540-100-1 CNC-Doppelsteppstich-Knopflochautomat CNC double lockstitch buttonholer Bedienanleitung / Operating Instructions 1 Aufstellanleitung / Installation Instructions 2 Serviceanleitung / Service Instructions 3 Postfach 17 03 51, D-33703 Bielefeld Potsdamer Straße 190, D-33719 Bielefeld Deutsch/Englisch Telefon +49 (0) 5 21/ 59 25-00 Telefax +49 (0) 5 21/ 9 25 24 35 www.duerkopp-adler.com Ausgabe / Edition: 09/2009 Änderungsindex Rev. index: 01.
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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: Part 3: Service Instructions Class 540-100-1 1. 1.1 1.1.1 1.1.2 Elements of the control panel Altering parameter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Numerical values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection of a parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 4 2. 2.
Index Page: 6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 Hook and needle bar Needle position . . . . . . . . . . . . . . . . . . . . . . . Reference position of the needle bar . . . . . . . . . . Setting the adjusting sheet . . . . . . . . . . . . . . . . Loop formation stroke position and distance between Needle bar height . . . . . . . . . . . . . . . . . . . . . . Needle protection . . . . . . . . . . . . . . . . . . . . . . Alignment of the bobbin case holder. . . . . . . . . . . . . . . . . .
1. Elements of the control panel Key Function If no text field is activated: – Change to the parent menu. If a text field is activated: – Change between the figures tenth, unit, ten etc. – Change between the lines in the menus. The selected line is always dark-shadowed. If a text field is activated: – Increase or reduce the value of the respective figure by one or change between the parameters in case of functions with several choices, e.g. between “Push button on“ and “Push button off“.
1.1 Altering parameter values 1.1.1 Numerical values Numerical values can be altered as follows: – Select the line with the value to be altered with the cursor keys ñ and ò. – Actuate the OK key. The cursor flashes under a digit of the numerical value. – Change between the digits with the cursor keys ï and ð. – Increase or reduce the value of the selected digit with the cursor keys ñ and ò.
2.
2.1 Submenu machine configuration (overview) Max. speed: Input Speed basting stitches: Input Scissors is moved out: Input n-stitches b. u. bartack/bartack tension on: Input n-stitches b. l. bartack/bartack tension on: Input n-stitches b. lip there/lip tension on: Input n-stitches b. lip back/lip tension on: Input n-stitches b.
3. Calling up the technician mode and entering the code In order to get into the technician mode a code has to be entered. For this purpose please proceed as follows: – Press the F key in the sewing mode. A window for entering the code appears. – Enter the technician code 25483. Confirm with the OK key. Note If a wrong code has been entered, the automate returns to the sewing mode. 4. Main menu of the technician mode No.
4.1.1 No. Parameter name T1.1.1 Max. speed 200 … 4000 Setting of the maximum speed in the sewing mode. The speed can be altered in steps of 100. T1.1.2 Speed basting stitches 200 … 4000 Setting of the speed for the basting stitches T1.1.3 Move out the scissors 0 … 10 Number of stitches after which the scissors moves out and releases the clamped needle thread T1.1.
4.1.4 Submenu for the thread monitor configuration No. Parameter name T1.4.1 T1.4.2 Symbol Range Description Repair mode A, B, C Selection of the repair mode to be used. Needle thread monitor 0 … 10 Number of stitches not registered by the thread breakage monitor before an error message is displayed. At the value 0 the thread breakage monitor is switched off. Description repair modes T1.4.1 Method A: The buttonhole has to be unstitched and sewn again.
4.1.5 Submenu for the configuration of condensed stitches No. Parameter name Symbol T1.5.1 Number of 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 0…9 -4 … 4 Lip there Fig.
4.1.6 Submenu for entering machine times No. Parameter name Symbol Range Description T1.7.1 PedðStart 0 … 9000 ms Delay time between stepping down the pedal position 2 and the sewing motor start T1.7.2 EndðCage 0 … 9000 ms Delay time between sewing end and lifting of the cage T1.7.3 CageðRef 0 … 9000 ms Delay time between lifting of the cage and reference start 4.2 Submenu for the configuration of the operating elements No. Parameter name T2.
4.3 Submenu for test functions No. Parameter name T3.1 Multitest Select the submenu Multitest T3.2 Events Select the event display T3.3 DAC III Select the submenu DAC III Parameter T3.4 Data reset Submenu Reset T3.5 Memo dongle Select the submenu Memo dongle 4.3.1 Symbol Description Submenu Multitest No. Parameter name 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.
4.3.1.1 Submenu Output test – Select the output to be tested with the cursor keys ñ and ò . – – Press the OK key. The selected output is switched on / off. The switching state of the output is indicated in the display.
4.3.1.3 Submenu Automatic input test The changes of the state of all inputs are displayed automatically. 4.3.1.4 Submenu Sewing motor test – – – Press the OK key in order to start the sewing motor. The sewing motor speed is displayed. With the cursor keys ñ and ò the speed can be altered in steps of 100 rpm within the speed limits. Press the ESC key in order to stop the sewing motor. 4.3.1.5 Submenu Step motor test No. Parameter name Symbol Range Description T3.1.4.
4.4.2 Submenu DAC III No. Parameter name T3.3.1 Date/Time Submenu for setting the time and the date ð see chapter 4.2 (T2.2) of this instruction manual T3.3.2 Temperature Display of the current temperature inside the DAC III in °C T3.3.3 Intermediate circuit voltage Display of the current intermediate circuit voltage in V 4.4.3 Symbol Description Submenu Reset No. Parameter name Symbol Description T3.4.1 Buttonholes Selection ® Confirmation Reset to default the buttonhole geometry.
4.4.3.1 Dongle contents Data dongle connected If a data dongle is plugged in, all 50 buttonhole programs or all 16 free contours respectively are displayed. Buttonhole programs are named as follows: Upper bartack type-Cutting length-Lower bartack type. The corresponding bartack shape is shown in the display. e.g.: A14.2A (“A” means straight bartack and “14.2" the cutting length) In case of free contours the name is given when programming the contour on the PC.
T3.5.2.4 Free contours The 16 program locations for free contours of the dongle are displayed. - Select the free contour to be loaded with the cursor keys ñ and ò. When selected the buttonhole number can be given on the machine (51 or 52). Press the key - P in order to copy the selected buttonhole program to the machine. Confirmation: “Yes” - the free contour is copied “No” - back to the submenu Loading 4.4.3.3 Submenu Saving No. Parameter name Description T3.5.3.
4.4.3.4 Formatting In order to be able to save buttonhole data on a data dongle this has to be formatted. A data dongle can only be used on a machine class for which it has been formatted. If you have formatted the dongle on e.g. class 540-100-1, you can only save buttonhole programs of the 540-100-1 on the dongle. If the dongle is to be used on another machine class, it has to be formatted on this class anew.
5. Knife setting 5.1 Aligning the knife and adjusting the knife height 1 2 Standard: The knife should penetrate the knife slot centrally. During the cutting open the knife should remain in the knife slot for a depth of 0.2 mm in its upper dead center. 3 Setting: – Remove the knife. – Move the knife block down via parameter T3.1.1 outputs of the submenu Multitest – Loosen screw 2.
5.2 Setting of the knife incision damper 1 2 Standard: When switching 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.
6. Hook and needle bar 6.1 Needle position 3 5 4 Standard: The needle (80 Nm) should have a distance of 1.8 mm to the front edge of the knife. Setting: – Loosen screw 3 through drill-hole 4 in the arm. – Shift the needle bar linkage 5 according to the instructions. – Tighten screw 3 again. 3 Attention After correcting the needle position check the distance between hook and needle (chapter 6.4) and adjust it, if required. 6.
Standard reference position of the needle bar: – Switch the machine on and let it move to the initial position. – Switch the machine off again. Correction: – Loosen the screws 8 and shift the proximity switch 6 according to the instructions. – Tighten the screws again. – Readjust the adjusting sheet, if required. Chapter 6.3 Setting the adjusting sheet. 6.
6.4 Loop formation stroke position and distance between hook and needle 3 1 2 3 Standard : In loop formation stroke position the hook tip should be at the level of the middle of the needle. The looping stroke amounts to 2 mm ±0.2 mm up to 4 mm throw width and 2.2 mm ±0.2 mm for a throw width of more than 4 mm. In loop formation stroke position the hook tip should be as close to the needle as possible without touching it. Setting : – Pull out the locking pin 1. – Loosen the screws 2.
6.5 Needle bar height 4 Standard : In the furthest right entry point the hook tip in looping stroke position should be 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.
6.6 Needle protection 1 Standard: In the furthest right needle entry point the needle protection in looping stroke position should abut on the needle without pushing it aside. Setting : – Bring the machine in looping stroke position. – The bolt of the needle bar linkage must be at the left flank of the adjusting sheet (furthest right entry point). – Attach the needle protection 1 in such a way that the needle is slightly pushed out of the way.
7. Aligning the throat plate as to the needle 4 3 Standard: The needle should penetrate in the centre of the needle hole. Setting: – Loosen screws 3 and 4 in the throat plate. – Press the throat plate against the left stop guide and shift according to the instructions. – Tighten screws 3 and 4 again. 8. Thread tension plate 8.1 Thread puller setting 4 5 Standard: Caused by the pulling of the needle thread the first stitch of the buttonhole is sewn without thread tension.
8.2 Thread take-up spring and thread regulator 5 4 2 1 3 Standard: While the thread lever is moving down from its upper dead center, the thread take-up spring should hold the thread tight until the needle penetrates the fabric. Setting of the thread controller spring: – 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. 3 Setting of the thread regulator: – Loosen screw 4.
9. Sewing basket 9.1 Setting of the cloth presser block (lifting stroke) 1 2 3 Standard: The maximum stroke of 12 mm must not be exceeded. When exceeding the stroke the needle thread scissors would be pressed against the knife. Setting: – Lower the sewing basket. – Loosen the screws 1. – Loosen the counternut 2. – Turn the threaded 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.
9.3 Alignment of the sewing basket as to the throat plate 6 8 7 9 3 Standard: When the sewing basket is lowered, the inner window of the sewing basket should stand centrally to 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.
9.4 Reference position of the sewing basket 1 2 Standard: In reference position the distance between the needle and the inner edge of the cage should amount to 1 - 1.5 mm. Correction: – Switch the machine on. – Push the pedal backwards. The sewing basket is lowered. – Measure the distance between the inner edge of the cage - needle. – Loosen the screws 1. – Shift the plate 2 against towards the needle ® the distance will be reduced.
10.1 Setting of the closing path 5 6 7 3 4 Standard: With the bobbin thread scissors closed the cutting edges should have moved approx. 1 mm one on top of the other. Setting: – Lift the cage. – Carefully dismount the throat plate (the knife parts must not move). – If required, turn the eccentric 8 after loosening the screw 9. 3 8 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.
10.2 Adjusting the spring sheet of the thread rest 7 Standard: 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.
11. Needle thread scissors 11.1 Function sequence Motional sequence Initial position – – – Sewing basket lifted. The closed scissors holds the thread. Scissors is swivelled in. – – – Sewing basket lowers. The closed scissors holds the thread clamped. Scissors is swivelled in. – – – – Sewing start The needle thread is laid in the lip there. The path until the scissors opens is adjusted under T1.1.3. The scissors is swivelled aside by a block.
11.2 Removal and check of the needle thread scissors 1 2 4 3 Standard: Before mounting and adjusting the needle thread scissors the following has to be observed: – The edges of the thread clamping plate have to be rounded and highly polished . – The thread has first to be clamped and then cut by the movable part of the scissors. – The thread clamping plate must rest on the clamping surface in parallel position because otherwise no perfect clamping is guaranteed when sewing.
11.3 Alignment of the scissors block 1 2 Standard 1: The scissors block should be at the same level as the lug of the cage presser bar. Standard 2: – The scissors block should be aligned in parallel position to the sewing 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.
Notes: 36
11.4 Scissors swivelled in Standard: (throw width 3 and 4 mm) When the sewing basket is lowered, there should be a distance of 0.5 mm between the front edge of the scissors and the right edge of the sewing basket. 3 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. 1 Setting: – Turn the locking pin 1 according to the instructions.
11.5 Height adjustment 4 5 3 2 Standard: The needle thread scissors should not rest on the sole of the cage. (Distance approx. 0.1 mm) Setting: – Loosen threaded pin 2 with the sewing basket lowered. – Turn the axle until pin 3 lifts the scissors. – Tighten threaded pin 2. 11.6 Scissors swivelled out 7 4 6 Standard: When swivelled out, the front edge of the scissors should be at the same level as the inner edge of the cage.
1,3 - 1,5 mm 11.7 Distance to the needle Standard: When the sewing basket is lowered, the distance between the needle thread scissors and the needle should amount to 1.3 - 1.5 mm. Setting: – Position the needle in the needle hole. – Loosen threaded pin 4 and shift the holding block until the spacing is set. 11.8 Opening the scissors 1 2 Standard: The scissors should open as early as, without touching the needle. Setting: – Position the needle in the left entry point.
11.9 Setting of the closing path 2 Standard : With the needle thread scissors closed the two cutting edges should have moved 1 mm one on top of the other. Setting: – Switch the machine on. – Select parameter T3.1.1 Outputs of the submenu Multitest and switch output Y1. The sewing basket is lowered. – Open the scissors manually. – Loosen threaded pin 2. – Switch the output Y1 by pressing the OK-key. The sewing basket is lifted and the closing block bar is moved out until it hits the cloth presser bar.
Hint A too long holding of the needle thread leads to a displacement of the stitches in the seam beginning. By using the configuration of the parameter “Position last stitch” T1.5.4 in the technician level, it is possbile to set the position of the last knotting stitch of the buttonhole. It will then determine the position of the thread being cut in the scissors. Through altering the above parameter an improvement of the thread insertion at the beginning of the buttonhole may be possible. 12.
13. Bobbin winder 1 2 Standard: When the bobbin is full, the winding process should stop automatically. Setting: – Unscrew the cover of the case. 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.
14. Solenoid valves Function test: – T3.1.1 Select the submenu Output test – The following outputs can be switched: 1 = Control cylinder 2 = Scissors cylinder 3 = Lip tension 4 = Knife cylinder 6 7 1 2 3 4 7 3 Exchange: – Pull the hoses off. – Remove the plug 6 out of the holder. – Unscrew screws 7 and take 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.
15. Exchange of the sewing basket 4 5 3 – – – – – – Switch the machine off. Reduce the sewing basket pressure. Loosen screw 3. Change the sewing basket and tighten screw 3 again. Readjust spring 5 after 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.
16. Stretching the drive belts The drive-belts are maintenance-free and should not be restretched. 1 3 – 3 Dismount handwheel and belt protection. 2 Stretching of the drive belt motor-arm shaft: – Loosen screws 1. – Tighten the belt by shifting 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.
Notes: 46
