmed their design compliance with applicable European and na-

tional regulations. The proper use of the built-in components is described

in the corresponding manufacturer's instructions.

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

Transport

Dürkopp Adler cannot be held liable for breakage and transport damages.

Check the delivery immediately upon receiving it. Report any damage to

the last transport manager. This also applies if the packaging is not

damaged.

Leave machines, equipment and packaging material in the condition in

which they were found when the damage was discovered. This will ensure

any claims against the transport company.

Report all other complaints to Dürkopp Adler immediately after receiving

the product.

About these instructions

10 Service Instructions 550-867 - 00.0 - 12/2017

Safety

Service Instructions 550-867 - 00.0 - 12/2017 11

2 Safety

This chapter contains basic information for your safety. Read the instruc-

tions carefully before setting up or operating the machine. Make sure to

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.

These instructions must be available at the machine's location at all times.

Work on live components and equipment is prohibited. Exceptions are de-

fined in the DIN VDE 0105.

For the following work, switch off the machine at the main switch or

disconnect the power plug:

• Replacing the needle or other sewing tools

• Leaving the workstation

• Performing maintenance work and repairs

• Threading

Missing or faulty parts could impair safety and damage the machine.

Only use original parts from the manufacturer.

Transport Use a lifting carriage or forklift to transport the machine. Raise the machine

max. 20 mm and secure it to prevent it from slipping off.

Setup The connecting cable must have a power plug approved in the relevant

country. The power plug may only be assembled to the power cable by

qualified specialists.

Obligations

of the operator

Follow the country-specific safety and accident prevention regulations and

the legal regulations concerning industrial safety and the protection of the

environment.

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 be met by

the personnel

Only qualified specialists may:

• Setting up the machine

• Performing maintenance work and repairs

• Performing work on electrical equipment

Only authorized persons may work on the machine and must first have

understood these instructions.

Safety

12 Service Instructions 550-867 - 00.0 - 12/2017

Operation Check the machine during operating for any externally visible damage.

Stop working if you notice any changes to the machine. Report any chang-

es to your supervisor. Do not use a damaged machine any further.

Safety

equipment

Safety equipment should not be removed or deactivated. If it is essential

to remove or deactivate safety equipment for a repair operation, it must be

assembled and put back into operation immediately afterward.

2.2 Signal words and symbols used in warnings

Warnings in the text are distinguished by color bars. The color scheme is

based on the severity of the danger. Signal words indicate the severity of

the danger.

Signal words Signal words and the hazard they describe:

Symbols The following symbols indicate the type of danger to personnel:

Signal word Meaning

DANGER (with hazard symbol)

If ignored, fatal or serious injury will result

WARNING (with hazard symbol)

If ignored, fatal or serious injury can result

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

Symbol Type of danger

General

Electric shock

Safety

Service Instructions 550-867 - 00.0 - 12/2017 13

Examples Examples of the layout of warnings in the text:

 This is what a warning looks like for a hazard that will result in serious

injury or even death if ignored.

 This is what a warning looks like for a hazard that could result in seri-

ous or even fatal injury if ignored.

 This is what a warning looks like for a hazard that could result in

moderate or minor injury if the warning is ignored.

Puncture

Crushing

Environmental damage

Symbol Type of danger

DANGER

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

WARNING

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

CAUTION

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

Safety

14 Service Instructions 550-867 - 00.0 - 12/2017

 This is what a warning looks like for a hazard that could result in envi-

ronmental damage if ignored.

 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.

NOTICE

Type and source of danger!

Consequences of non-compliance.

Measures for avoiding the danger.

Working basis

Service Instructions 550-867 - 00.0 - 12/2017 15

3 Working basis

3.1 Following the order of the settings

Order

The setting positions for the machine are interdependent.

Always comply with the order of individual setting steps as specified.

It is absolutely essential that you follow all notices regarding prerequisites

and subsequent settings that are marked with in the margin.

Information

Some shafts of the machine have flat surfaces ( p. 16). These surfaces

makes it easier to set up the machine.

For all settings on the surface, the first screw in the direction of rotation is

screwed onto the surface.

WARNING

Risk of injury!

If setting operations on stitch-forming parts are not

performed with faultless needles, the machine may

produce faulty tearing seams. Faulty tearing seams

can cause serious injuries, including death.

Insert a new, faultless needle before all setting

operations on stitch-forming parts.

NOTICE

Property damage may occur!

Possible damage to the machine from using faulty needles for

setting operations on stitch-forming parts.

Insert a new, faultless needle before all setting operations on stitch-

forming parts.

NOTICE

Property damage may occur!

Risk of machine damage from incorrect order.

It is essential to follow the working order specified in these

instructions.

Working basis

16 Service Instructions 550-867 - 00.0 - 12/2017

3.2 Laying the cables

Ensure that all cables are laid in the machine such that the function of

moving parts is not hampered.

To lay the cables:

1. Lay any excess cabling neatly in proper cable snakes.

2. Bind together the cable loops with cable ties.

Important

Tie loops wherever possible to fixed parts.

The cables must be secured firmly.

3. Cut off any overlapping cable ties.

3.3 Flats on shafts

Fig. 1: Flats on shafts

Some shafts (2) have flat surfaces (1) at the points where the components

are screwed on. This stabilizes the connection and makes setting easier.

Important

Ensure that the screws are completely flush with the surface.

NOTICE

Property damage may occur!

Excess cables can impair the functioning of moving machine parts.

This impairs the sewing function and can result in damage.

Lay excess cable as described in these instructions.

(1) - Flat (2) - Shaft

①

②

Working basis

Service Instructions 550-867 - 00.0 - 12/2017 17

3.4 Setting the handwheel into position

Fig. 2: Setting the handwheel into position

Some settings require that the handwheel be moved to a certain position.

To set the handwheel to the desired position:

1. Turn the handwheel (2) until the desired degree number is parallel to

the marking (1).

(1) - Marking (2) - Handwheel

①

②

Working basis

18 Service Instructions 550-867 - 00.0 - 12/2017

3.5 Locking the machine in place

Fig. 3: Locking the machine in place (1)

For some settings, the machine must be locked in place. To do this,

the locking peg (4) is inserted into an arresting groove on the arm shaft

crank (1), blocking the arm shaft.

There are 2 securing positions:

•Position I: Loop stroke position

• 5 mm end in the large arresting groove (2)

• Setting the loop stroke and needle bar height

•Position II: Handwheel zero position

• 3 mm end in the small arresting groove (3)

• Setting the handwheel position and checking the top dead center

for the needle bar

(1) - Arm shaft crank

(2) - Large arresting groove

(3) - Small arresting groove

(4) - Locking peg

③

②

①

④

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