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.
Contents Page: Foreword and general safety instructions Part 1: Operating Instructions Class 540-100-1 (Edition: 09/2009) 1. 1.1 1.2 Product description Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Subclasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6 2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. 3.
Contents Page: 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.7.1 5.7.2 Buttonhole programming Composition of a buttonhole . . . . . . Submenu programming (general view) Parameter programming mode . . . . . Adjusting the cut length . . . . . . . . . Selecting a start variant . . . . . . . . . Setting buttonhole seam . . . . . . . . Setting bartack . . . . . . . . . . . . . . Selectable bartack types . . . . . . . . Programming menu “bartack” . . . . . . . . . . . . . . 26 28 29 30 30 31 32 32 33 6. 6.1 6.2 6.
1. Product description The Dürkopp Adler 540-100-1 is a CNC double lockstitch buttonhole machine with stepping motor technology for the sewing of flat form linen button holes in light to medium weight material. Maximum buttonhole length is 65 mm and maximum buttonhole width is 6 mm (equipment dependent). Including a knife for all cutting lengths, longitudinal or transversal setting possible, fine adjustment of the buttonhole with the push of a button, integrated direct DC drive.
1.2 Sub classes 540-100-1 For the sewing of raised-form or flat-form linen buttonholes in light to middle weight material, with electronically driven thread tensioner. Buttonhole length max. 70 mm, buttonhole width max. 6 mm. A knife for all cut lengths. 2.
3. Operating the machine head 3.1 Needle threading Caution: Danger of injury ! The needle should only be threaded when the sewing automat is switched off.
3.2 Winding the hook thread 1 2 3 Threading the hook thread is independent of sewing operation. – Put the thread on the thread stand. – Thread the hook as shown in the picture. – Put the empty bobbin onto the bobbin winder 1. – Wind the hook thread clockwise about 5 times around the bobbin core. – Swing winder lever 2 towards spool and click in. The thread will be wound on. – Winder lever 2 ends the spooling event when the bobbin is full. – After spooling snap out the bobbin thread from thread clamp 3.
5 Threading the bobbin – Place the full bobbin in the bobbin housing top, whereby the bobbin has to turn in anti-clockwise direction when the hook threader is pulled. – Pass the hook thread through the slit 6 and under the spring. – Dependent on chosen buttonhole the hook thread has to go through slit 9 for raised-form buttonholes and slit 10 for flat-form buttonholes.
3.4 Changing the needle Caution: Danger of injury ! Switch off at main power switch ! Only change the needle when the sewing automat is switched off ! 1 – – – – – Loosen screw 1. Pull needle form the needle bar. Insert the new needle to the stop in the bore of the needle bar. Set the needle so that the needle scarf lies on the backward facing side of the knife. Tighten screw 1. CAUTION ! If the needle thickness is changed, the distance between the hook and the needle may need to be changed.
3.5 Changing the knife Caution: Danger of injury ! Switch off at main power switch ! Only change the knife when the sewing automat is switched off ! CAUTION ! Ensure that the lifted basket has a minimum distance of 1mm between the upper thread scissors and the bottom knife edge. 2 3 1 Knife removal – Loosen screw 2. – Remove knife 3. Knife insertion – Insert new knife and set it right at the top. – Tighten screw 1.
3.6 Checking the knife height Rule: The knife point is needed only when diving into the material. The knife point should not leave the throat plate during the cutting procedure. CAUTION ! Ensure that the lifted basket has a minimum distance of 1mm between the upper thread scissors and the bottom knife edge. Note ! When a knife is sharpened, its length will be shorter. With the insertion of the sharpened knife the knife height may need to be corrected.
3.7 Thread tension (540-100) 1 2 Thread tension 1 The tension serves the purpose of sewing flat-form tacks and buttonhole seams. The tension is always effective and opens only with thread cutting. 1 Thread tension 2 The thread tension can be switched on and off. The complete tension of thread tension 1 and thread tension 2 generate raised-form tacks and buttonhole seams. The selection can be freely programmed for each buttonhole section of a buttonhole.
Notes: 14
3.8 Electronic thread tension (540-100-1) 1 Setting or altering the thread tension values – Switch on the machine. – Display the main menu. – Select the menu item “Thread tension” using the p and q keys and confirm by pressing “OK”. Seam Bartack [%] : value (e.g. 35) [%] : value (e.g. 20) Explanation Changes the forward/backward seam Changes the upper/lower bartack Seam (fwd.) Upper bartack Seam (bw.
3.9 Regulating the sewing basket lifting height 1 2 3 CAUTION ! Ensure that, – a distance of at least 1 mm lies between top thread cutter and the knife bottom edge of the lifted basket – the knife point does not protrude out of the basket bottom. Factory setting for the basket lifting height is 12 mm. Adjust the basket lifting height in the following way: – Switch off the machine. – Loosen screws 1 and 2. – Increase the basket lifting height: Turn set screw 3 clockwise.
4. Control panel and control unit In this operating manual only the functions of the keys and the parameter changes that the operator can make are listed. 4.1 Control panel Through the operating panel the control is programmed and the functions for the respective seams are set. This occurs partly through direct pressing of the corresponding key or through parameter adjustment. The input of parameters occurs in programming mode “P”. The parameter and the corresponding values are shown on the display.
4.1.1 Key Control panel elements Function When no input panel is activated: – Change to the higher level menu. – In the main menu, change between the buttonhole programs within a sequence. When an input panel is activated: – Change between the digits tenths, units and tens. – Change lines within the menu. The active line appears white on black.
4.2 Changing parameter values 4.2.1 Numerical values Numerical values can be altered in the following ways: – With the arrow keys ñ and ò choose the line in which the value needs to be changed. – Press the OK key. The curser blinks under the position of the value to be changed. – With the arrow keys ï and ð change between the values. – With the arrow keys ñ and ò increase or decrease the chosen value.
4.3 Main menu Symbol Parameter Meaning Buttonhole number N1 Selection of the buttonhole to be sewn - Program number 1 to 50 contains buttonhole programs. Program number 51 and 52 contain free contour sewing programs. - The preprogrammed form of the chosen buttonhole is shown in the left half of the display.
4.4 Hook thread monitoring Hook thread monitoring mode of operation: Hook thread monitoring is carried out by counting the buttonholes. With the insertion of a full bobbin the hook thread counter is set to a predetermined value. This value is subtracted by one with each complete cycle. When the value 0 is reached the operator receives an information message. There should be some remaining thread on the bobbin.
Hook thread counter on and off N7.3 The function of the hook thread counter is either switched on or off. – Select the relevant line with the ñ and ò keys. – Press the OK-key. – Select the parameter On or Off by using the arrow keys ñ and ò. The main menu will indicate no parameter with the hook thread counter switched off. 4.5 Soft start on /off – Select the “Soft start” in the main menu with the arrow keys ñ and ò. – Press the OK-key.
4.6.2 Switching the sequence mode on / off Switching the sequence mode on or off – Press the S-key. The control panel changes to the menu for the programming of buttonholes sequences. – With the arrow keys ñ and ò select the relevant line – Press the OK-key. – With the arrow keys ñ and ò choose between on(sequence mode) or off (single buttonhole mode) – Confirm by pressing the OK-key. – 4.6.3 To return to the main menu press the ESC-key.
Select another buttonhole to be sewn within the sequence Selection between the different programmed buttonholes is always possible when the sewing menu is displayed – Press the arrow keys ï or ð. The next or previous buttonhole is selected within the displayed sequence. 4.7 Programming of sequences Up to 20 buttonhole sequences can be programmed. Each sequence can contain up to 20 buttonholes. 4.7.1 Programming a single sequence Select program menu sequence – Press the key “S” on the control panel.
4.7.2 4.7.3 Adding a buttonhole at the end of a sequence – Select the last line “Buttonhole X: 0" in the programmed buttonhole sequence with the arrow keys ñ and ò. – – Press the OK-key. Select the desired buttonhole program (1 to 50) with the arrow keys ñ and ò. – Press the OK-key to confirm the selection. With the confirmation of the buttonhole program a new menu line appears containing the buttonhole to be programmed. – Press the ESC-key to return to main menu.
5. Buttonhole programming 5.
First bartack First bartack to be sewn in connection to the leading buttonhole seam Final bartack Final bartack in connection to the trailing buttonhole seam Leading buttonhole seam Buttonhole seam from sewing start to the first bartack Trailing buttonhole seam Buttonhole seam between first bartack and final bartack Buttonhole width Distance between the outer stitches of a buttonhole Cut length Length of the knife’s cutting edge in mm Cut length Length of the buttonhole to be cut in mm (=Button
5.
5.3 Parameter programming mode Buttonhole number P1 1 … 50 Selection of the buttonhole number Cut length P2 6.0 … 65.
5.4 Adjusting the cut length Correcting the buttonhole length (Cut length). The adjustment is possible in both, the main menu and programming mode. – Select the line “cut length” in the main menu with the arrow keys ñ and ò – Press the OK-key. The curser blinks under a digit value. – Change between the digits with the arrow keys ï and ð. – Increase or decrease the value of the selected digit with the arrow keys ñ and ò. – Press the OK-key to confirm the value. 5.
5.6 Setting buttonhole seam In the program menu “Buttonhole seam” Select program menu Buttonhole seam – Press the P-key. – Select the line “Buttonhole seam” with the arrow keys ñ and ò. – – Press the OK-key. Select the relevant line with the arrow keys ñ and ò. – – – Press the OK-key. The curser blinks under one of the digit values. Change between the digits with the arrow keys ï and ð. Increase or decrease the value of the chosen digit with the arrow keys ñ and ò. – Press the OK-key to confirm.
5.7 Setting bartack 5.7.1 A Selectable bartack types Cross tack (horizontal) top bottom B Round tack (to the middle point) top bottom C Taper tack top bottom D Round tack (horizontal) top bottom E Cross tack (vertical) top bottom F Cross tack (divided) top bottom G Eye tack top bottom H Simple tack (bartack) top always together bottom The upper and lower tacks of the tack types A to G can be freely combined e.g. G eye tack as the top tack and C taper tack as the lower tack.
5.7.2 Programming menu “Bartack” Select programming menu “Bartack” – Press the P-key. – Select line “upper tack” or “lower tack” with the arrow keys ñ and ò. – – Press the OK-key. Select the desired parameter with the arrow keys ñ and ò. – – – – Press the OK-key. The cursor blinks under a digit of the value. Change between digits with the arrow keys ï and ð. Increase or decrease the selected value with the arrow keys ñ and ò. – Press the OK-key to confirm. – Press the ESC-key.
P6.1/ P7.1 A cross tack(horizontal) , F Cross tack (divided) Tack stitch distance P 6.2/ P 7.2 0.2 ... 1.0 mm Distance in the y-axis of a double stitch. Tack length P 6.3/ P 7.3 0.6 ... 6.0 mm Length of the tack in the y-axis. The input of parameter P7.3 is only possible when the top and bottom tack types are not similar! Tack width Right offset P 6.4/ P 7.4 -1.0 … 1.0 mm The width of the tack is defined through the buttonhole width.
P6.1/ P7.1 E Cross tack (vertical) Tack stitch distance P 6.2/ P 7.2 0.2 ... 1.0 mm Distance in the y-axis of a double stitch Tack length P 6.3/ P 7.3 0.6 ... 6.0 mm Length of the tack in the y-axis. The input of parameter P7.3 is only possible when the top and bottom tack types at are not similar! Tack width Right offset P 6.4/ P 7.4 -1.0 … 1.0 mm The width of the tack is defined through the buttonhole width. With the use of right offset the width of the tack to the right can be increased.
6. Knitwear mode Use the knitwear mode when stretchable material is to be sewn. In the knitwear mode buttonholes are seamed several times in order to ensure a higher stability. It is possible to combine a straight basting stitch with a following single or double zigzag. It is also possible to choose whether cutting should take place during the last seam sewing or the one before. The following modes are available: – Combination “1” Double zigzag Cutting during the last cycle.
6.1 Selecting or switching off knitwear mode Select knitwear mode – Press the P-key. – Select the parameter “Knitwear” with the arrow keys ñ and ò. – – Press the OK-key. Select the setting “on” with the arrow keys ñ and ò. – Press the OK-key to confirm the selection.
6.2 Submenu basting stitches Seam cycles P9.1 0/1 Number of the basting stitch seam cycles Stitch length P 9.2 0.3 … 3.0 mm Stitch length of the basting stiches Thread tension P 9.3 0...100% Value of the tread tension for basting stitches. This parameter can only be selected when electric thread tension control is available. 6.3 Submenu Zigzag Seam cycles P10.1 1/2 Stitch length P 10.2 0.3 … 3.0 mm Buttonhole width P10.3 1.0...P4.3 Speed P10.4 200 … 4000 RPM Thread tension P 10.5 0...
7. Sewing procedure 7.1 Normal sewing procedure Switching on of the automat – Check on the maintenance unit that an air pressure of 6 bar is present. – Switch on the main switch of the automat. – The machine software will be loaded. – The needle goes to the reference position. – The sewing basket goes to the reference position and raises. – The automat is ready to sew. 0 1 2 0 R Sewing – Position material to be sewn under the raised sewing basket. – Press the foot pedal forward to position 1.
– – Hook and needle thread can now be threaded or checked. Further measures according to the thread breakage modes Method A, B or C preset in the technician level (see thread breakage mode). – By pressing the ESC-key the thread breakage mode can be ended. The automat references, the sewing basket is lifted and the material is released. Thread breakage mode There are three possibilities to clear a thread breakage. The respective method has to be preset in the technician level.
8.
Number Error position Description Cause Error elimination 2158 Step motor x-axis Speed - Step motor - Control - Check step motor - Check control 2201 Step motor y-axis Referencing timeout - Reference switch - Step motor - Control - Check reference switch - Check step motor - Check control 2252 Step motor y-axis Overcurrent - Step motor - Control - Check step motor - Check control 2253 Step motor y-axis Overvoltage - Step motor - Control - Check step motor - Check control 2255 Step
Number Error position Description Cause Error elimination 4304 Memo-Dongle Wrong type Boot-Dongle is inserted Use Memo-Dongle 4307 Memo-Dongle Wrong class Dongle of the wrong class was inserted Insert correct Dongle Format the Dongle 5101 Contour dataadministration EEPROM not initialized - Control - Control contains no machine program - Check control - Install machine program 5104 Contour dataadministration Checksum error - Control The machine resets itself automatically.
9. Maintenance 9.1 Cleaning and inspection Check air pressure and adjust – The operating pressure is 6 bar. – Turn screw 1 to adjust pressure Reduce pressure: Turn screw 1 anti-clockwise. Increase pressure: Turn screw 1 clockwise. 1 2 3 4 Scheduled maintenance Explanation Machine head Remove sewing dust, thread rests and cutting waste.
9.2 Oil lubrication Caution: Danger of injury ! Oil can cause skin eruption. Avoid protracted contact with the skin. In the event of contact, thoroughly wash the affected area. ATTENTION ! The handling and disposal of mineral oils is subject to legal regulations. Deliver used oil to an authorized collecting station. Protect your environment. Take care not to spill oil. Check regularly the oil level in both of the supply containers 1 and 2.
Notes: 46
