Adler 745-22 User manual

Contents Page:
Part 4: Instructions for programming DA-Microcontrol Cl. 745-22; -23; -24
Program-Version: 745-22; -23 = 745 P08; 745-24 = 745 Q01
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Description of the Controls
2.1 Keys on the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Internal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3.1 Display of the 745-22;-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3.2 Display of the 745-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Description of the Function Keys
3.1 Setting and Adjusting the Sewing Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Sewing a Seam Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Setting the Piece Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Selecting the Positioning Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Switching the Tape Feed On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Switching Tacking On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Selecting the Closing Order of the Flap Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.8 Switching the Corner and Center Knives On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.9 Switching the Light Barrier On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.10 Correcting the Seam Beginning and Seam End . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11 Correcting the Corner Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.12 Tape Length when Sewing with the Light Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Sewing of Bias Pocket Corners (745-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. Selecting the Sewing and Testing Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. Sewing Programs 745-22
6.1 Sewing of Simple, Dual and Asymmetrical Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Sewing with Automatic Carriage Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.3 Sewing with Material Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 Sewing with Zipper Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.5 Sewing with Zipper Cutter and Automatic Carriage Return . . . . . . . . . . . . . . . . . . . . 18
6.6 Sewing with Zipper Cutter and Material Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7. Sewing Programs 745-23
7.1 Sewing of Dual Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Sewing of Dual Piping with Automatic Carriage Return . . . . . . . . . . . . . . . . . . . . . . 19
7.3 Sewing of Dual Piping with Material Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4 Sewing of Dual Piping with Piping Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.5 Sewing of Dual Piping with Piping Reverser and Automatic Carriage Return . . . . . . . . . . 20
7.6 Sewing of Single Piping with Piping Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.7 Sewing of Single Piping with Piping Reverser and Automatic Carriage Return . . . . . . . . . 21
7.8 Sewing of Asymmetrical Piping with Piping Reverser . . . . . . . . . . . . . . . . . . . . . . . 21
7.9 Sewing of Asymmetrical Piping with Piping Reverser and Automatic Carriage Return . . . . . 21
7.10 Sewing of Simple and Asymmetrical Piping without Piping Reverser . . . . . . . . . . . . . . . 22

7.11 Sewing of Simple and Asymmetrical Piping without Piping Reverser
with Automatic Carriage Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.12 Sewing of Simple and Asymmetrical Piping without Piping Reverser
with Material Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8. Sewing Programs 745-24
8.1 Sewing of Dual Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2 Sewing of Dual Piping with Automatic Carriage Return . . . . . . . . . . . . . . . . . . . . . . 23
8.3 Sewing of Dual Piping with Material Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9. Aid Programs
9.1 Center Knife Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.2 Setting the Bobbin Thread Counter (745-22;-23) . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.3 Changing the Positioning Point Manual / Automatic . . . . . . . . . . . . . . . . . . . . . . . . 24
9.4 Testing the Piping Reverser for Dual Piping (745-23) . . . . . . . . . . . . . . . . . . . . . . . 25
9.5 Testing the Piping Reverser for Simple Piping (745-23) . . . . . . . . . . . . . . . . . . . . . . 25
9.6 Testing the Piping Reverser for Asymmetrical Piping (745-23) . . . . . . . . . . . . . . . . . . 25
10. Setting Programs
10.1 Testing the Positioning Procedure for Dual Piping (745-23) . . . . . . . . . . . . . . . . . . . 26
10.2 Loading of standard values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.3 Setting the Remaining Thread Monitor(Light Reflection Barriers) . . . . . . . . . . . . . . . . 26
10.4 Testing the Zipper Cutter (745-22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.5 Checking Needle und Center Knife Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.6 Testing the Positioning Procedure (745-23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.7 Setting the Light Barrier for Seam Beginning/Seam End . . . . . . . . . . . . . . . . . . . . . 28
10.8 Setting the Material Strip Reverser (745-23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11. Testing Programs
11.1 Program Version and Check-Sum Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.2 Checking the Step Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3 Checking the Seriel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.4 Testing the Memory and Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.5 Checking Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.6 Checking the Front Panel Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.7 Checking the Input Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.8 Selecting Input Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
11.9 Selecting Output Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.10 Sewing Drive: Pedal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.11 Positioning the Machine Head in the 2nd Needle Position/Revolution Test . . . . . . . . . . . 36
11.12 Positioning the Machine Head in the 1st Needle Position . . . . . . . . . . . . . . . . . . . . . 37
11.13 Positioning the Machine Head with Cutting Revolutions . . . . . . . . . . . . . . . . . . . . . 37
11.14 Positioning the Machine Head and Thread Trimming . . . . . . . . . . . . . . . . . . . . . . . 37
12. Function Displays and Error Messages
12.1 Displays for Operating Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
12.2 Displays by Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
12.3 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
13. Step Motor Output
13.1 Programing Switches on the Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
13.2 Displays on the Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1. General
The MICROCONTROL controls of the DÜRKOPP ADLER 745-22;-23;
-24 include the integrated comprehensive MULTITEST testing and
monitoring system.
A microcomputer assumes the control tasks, monitors the sewing
process and signals operating faults and malfunctions.
Special programs facilitate mechanical adjustments and make
possible a rapid testing of the input and output elements without
additional measuring apparatus.
Errors and test results are shown in a 2 x 16 digit display.
Under normal working conditions the display shows information to
operation and the sewing process.
When an operating error or malfunction occurs the functions are
interrupted. The cause is shown in the display by the appropriate error
symbol.
In most cases the error symbol will disappear when the cause of the
fault has been remedied.
In some cases the main switch must be turned off during error
correction for safety reasons.
A portion of the error messages are meant only for the service
personnel.
All functions can be called up and changed by pressing the
appropriate key. The unit must be in its initial position for this.
When the unit is switched on the controls conduct several
comprehensive self-tests. Among other things the program and data
memories and the display are checked for flawless operation at this
time.
After the machine is switched off the set values of the individual
functions are stored in the program and data memories (battery
buffered) and automatically activated when switched on
again.
ATTENTION !
The controls for the Class 745-24 are not compatible with the controls
for the Class 745-22;-23.
Controls 745-22;-23: Parts no. 9850 745040
Controls 745-24: Parts no. 9850 745030
3

2. Description of the Controls
2.1 Keys on the Front Panel
Key Function Key Function
Selecting Sewing and Testing Programs
Sewing Length L1
Sewing Length L2
Sewing Length L3
Sewing a Seam Series
Correcting of Seam Beginning/End when
Sewing Flaps with Light barrier
Correcting the Corner Knives at
Seam Beginning and Seam End
Setting Tape Length when Sewing with
Light Barrier
Setting the Counter
Stopping the Current Program,
Activating a Selected Program
Increase Parameter Value
Decrease Parameter Value
Light Barrier On
Selecting the Positioning Point
Tape Feed On/Off
Tacking On/Off
Selecting the Closing Order of the
Flap Clamps
Center Knife and Corner Knife
On/Off
4

2.2 Internal Switches
In the control behind the display there are three pre-selector switches
for setting certain machine parameters.
CAUTION !
The switches are only evaluated once when the sewing unit is turned
on.
After changing a switch setting switch the main switch off and then on
again or operate the STOP key.
DIP-Switch b417:
745-22;-23 745-24
b417 Function OFF ON OFF ON
.1 Stitch Length 2,5 mm 3,2 mm 2,5 mm 3,2 mm
.2 Stitch Condensation Stitch Length 0,8 mm 1,4 mm 0,8 mm 1,4 mm
.3 Maximum Sewing Length 180 mm 200 mm 180 mm 200 mm
.4 Thread Monitor ON OFF No function
.5 Locking Vacuum (b8 / s14) OFF ON OFF ON
.6 Late Opening of the Flap Clamps OFF ON OFF ON
.7 with Reverser Device OFF ON No function
.8 Continuous Operation OFF ON OFF ON*
(only in combination with .4 "OFF")
* Thread monitor is turned off
745-22;-24: b417.7 = OFF
745-23: b417.7 = ON (with Reverser Device)
Dial b401: Dial b402:
Sewing Revolutions Operation Mode of the Left Transport Clamp
b401 = 1 2500 1/min b402 = 0 No function
b401 = 2 2750 1/min b402 = 1 Lower left transport clamp
b401 = 3 3000 1/min separately
b402 = 2 Lower left transport clamp with the
right
DIP-Schalter b417 b401 b402
on
off
5

2.3 Display
The Microcontrol is equipped with a 2 x 16-digit display.
It shows the program number, sewing lengths, bobbin thread reserve
and piece count. By operating errors or malfunctions the functions are
interrupted and the cause shown by the appropriate error symbol.
The operational readiness of the sewing unit is shown by having the
current parameters in the display. The settings are the same as those
last selected before the machine was switched off.
2.3.1 Display of the 745-22;-23
Display example 1: With selected sewing length
Program number
Selected sewing length
Stored sewing length in mm
Bobbin thread reserve
Piece counter
Display example 2: With programmed length series
Program number
Current sewing length
Stored length in mm
Then stacking
4. Length to be sewn
3. Length to be sewn
(Current sewing distance is underlined)
2. Length to be sewn
1. Length to be sewn
6

2.3.2 Display of the 745-24
With the 745-24 a symbol for the bias of the corner incisions appears
in the right half of the first line of the display.
Through this symbol the seamstress can establish which bias has
been set for the currently selected program.
The "=====" symbol, for example, denotes straight pocket corners at
the seam beginning and seam end.
Display example 1: With selected sewing length
Bias pocket openings
Selected sewing length
Stored sewing length in mm
Piece counter
Display example 2: With programmed length series
Bias pocket openings
Current sewing length
Stored length in mm
Then stacking
4. Length to be sewn
3. Length to be sewn (here: Light barrier seam)
2. Length to be sewn
(The arrow marks the current sewing length)
1. Length to be sewn
If the display remains blank after the main switch has been turned
on, then the 1,6 A fuse(on the underside of the mains unit) is to be
replaced.
7

3. Description of the Function Keys
The values for the various functions can be set as follows:
–Call up the desired function by pressing the appropriate function
key.
The function will be shown in the display with a blinking cursor.
–Change the set value with the "+/ -" keys.
–Press the same function key again.
The change is completed.
The unit is ready to start again.
3.1 Selecting and Changing Sewing Length
With the L1, L2 and L3 keys three sewing lengths stored in memory
can be selected. A change of the sewing length can only occur before
the feed procedure has begun.
–Select the stored sewing length by pressing the key L1, L2 or L3.
The selected sewing length is shown in the right half of the first
display line.
–If "L?" appears in the display, then a sewing length without an
allowable value in memory was selected.
Enter an allowable value with the "+/-" keys or select a different
sewing length.
–Change the set sewing length with the "+/-" keys.
–Press the function key (L1, L2 or L3).
The set sewing length will be stored in memory.
It will remain in memory until it is changed again.
–For further details see chapter 5 and 6 ("Sewing Programs").
CAUTION !
When changing the sewing length L1 it is essential that the corner
knife interval also be altered at the same time.
Setting the Corner Knife Interval
That sewing length which is most often sewn should be stored under
L1.
The interval between the corner knives must be set so that it is the
same as the sewing length stored under L1.
With all other sewing lengths the corner incision occurs seperately in
two strokes. After the incision of the first corner knife the material is
transported to the second corner knife.
Exception:
With Class 745-23 the corner knives must always be switched on or off
together.
Positioning the Material
–With short seams under 75 mm place the material at the forward
positioning point.
–If, by sewing lengths under 75 mm, the rear positioning point is
chosen, then the error message " ERROR" will appear in the
display. You must then change to the forward positioning point.
–With placing at the rear positioning point the following condition
must be satisfied: L1 - L2(L3) < 50
Otherwise the error message " ERROR" will appear in the
display. You must then change to the forward positioning point.
8

3.2 Sewing of a Seam Series
With the aid of the "F" key a stored series of up to four seams can be
called up.
745-22;-23:The series can be made up of any desired order of the
three sewing lengths L1, L2 and L3.
745-24: The series can be made up of any desired order of the
sewing lengths L1, L2, L3 and the light barrier seams LX1,
LX2 and LX3.
Calling up the Series
–Call up the series by pressing the key "F".
The series is shown in the lower display line.
The current sewing length has a special marking:
745-22;-23: The current sewing length is underlined (e.g. "L2").
745-24: The current sewing length is preceded by an arrow
(e.g. "->L1").
The current sewing length with the appropriate value in millimeters
is shown in the right half of the upper display line (see display
example 2).
–A star "*" behind a sewing length means that stacking occurs after
this length is sewn.
Without stacking the material is transported back to the feed area
after sewing.
Then the next sewing length is automatically activated.
–Using the "+/-" keys any desired sewing length in the series can be
activated.
Key "+": Cursor to the right
Key " -": Cursor to the left
–To exit from the series press the keys L1, L2 or L3.
The approriate sewing length (L1, L2 or L3) is activated.
–To exit form the series with the 745-24 press the key " ".
The light barrier seam is activated.
Programming a New Series
The values for the programmed sewing lengths must established
before entering the series mode (see "Selecting and Adjusting the
Sewing Length").
–Press and hold the key "F".
–At the same time press the key "-".
The previous series is erased.
–By pressing the keys L1, L2 and L3 up to four sewing lengths can
be entered in the desired order.
–745-24 only: After selecting a sewing length the following functions
can be set for this length using the appropriate keys:
Light Barrier On / Off
Positioning Point
Tape Feed On / Off
Tacking On / Off
Closing Order of the Flap Clamps
Corner and Center Knives On / Off
9

CAUTION !
The functions set with the keys only valid for the sewing program in
the series mode.
The settings have no effect on the sewing programm beyond the
series mode.
–745-24: Each entry of a sewing length must be confirmed with the
"Σ" key.
–745-24: Programming the light barrier seam LX1, LX2 or LX3:
Press the " " key until the desired light barrier seam X1, X2 or
X3 appears in the display.
Set the desired functions for the selected sewing lenght using the
keys listed on page 9.
Confirm with the "Σ" key.
–After selecting a sewing length (L1, L2 or L3) stacking after this
sewing length can be programmed by pressing the "+" key.
CAUTION !
With the 745-24 the selection of the sewing length and the functions
must first be confirmed with the "Σ" key.
Then stacking after this sewing length can be programmed by pressing
the "+" key.
–By pressing the "-" key the last entry is erased.
–To start the series press the key "F" again.
The first sewing length is automatically set.
3.3 Setting the Piece Counter
By pressing this key the piece counter is reset to 0000.
The current piece count is shown in the left half of the lower display
line. The piece counter shows the number of pieces made since the
last resetting of the counter.
3.4 Selecting the Positioning Point
Depending on the type of sewing pieces the feed occurs at the forward
or rear positioning point.
By pressing this key the positioning point is changed.
If the LED above the key is lit then the forward positioning point was
selected.
The changeover between manual and automatic alteration of the
positioning points occurs in program P42.
3.5 Switching the Tape Feed On/Off
By pressing this key the tape feed is switched on and off.
If the LED above this key is lit then the tape feed is switched on.
10