550-867 Betriebsanleitung Service Instructions
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.
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.
Index Page: Preface and General Safety Instructions Service Instructions Class 550-867 (Edition 12/2011) 1 1.1 1.2 1.3 General notes Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the locking positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graduation on the handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.1 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.
Index Page: 2.10.1 2.10.2 2.10.3 2.10.4 2.11 2.11.1 2.11.2 2.11.3 2.11.4 2.11.5 2.12 2.13 2.13.1 2.13.2 2.14 2.15 Thread regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread take-up spring. . . . . . . . . . . . . . . . . . . . . . . . Thread tension plate. . . . . . . . . . . . . . . . . . . . . . . . . Measuring system for thread tension. . . . . . . . . . . . . . . Short thread cutter. . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . .
1 General The present service instruction describes the adjustment of the special sewing machine 550-867. ATTENTION! The operations described in the service instructions must only be executed by qualified staff or correspondingly instructed persons respectively! Caution: Risk of injury! In case of repair, alteration or maintenance work turn off the main switch and disconnect the machine from the pneumatic supply system.
1.2 Description of the locking positions 3 4 2 1 With the locking pin 1 and the arresting grooves 2 and 3 in the arm shaft crank 4 the sewing machine can be arrested in two adjusting positions.
1.3 Graduation on the handwheel 1 2 3 The handwheel 2 has a graduation printed on it. Certain settings are carried out according to the position of the handwheel. – Turn the handwheel until the degree mark mentioned in the present instructions points to the index 3. – Carry out the described adjustment. Setting the handwheel – Set the handwheel to the degree mark 50° – Loosen the threaded pin for the handwheel through opening 1.
2 Sewing machine 2.1 Position of the arm shaft crank on the arm shaft 2 4 3 1 2 1 Caution: Risk of injury! Turn off the main switch. Check and set the position of the arm shaft crank only when the machine is switched off. Standard checking The arm shaft crank 1 is fastened on the arm shaft 4 with three threaded pins 2. The threaded pins must sit on the flat spot 3. Correction – Loosen the threaded pins 2 on the arm shaft crank.
2.2 Upper and lower toothed belt wheel / toothed belt 2.2.1 4 Position of the upper toothed belt wheel 3 2 1 3 2 Caution: Risk of injury! Turn off the main switch. Check and set the position of the upper toothed belt wheel only when the machine is switched off. Standard checking The toothed belt wheel 2 is fastened on the arm shaft 4 with two threaded pins. The threaded pins must sit on the flat spot 1. The distance between the toothed belt wheel 2 and the bobbin winder wheel 3 must amount to 0.
2.2.2 Position of the lower toothed belt wheel 1 5 4 3 2 1 Caution: Risk of injury! Turn off the main switch. Check and set the position of the lower toothed belt wheel only when the machine is switched off. Standard checking The threaded pins in the toothed belt wheel 2 must sit on the flat spot 1 of the lower shaft 5. The toothed belt wheel must be positioned in a way that the toothed belt 4 bears against the belt tensioner ring 3 when the handwheel is turned but without being dislocated.
2.3 2.3.1 Bottom feed and stepping motor Pre-setting 1 2 3 4 5 6 7 Caution: Risk of injury! Turn off the main switch. Adjust the basic setting only with the sewing machine switched off. Pre-setting – Fix the screws 1 and 3 on the flat spots of the shaft 2. – Loosen screw 4. – Bring the gear tongues 5 into parallel position and align the markings 6 and 7. – Tighten screw 4. Fine adjustment (see software chapter 4.
2.3.2 Position of the feed dog in the throat plate cutout 2 9 8 7 6 5 4 3 14 Caution: Risk of injury! Turn off the main switch. Check and set the position of the feed dog and stitch regulator gear only when the machine is switched off. – – – – – – – – 10 11 – Loosen the threaded pins on the adjustment rings 8 and 9. Loosen screw 5. Align the feed dog in the center of the throat plate cutout. Arrest the shaft 7 with the adjustment rings 8 and 9 and tighten the screws.
11 – – – – – – 12 13 Set the lever on the step motor to marking. Set the gear to “0”. In order to do so, turn the positioning frame 14 so that the tongues come parallel to each other. Tighten the screw 13 on the block 12. Align the feed dog in longitudinal direction in the center of the throat plate cutout. Tighten screw 5 (see picture on page 10). Fit in the spring 1 (see picture on page 10) on the positioning frame and the fastening bracket.
2.3.3 Feeding motion of the feed dog 1 Caution: Risk of injury! Turn off the main switch. Check and set the feeding motion of the feed dog only when the machine is switched off. Standard checking When the machine is in position “190°” the feed dog must not move upon actuating the stitch regulator if the maximum stitch length is set. – Set the maximum stitch length. – Turn the machine to position “190°”.
2.3.4 Lifting motion of the feed dog 1 Caution: Risk of injury! Turn off the main switch. Check and set the lifting motion of the feed dog only when the machine is switched off. Standard checking The feed dog should stand at the same height at the needle’s entering and leaving the throat plate. – Turn the handwheel and check the movement of the feed dog. Correction – Loosen the threaded pin on the lifting cam 1. – Turn the lifting cam. – Tighten the screws on the lifting cam 1. – Check the setting.
2.3.5 Feed dog height 2 1 Caution: Risk of injury! Turn off the main switch. Check and set the height of the feed dog only when the machine is switched off. Standard checking For a safe forward movement of the material the feed dog 2 must be in its highest position for machines with KFA (short thread cutter) 0.8 mm above the throat plate surface. – Turn the handwheel until the feed dog 2 has reached its highest position.
2.3.6 Balance weight 1 3 2 Caution: Risk of injury! Turn off the main switch. Check and set the balance weight only when the machine is switched off. Standard checking The balance weight 1 has to be positioned in a way that, with the handwheel in position “210°”, a stuck in Allen key 3 stands parallel to the bed plate 2. – Check the position of the balance weight. Correction – Loosen the screws on the balance weight 1. – Turn the balance weight 1 accordingly.
2.4 Transmission lever 3 2 1 4 Caution: Risk of injury! Turn off the main switch. Check and set the transmission lever only when the machine is switched off. Standard checking The lever 3 transmits the movement of the advance shaft to the needle bar linkage. The lever 3 must be positioned in a way the distance between the surface of the arm 1 and the center of the bolt 2 amounts to 123,6 mm with the stitch length set to “0”. – Set the stitch length to “0” by aligning the markings 6 and 7.
2.5 2.5.1 Needle bar linkage Align the needle bar linkage laterally 2 1 4 3 Caution: Risk of injury! Turn off the main switch. Check and set the needle bar linkage only when the machine is switched off. Standard checking The needle must penetrate the center of the feed dog’s stitch hole. – Insert a new needle. – Turn down the needle bar with the handwheel. – Check the lateral position of the needle in the stitch hole. Correction – Loosen the screws on the adjustment rings 3 and 4.
2.5.2 Needle penetration in feeding direction 2 1 3 Caution: Risk of injury! Turn off the main switch. Check and set the needle penetration only when the machine is switched off. Standard checking The needle is supposed to penetrate the center of the feed dog’s stitch hole with the stitch length set to “0”. – Insert a new needle. – Set the stitch length to “0” by aligning the markings 4 and 5. – Turn down the needle bar with the handwheel. – Check the position of the needle in the needle hole.
2.6 Hook, looping stroke and needle bar height 2.6.1 Looping stroke 3 Caution: Risk of injury! Turn off the main switch. Check and set the looping stroke only when the machine is switched off. Standard checking The looping stroke is the way of the needle bar from its bottom dead center to the point where the hook tip 2 is at the middle of the needle 1. The looping stroke is 2 mm. – Arrest the machine head in position I (Locking pin Ø 5 mm in the large groove).
2.6.2 Needle bar height 3 2 1 Caution: Risk of injury! Turn off the main switch. Check and set the needle bar height only when the machine is switched off. Standard checking The needle bar’ s height is to be set in a way that the hook tip stands in the lower third of the needle scarf with the stitch length set to “ 0 “ in the looping stroke position. – Set the stitch length to “ 0” by aligning the markings 4 and 5. – Arrest the sewing machine in position I (looping stroke position).
2.6.4 Distance between hook and needle 3 2 1 Caution: Risk of injury! Turn off the main switch. Check and set the distance between hook and needle only when the machine is switched off. Standard checking In looping stroke position the distance between the hook tip and the needle scarf is to be max. 0.1 mm. Correction – Check whether the needle is dislocated by the hook guard 5 in looping stroke position. If this is the case, the hook guard 5 must be readjusted accordingly (see chapter 2.6.4).
2.6.5 Needle guard 2 1 Caution: Risk of injury! Turn off the main switch. Check and set the needle guard only when the machine is switched off. Standard checking The needle guard 2 is to prevent a contact of the needle with the hook tip. In looping stroke position the needle should be slightly dislocated. – Check the needle guard. Correction – Turn the machine into looping stroke position. – Adjust the needle guard by twisting the screw 1.
2.7 2.7.1 Bobbin case opening General The thread lever has to pull the thread through between the bobbin case and its holder. For the thread to slip through without any hindrance the bobbing case must be opened in this particular moment. That way the desired seam pattern can be achieved with the least thread tension possible. Wrong settings can have the following consequences: – Thread breakage – Eyes on the seam’s bottom side – Loud noises 2.7.
3 2 1 5 Correction – Loosen screw 4. – Shift the cover on the hook housing downward. – Loosen screw 5. – Adjust the bobbing case opener 3. – Tighten screw 5 again. – Put the cover back again. – Tighten screw 4.
2.7.3 Timing of opening 3 2 1 6 5 4 Caution: Risk of injury! Turn off the main switch. Check and set the bobbin case opener only when the machine is switched off. Standard checking After having taken up the loop, when the hook tip 2 is below the bobbin case opener (handwheel position 350°) the sewing thread should be able to slip through unimpededly between the bobbin case opening finger 3 and the bobbin case 1. – Turn the handwheel to position “350°”.
2.8 2.8.1 Feeding foot and presser foot Feeding foot and presser foot stroke 2 1 4 3 Caution: Risk of injury! Turn off the main switch. Check and set the stroke of the sewing feet only when the machine is switched off. Standard checking Setting of the cylinder With the multi-position cylinder lifted the tongues 4 of the stitch regulator gear have to be flush. When actuating the multi—position cylinder and when turning the handwheel the stroke of the sewing feet 1 and 2 should be identical.
2.8.2 Stroke motion of the feeding foot 2 1 3 Caution: Risk of injury! Turn off the main switch. Check and set the stroke motion only when the machine is switched off. Prerequisite · · The strokes of the feeding foot and the presser foot are identical (see chapter 2.8.1). Correct timing of the feeding dog’s lifting motion (see chapter 2.3.3) Standard The descending feeding foot 2 is, with max. sewing foot stroke and max.
2.8.3 Sewing foot pressure 1 Standard checking The material to be sewn must not “float”. It should not be exerted more pressure than necessary. Correction – Set the sewing foot pressure by turning screw 1. Increase the pressure = Turn screw 1 clockwise. Decrease the pressure = Turn screw 1 counter-clockwise.
2.9 2.9.1 Sewing foot lifting Mechanical sewing foot lift 1 2 1 5 4 3 Caution: Risk of injury! Turn off the main switch. Check and set the clearance of the lifting mechanism only when the machine is switched off. Standard checking The lifting shaft 6 is supposed to run softly but should have no end play. The clearance in the lifting mechanism should be approx. 0.5 mm between the spring guide 2 and the lifting lever 1. – Lower the sewing feet. – Turn the handwheel until the presser foot touches down.
2.9.2 Height of the sewing feet arrested with hand lever 1 3 2 Caution: Risk of injury! Turn off the main switch. Check and set the sewing foot lifting only when the machine is switched off. Standard checking The sewing feet 4 are arrested in lifted position with the hand lever 1, for example in order to exchange the sewing feet or to run the sewing machine without any material or to wind up the hook thread.
2.9.3 Height of the lifted sewing feet 2 1 3 Caution: Risk of injury! Turn off the main switch. Check and set the height of the lifted sewing feet only when the machine is switched off. Standard checking The pneumatically or via knee lever lifted sewing feet 4 are supposed to have a distance of 20 mm to the throat plate, when the needle bar is in its upper dead center. The screw 2 limits the travel of the lifting lever 3. – Lower the sewing feet.
2.10 Thread-guiding parts 2.10.1 Thread regulator 1 2 Caution: Risk of injury! Turn off the main switch. Check and set the thread regulator only when the machine is switched off. Standard checking The position of the thread regulator 1 depends on the thickness of the material to be sewn, the thread size and the chosen stitch length. It has to be set so that the thread is guided around the hook and kept under control.
2.10.2 Thread take-up spring 3 2 1 4 Caution: Risk of injury! Turn off the main switch. Check and set the thread take-up spring only when the machine is switched off. Standard checking The standard setting for the spring travel and spring tension only apply to usual thread sizes. Very thick or very thin threads or sewing material may necessitate different settings.
2.10.3 Thread tension plate 4 2 3 1 ATTENTION! Repair works on the thread tension plate 1 may only be effectuated by Dürkopp Adler. Trying to repair it on one’s own will destroy the exact calibration and leads to loss of warranty. 2.10.4 Measuring system for thread tension ATTENTION! In order to ensure the quality of sewing results continuously the measuring system for thread tension has to be checked and calibrated at least once a year.
2.11 Short thread cutter 2.11.1 General 2 1 3 Thread-pulling knife height As standard the height of the thread-pulling knife is set through the washers underneath the knife carrier 3 to a distance of 10.9±0.05 between the upper edge of the knife carrier 3 and the screw-on area of the hook bearing (see the picture). Pay attention to the number of washers when dismantling the thread-pulling knife! Position of the thread-pulling knife The thread-pulling knife 1 cannot be shifted on the knife carrier 3.
2.11.2 7 Locking latch for the thread-pulling knife 12 4 10 11 10 12 11 13 ATTENTION: Danger of breakage! The sewing machine must not be used without the thread-pulling knife. The back stop (anti-rollback) for the bobbin case 2 is situated on the thread pulling knife. Standard checking In the thread-pulling knife’s 1 resting position, between the locking latch 10 and the locking bolt 11 should not be a distance of more than 0.1mm.
2.11.3 Thread pulling knife 14 1 3 7 5 4 Caution: Risk of injury! Turn off the main switch. Check and set the thread-pulling knife only when the machine is switched off. ATTENTION! The sewing machine must not be used without the thread-pulling knife. The back stop (anti-rollback) for the bobbin case 2 is situated on the thread pulling knife.
14 1 7 5 4 Correction – – – – – – – 6 7 12 13 8 – – – – Loosen the screws (4x) on the clamping ring 5 and shift it towards the hook bearing. Tighten the screws (4x) on the clamping ring 5 again in order to avoid changing the looping stroke’s position. Loosen the screws (2x) on the control cam 4. Twist the lever 6 until it stops against the stop screw 13. Set the distance between the control cam 4 (highest point) and the roller 7 to 0.1 mm. Tighten the screws (2x) on the control cam 4 again.
2.11.4 Counter knife 1 7 4 Caution: Risk of injury! Turn off the main switch. Check and set the counter-knife only when the machine is switched off. Standard checking The thread is to be trimmed safely with as little pressure as possible. A low trimming pressure keeps the knife wear low! It must be possible to safely trim two of the thickest sewing threads simultaneously. – Turn the handwheel until the thread-pulling knife can be swung out after releasing the latch.
20 1 2 19 2 20 19 1 Correction of the cutting pressure – Swing out the thread-pulling knife 1 far enough so that the marking 19 stands next to the blade of the counter-knife 2. – Loosen screw 20. – Turn the counter-knife 2 against the thread-pulling knife 1. – Tighten the screw 20. Note: Through the eccentric cut of the thread-pulling knife 1 a cutting pressure is automatically exerted when the two blades superpose.
2.11.5 Cutting position 1 6 7 4 Standard checking With the factory setting the cutting position corresponds to the position “thread lever in its upper dead center” (65°on the handwheel). – Turn the handwheel to position 0°. – Release the locking latch. – Swing out the thread-pulling knife 6 manually. In order to do so push the lever 7 with the roller to the right against the control cam 4. – Insert the thread into the thread-pulling knife 1. – Turn the handwheel until the thread is cut.
2.12 Important notes concerning electrostatic discharges (ESD) ATTENTION! Before effectuating any works on electronic components: Turn off the main switch. Remove the plug from the socket. · · · · 42 Electrostatic discharges can cause damage to PCBs and other components. You can obtain a certain protection by wearing anti-static gloves or wrist-wraps that you can connect for grounding on the mass of any unpainted metal piece of the machine head or on the switch cabinet.
2.13 Potentiometer in the arm Sewing machines with thread trimmer are equipped with a potentiometer in order to limit the sewing speed of higher sewing foot strokes. Through this potentiometer the control unit recognizes the sewing foot stroke and limits the sewing speed. 1 2.13.1 2 4 3 Basic setting without control panel Set sewing machines without control panel according to the following description. Caution: Risk of injury! Turn off the main switch.
2.13.2 Basic setting with the control panel V810 or V820 1 2 Caution: Risk of injury! The adjustment of the potentiometer is done with the main switch switched on. Work with utmost caution. – – – – – – – – 44 Loosen the stop screw 1 for the potentiometer 2. Keep the key “P” pressed and turn on the main switch. Enter the technician level. Select the parameter “F-188”. Actuate the key “E”.
2.14 Connections PCB For the sake of completeness, the various connections of the PCB mentioned below are explained here. Connection X1 X2 X3 X4 X11 X12 X13 X14 X15 X16 X17 X18 X19 X20 X21 X22.1 X22.2 X22.3 X22.4 X22.5 X22.6 X22.7 X22.
2.15 Setting the sliding clutch 3 2 1 Caution: Risk of injury! Turn off the main switch. Set the sliding clutch only with the sewing machine switched off. The factory setting of the sliding clutch is at about 8 Nm and is marked with the point 1 on the sliding clutch. – Loosen screw 3. – Twist the sliding clutch 2 accordingly. Direction + = increasing the torque Direction - = decreasing the torque – Tighten screw 3 again.
3 Lubrication Caution: Risk of injury! Oil can cause skin rashes. Avoid longer skin contact. After contact wash yourself thoroughly. ATTENTION! The handling and disposal of mineral oils is subject to legal regulations. Deliver used oil to an authorized collecting station. Protect your environment. Be careful not to spill any oil.
3.1 Hook lubrication 1 Caution: Risk of injury! Turn off the main switch. Adjust the hook lubrication only with the sewing machine switched off. Make a functional test with utmost caution when the sewing machine is running. Standard checking The necessary oil quantity for the correct lubrication of the hook is factory set by the manufacturer. It may be modified, only in exceptional cases. The required oil quantity depends on the sewing threads to be processed and on the fabric.
3.2 Maintenance Caution: Risk of injury! Turn the main switch off ! The maintenance of the sewing machine must only be done when the machine is switched off. The daily or weekly maintenance work (cleaning and oiling) to be carried out by the operators of the sewing machine is described in the operating instructions (part 1). It is only listed in the following table for the sake of completeness.
4 Setting of the tearing seam visualization software 4.1 General 4.1.1 Security levels The software of the sewing unit 550-867 has as standard equipment 3 security levels.
4.1.2 Data backup The sewing unit 550-867 has been configurated in the factory so that it is ready for operating. To this end the operating system“Microsoft XP” as well as the Dürkopp Adler software “SAB” has been provided with all the necessary settings. These settings (factory settings) are additionally delivered in the form of a computer “backup”. Dürkopp Adler uses as backup software the program Acronis ® Backup & Recovery ® see http://www.acronis.
4.1.4 Logging in with scanner and barcode 2 3 – – 52 Press the switch 2 underneath the table top. The integrated lamp lights up. Scan in the barcode of the operator using the hand scanner 3. The corresponding security level is activated.
4.2 Exiting the system – Press the button “End”. The following screen will appear: – Press the button “PC off”. The system will be shut down and the PC switched off. Note: Exiting by pressing the “Yes” will lead the user to the Windows graphic user interface (only possible with the security level 2).
4.3 Setting a new operator Before the engineered sewing station can be used the operator has to be logged in. The person logging in the new operator has to be authorized to access at least security level 2. Note! The length of the card barcode has to be predefined in the setup. – Log in to the system – Press the “Access” button – Press the button “New”. The following screen will appear: – – – – – – – – – Enter the name of the new operator and determine his security level. Enter the personnel id number.
4.4 Deleting an operator In order to carry out this operation the user must be authorized to access security level 2. – Log in to the system – Press the “Access” button – Press the button “Delete”. The following screen will appear: – – – Select the corresponding operator. (for example: Operator name Andree) Press the button “Delete operator”. The following screen will appear: Press the button “Yes”. The operator will be deleted from the list.
4.5 Displaying the operators – – – Log in to the system Press the “Access” button Press the “Disp op.” button. The following screen will appear: – Press “Operator screen”. The following screen will appear: – – Select an operator symbol from the list. Press “Open”. The symbol will be loaded.
4.6 Seam patterns Upon pressing the button “seam patterns” new seam patterns can be created or existing seam patterns can be edited or deleted. – Press the button “Seam patterns”.
4.6.1 Creating a new seam pattern – Press the button “new seam pattern”. A screen displaying all existing seam patterns and their alteration status will appear. 2 1 – Press “Seam pattern code” 2. The following input screen will appear. – – – Enter the seam pattern code. Press the “Return” button. Press “Seam pattern name” 1. The following input screen will appear. – – Enter the name of the seam pattern. Press the “Return” button.
– Press the “OK” button. An input screen for the number of seam sections will appear. – – Select the number of seam sections, for example “3”. Press the “OK” button. The new seam pattern will be displayed.
– Select the individual seam sections by clicking on them and enter the corresponding seam parameters. The selected seam segment is displayed with a raised bar.
Inserting a seam section – Select the seam section that will follow the new section that is to be inserted. – Press the “Insert” button. The following screen will appear. – Press the “OK” button. The inserted seam section 1 will be displayed. – Select the new seam section by clicking and enter the corresponding seam parameters. After setting the seam parameters, press the button “Memorize”.
Delete a seam section 1 – – – 62 Press the seam section that is to be deleted. For example: Seam section 1. Press the button “Delete”. The following screen will appear: Press the “OK” button. The seam section will be deleted. Three seam patterns are displayed.
4.6.2 Editing a seam pattern – Press the “Edit a seam pattern” button. A list of all existing seam patterns and their alteration status will be displayed. – – Enter the seam pattern code. Press the “OK” button. The selected seam pattern will be displayed on the screen. – Call up the individual seam sections and effectuate the desired alterations. Press the button “Memorize”.
4.6.3 Copying a seam pattern – Press the button “Copy a seam pattern”. A list of all existing seam patterns and their alteration status will be displayed. – Enter the code of the seam pattern that is to be copied. For example: Seam pattern 003. Press “seam pattern code”. Enter a new number for the seam pattern code. For example: 004 Press the “OK” button. Press “seam pattern name” and enter a new name. Press the “OK” button. The following screen will appear. – – – – – – 64 Press the “OK” button.
4.6.4 Deleting a seam pattern – Press the button “Delete a seam pattern”. A list of all existing seam patterns and their alteration status will be displayed. – Enter the seam pattern code. For example: Seam pattern 004 Press the button “OK”. A confirmation request will appear: – – Confirm the request with „Yes“. The seam pattern 004 will be deleted.
4.7 Data base The finished seams are recorded and the data are memorized in a data base. Via the button “Data base” these recorded data can be displayed, printed and copied. 1 – The selection of the desired data takes place via button 1 File Each day a new file is created. With the “Files” button an older file can be displayed. – Press the “Files” button. The following menu will appear: – – Press the requested file. Press “Open”.
”Copy” The selected daily file will be copied to a previously determined directory. ”Help” A list of the error codes will appear (see chapter 6.7) ”Thread Tens” File that indicates the thread tension values of each individual stitch within the documented seam sections.
4.8 Checking Via the button “Check” functions are available that serve to secure and restore files, to inform about sewing materials and sewing parameters as well as to test, adjust and set-up the integrated sewing station. “Backup System” When this function is activated all system-relevant settings will be saved. – Press “Backup system”.
– Press the “OK” button. A selection window will appear. – – Select the backup location. Press “OK”. The backup will be saved. “Restore System” System-relevant data are imported into the system. The requested parameters can be set previously.
”Print BC label” When this function is activated the label printer will print a barcode label. “Backup file DB” When this function is activated all data base records of the sewing station will be saved under the corresponding machine number. For the way of proceeding see Backup System “Data import” Backup files of older software versions will be imported. For the way of proceeding see Backup System “Copy dump files” When this function is activated all dump files will be copied.
“Setup” When this function is activated system settings can be entered “General settings” When this function is activated the language is selected, code numbers for the manufacturer and the sewing station are attributed, relevant barcode digits determined and the sewing equipment that is to be used selected.
72 Read bobbin no. with stat. scanner Bobbin identification via barcode (optional) existing / not existing With seam scanner Monitoring of the end label (optional) existing / not existing Cone switch for the needle thread Monitoring of the thread cone via proximity switch. The barcodes are read with the hand scanner. existing / not existing Cone switch for the hook thread Monitoring of the thread cone via proximity switch. The barcodes are read with the hand scanner.
Thread tension regulator on When using an ETT nominal and and actual values are compared and corrected (adjusted) ON/OFF Edge detection Optional equipment for the detection / controlling of the distance between needle and material edge existing / not existing Enables different Bartack stitches for initial or end bartacks in the particular seam sections ON/OFF Bartack stitches for each SS progr.
Barcodes Via the “Barcode” field the barcode definitions can be adjusted, saved or newly loaded. In order to do so the relevant barcode digits are defined through the setting of masks. 1= The digit of the barcode will be read. 0= The digit of the barcode will be ignored. 1 Entry of the nominal values Changing the barcode definition – Press the corresponding barcode row 1 An input screen will appear. – – – Enter the barcode definition. Press the “OK” button. The new definition is adopted.
Memorizing a barcode definition – Press the “Save” button. A selection window will appear. – – Enter a file name. Press “Save”. The definition is memorized. “Label” Via the “Label" button the layout of the end label can be determined. The barcode information that will be printed is determined. Via the button “Define ext. label print” additional information can be included on the end label. 3 1 2 1 Determining the end label barcode type See chapter 4.9. 2 Determining the end label layout See chapter 4.
“Load” Via this button a barcode set-up file can be loaded. – Press “Load”. A selection window will appear. – – Press the requested file. Press “Open”. The file will be loaded. “Save” Via this button a barcode definition can be memorized. – Press “Save”. A selection window will appear. – – Enter a file name. Press “Save”. The file will be memorized. “Define ext. label print” Via this button an extended label print can be edited. With this function variable information can be printed on the endlabel.
”Path+Net” Via the “Path+Net” field the paths to be used when saving the record database and the system database can be determined, as well as the intervals between automatic saving. – Press “Change path”. The following screen will appear: – – Select the path. Press “OK”. The path will be adopted. Note: When using a network connection the path for the automatic copy of the record data base will be changed to the desired path.
“Threads” field When this function is activated a database containing the threads that are determined for the use with this system will be displayed. New threads can be entered and existing threads can be deleted. Important note Upon entering a new thread the Ident-No. has to be entered. Through the Ident-No. the system recognizes the thread. It is made up of the predefined digits of the thread barcode. Entering a new thread type – Press the button “New thread”.
– Press the button “Scan”. The following screen will appear: – – – Read the thread barcode with the hand scanner. Press “OK”. The thread barcode is adopted. Enter further thread data and confirm with “OK”. “Modify thread type” When this function is activated the selected thread type can be modified. “Delete thread type” When this function is activated the selected thread type can be deleted.
“Print DB” When this function is activated the seam database will be printed (only if a file printer is connected and has been activated in the setup). “Display DB” When this function is activated the seam data base will be opened and all seam parameters will be displayed.
“Bobbins” When this function is activated all registered bobbins will be displayed. By pressing the “Delete” button preselected bobbins can be deleted. – – Press the bobbin that is to be deleted. Press “Delete”. A confirmation request will appear: – Press “OK”. The bobbins will be deleted.
“Needle DB” If during the setup the component „needle control“ has been activated, the operator will be asked in certain intervals to check the needle and replace it, if necessary. These activities are recorded in the needle replacement data base. 82 – Press “Replacement”. The following screen will appear: – Press “Checked”.
“SM-Cali” and “Cali” If during the setup the component „calibration control“ has been activated, the operator will be asked in certain intervals to check the settings of the step motor and the thread tension sensor or to recalibrate them. These activities are recorded in the thread tension and step motor calibration data base.
“SM” When this function is activated the stitch length adjustment can be calibrated and checked. Checking the stitch lengths 1 – – – – – – 84 Pull the needle thread out of the needle. Put a piece of cardboard 1 under the sewing foot. Press the button “Check 2 mm”. Press the foot pedal. A predetermined section will be sewn. Measure the stitch length. Proceed as described for the other stitch lengths.
Calibrating the stitch lengths – – – Pull the needle thread out of the needle. Put a piece of cardboard 1 under the sewing foot. Press the button “Cali. 1”. The following screen will appear: – Press the button “Enter 100 stitches + length”. The following screen will appear: – Press the foot pedal. A predetermined section will be sewn. Measure the stitch length and enter it with the keyboard. Press “Return”. Repeat the procedure for “Cali. 2”. Memorize.
“I/O” When this function is activated the inputs and outputs of the system can be checked. “Scanner” When this function is activated the barcode scanners can be tested.
“Sewing motor” When this function is activated all the functions of the Efka DC motor can be checked. The preset settings like initial bartack, end bartack, speed, stitch length and so forth will be transmitted to the control unit via pressing the “Send” button and a seam will be seam will be triggered. Note: These entries can only be carried out via external operating panel of the type V820.
“Thread tension” This function is for the setting of the thread tension in consideration of the preset tolerance limits, the sewing speed, the lift stroke as well as the stitch length and for the checking of the thread tension after a Teach-in process in connection with a ETT. See chapter 6.6 Tolerance range of the thread tension. “Thread tens.file” After pressing this button a thread tension file can be loaded.
“Teach-In” During the monitored seam sections the values of the occurring thread tensions will be compared to a preset tolerance range. If the thread tensions deviate from the tolerance range more often than desired the seam will be defined as bad seam . Adjusting the thread tension to the required tolerance range The value of the needle thread tension is influenced by several factors like sewing speed, material, sewing thread, seam section etc.
Step 2: Thread tension at the operating point – Press “Begin test seam”. The following screen will appear: The determined values for step 2 will be displayed. – Press the button “next step”. – Carry out step 3 and 4. A screen displaying all registered values will appear. With the field “File name (NB number)” the determined values can be memorized.
4.
4.10 Determining the end label barcode In order to carry out changes in the barcode labelling system the operator must be authorized to security level 2. – Log in to the system. – Call up “Check”. – Call up “Setup”. – Call up “Label”. 1 In field 1 the layout of the endlabel barcode is displayed.
N2 Daily number of pieces (two digits);for example: 1234 = 34 N3 Daily number of pieces (three digits);for example: 1234 = 234 N4 Daily number of pieces (four digits);for example: 1234 = 1234 N5 Daily number of pieces (five digits);for example: 12345 = 12345 N6 Daily number of pieces (six digits); for example: 123456 = 123456 CP Number of digits and coding are defined by the mask that is specified under “Prim.barcode mask label”.
Defining the extended label print This option allows to additionally print the information listed below on the endlabel. The desired information is positioned on the endlabel by means of a defined program line. When the extended label print is activated, the information will always be printed at the predefined position, regardless of the barcode set-up file that has been loaded. ****************************************************************************** * * 550-867 D5 * 04. Nov.
4.11 Determining the endlabel layout In order to carry out changes in the barcode labelling system the operator must be authorized to security level 2. – – – – Log in to the system. Call up “Check”. Call up “Setup”. Call up “Label”. 1 1 2 3 4 – – – – – – – – – Enter the measured height of the label in the field “Label length”. for example: 25 mm Enter the space between the labels in the field “Gap”. for example: 3 mm Enter the desired label text into the fields 1.
4.12 Adapting barcode definitions In order to carry out changes in the barcode labelling system the operator must be authorized to security level 2. – – – – – – – – 96 Log in to the system. Call up “Check”. Call up “Setup”. Call up “Barcodes”. Select the corresponding type in the field “Primary barcode type”. This barcode is read via hand scanner. Select the corresponding type in the field “Thread barcode type”. This selection applies to both needle and hook thread.
for example · · Primary barcode: (read via hand scanner) 11112233001234567890 Primary barcode identification in the field “Prim. barcode ident. A”: (barcode for material and colour) 11110000000000000000 · ID number: 1111 If only pieces with the ID number “1111” are to be processed, this number can be entered in the field “Identifier A set value”. If pieces with various ID numbers are to be processed the ”Identifier A set value" field must remain blank. – The “Prim barcode ident.
Via the ID number the corresponding parameters will be requested from the data base (here the seam pattern with the number 330). Note Three-digit seam patterns are identified with seam pattern numbers between 100 – 999 (identifying numbers between 001 and 099 are not admissed. – The “Prim. barcode mask L/R” determines whether it is a right or left-hand seat. For example: · · · – Primary barcode: (read via hand scanner) 11112233001234567890 Primary barcode identification in the field “Prim.
330 330 The ID numbers are identical = OK. The sewing parameters No. 330 will be requested from the data base. 11112233001234567890 11112333001234567890 “Prim. barcode mask L/R”: 00000000110000000000 00000000110000000000 ID number: 00 00 The ID numbers are identical = OK. A right-hand seat will be sewn. The text for a right-hand seat will be printed on the endlabel. – Via the field “Prim. barcode mask label” information from the initial barcode can be printed onto the endlabel.
4.13 Setting the printer 1 Note! When exchanging the connected barcode printer 1 the old printer driver has to be deleted in the Windows printer menu and the new printer has to be installed. 4.13.1 Uninstall the printer driver On the Windows printer screen 1 two printer drivers (Zebra GK420t (ZPL) and Zebra GK420t) are displayed. 1 · · Zebra GK420t (ZPL) is a printer driver that the Windows operating system recognizes and installs automatically.
– – – – Open Windows Explorer. Open the local Disk (C:). Select the directory “Printer Driver”. Doubleclick the program “Driver Uninstall.exe”. The following screen appears: – Press the “Next” button. The installed printer drivers will be displayed. – – Select the driver “Zebra GK420T”. Press the “Remove” button.
The following screen appears: 102 – Press the“OK” button. The selected printer drivers will be deleted. – – – Select the driver “Zebra GK420t (ZPL)”. Press the “Remove” button. Press the “OK” button. The following screen will appear. – Press the “Next” button. – Press the “Finish” button.
4.13.2 Install a new printer Note! Connect the printer only after the setup has been successfully completed. – Doubleclick the program “Setup.exe” in the directory “PrinterDriver”. The following screen will appear: – – Select the desired language. Press the “OK” button. The following screen will appear. – Press the “Next” button.
2 1 – – – 104 Select on the screen 1 the printer mode “ Zebra EPL ”. Select on the screen 2 the correct printer appellation (see printer type label). Example: Zebra GK420t (EPL) Press the button “Next”. The following note will appear: – Press the “Continue Anyway” button. The screen for the printer connection will appear. – – Click the connection “USB001". Press the “Next” button.
The screen for the printer name will appear. – – Confirm the displayed printer name. Note! Make sure that between the word Zebra and the model number GK420t there are two blank spaces! – Press the “Next” button. The configuration assistant will appear. – Press the “Next” button. The setup for the barcode label will appear. – Press the “Customize” button. The screen for the paper size will appear.
1 2 3 106 – – – – Select the unit “Milimeters” in the field 1. Enter the label width in the field 2 (Width). Enter the label height in the field 3 (Height). Press the “OK” button. The following screen will appear. – Press the “Next” button. The screen for the printer mode will appear. – – Select “None”. Press the “Next” button. The screen for the media type will appear.
– – Select “Thermal Transfer”. Press the “Next” button. The screen for the calibration of the label will appear. – – Press the “Next” button. Press the “Finish” button. The screen for the printer test will appear. – Press the “Finish” button. On the Windows printer screen the installed printer driver will appear.
108 – – Connect the printer by using the USB-cable. Switch on the printer. After a while the Windows operating system will find a new printer. The hardware assistant will be launched. – – Select “No, not this time”. Press the “Next” button. The screen for the installation wizard will appear. – – Select “Install the software automatically”. Press the “Next” button.
– Press the “Continue Anyway” button. The screen for the driver search will appear. 1 – – Select in the field 1 (Copy files from) the path c:\PrinterDriver. Press the “OK” button. – Press the “Finish” button. The automatic installation has been successfully completed. On the Windows printer screen the installed printer driver will appear(Zebra GK420t (Copy1)) together with the notice that the new hardware has been installed successfully.
Note! Both printer drivers have to be installed in order for the printer to work properly and so that the operating system will not find a new hardware at each start-up. Rename the printer driver installed by the operating system for a better identification. 4.13.3 – – – Select the driver “Zebra GK420T (Copy1)”. Right-click with the mouse. Click “rename”. – Rename the driver to Zebra GK420t (ZPL).
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - 0791 550691 - 00.0 - EN - 12/2011 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.
