Dürkopp Adler 550-867 User manual

550-867
Operating Instructions

All rights reserved.
Property of Dürkopp Adler AG and protected by copyright.
Anyreuseofthesecontents,includingextracts,isprohibitedwithoutthe
prior written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG 2016
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Operating Instructions 550-867 - 00.0 - 11/2016 1
1 About these instructions....................................................................7
1.1 For whom are these instructions intended? ..........................................7
1.2 Representation conventions – symbols and characters........................8
1.3 Other documents...................................................................................9
1.4 Liability ................................................................................................10
2 Safety..................................................................................................11
2.1 Basic safety instructions......................................................................11
2.2 Signal words and symbols used in warnings.......................................12
3 Machine description..........................................................................17
3.1 Components of the machine ...............................................................17
3.1.1 Complete overview..............................................................................17
3.1.2 Upper part of the machine...................................................................18
3.1.3 Lower part of the machine...................................................................18
3.2 Proper use...........................................................................................19
3.3 Declaration of Conformity....................................................................20
4 Operation ...........................................................................................21
4.1 Preparing the machine for operation...................................................21
4.1.1 Switching on the machine ...................................................................22
4.1.2 Scanning barcodes..............................................................................23
4.1.3 Inserting/changing the needle .............................................................26
4.1.4 Feeding needle and hook thread.........................................................28
4.1.5 Threading the needle thread ...............................................................31
4.1.6 Winding the hook thread .....................................................................34
4.1.7 Inserting/changing the bobbin .............................................................37
4.1.8 Threading the hook thread ..................................................................40
4.2 Thread tension ....................................................................................41
4.2.1 Setting the hook thread tension...........................................................42
4.2.2 Setting the needle thread tension........................................................43
4.3 Setting the needle thread regulator.....................................................45
4.4 Locking the sewing foot in top dead center.........................................46
4.5 Setting the sewing foot stroke.............................................................47
4.6 Setting the sewing foot pressure.........................................................48
4.7 Setting the stitch length.......................................................................48
4.8 Buttons on the machine arm ...............................................................49
4.8.1 Switching the function of a button on and off ......................................50
4.8.2 Assigning a function to the favorite button ..........................................51
4.9 LEDs on the machine..........................................................................52
4.9.1 LEDs on the machine arm...................................................................52
4.9.2 LEDs on the tensioning plate ..............................................................53
4.10 Remaining thread monitor...................................................................54
4.11 Electropneumatic quick stroke adjustment..........................................58

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2 Operating Instructions 550-867 - 00.0 - 11/2016
4.11.1 Setting the function of the knee button................................................59
4.11.2 Switching on maximum stroke during sewing .....................................60
4.12 Switching on and off the sewing lamp.................................................61
4.13 Additional equipment...........................................................................62
4.13.1 End label scanner................................................................................62
4.13.2 Barcode scanner for needle and hook thread .....................................63
4.13.3 Bobbin identification ............................................................................64
4.13.4 Needle cooling from the top ................................................................65
4.13.5 Needle cooling from the bottom ..........................................................65
4.14 Sewing.................................................................................................66
4.14.1 Pressing the pedal...............................................................................69
4.14.2 Sewing in the end label.......................................................................71
4.15 Procedure in the event of a power supply disruption ..........................75
4.16 Switching off the machine ...................................................................76
5 Programming.....................................................................................79
5.1 Structure of the software.....................................................................79
5.1.1 Security levels (0-2).............................................................................79
5.1.2 Start screen.........................................................................................82
5.1.3 Main screen.........................................................................................83
5.1.4 Register screen...................................................................................85
5.1.5 Recurring elements.............................................................................86
5.1.6 Input window .......................................................................................87
5.2 Logging into the system ......................................................................88
5.2.1 Logging in with the hand scanner........................................................88
5.2.2 Logging in via software........................................................................89
5.3 Managing users...................................................................................90
5.3.1 Displaying users..................................................................................91
5.3.2 Storing a user image...........................................................................92
5.3.3 Creating a new user............................................................................93
5.3.4 Deleting users .....................................................................................95
5.4 Seam record sets................................................................................96
5.4.1 Opening the Seam record sets display.........................................97
5.4.2 Creating a new seam record set .........................................................98
5.4.3 Editing a seam record set
(Edit seam parameter record)................................................100
5.4.4 Copying a seam record set ...............................................................118
5.4.5 Deleting a seam record set ...............................................................120
5.4.6 Changing the thread
(Change thread in seam records) .........................................121
5.5 Database...........................................................................................123
5.5.1 Opening the Database display ........................................................123
5.5.2 Opening a protocol database ............................................................124
5.5.3 Printing a protocol file........................................................................125
5.5.4 Copying a protocol file (Copy)...........................................................125

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Operating Instructions 550-867 - 00.0 - 11/2016 3
5.5.5 Error codes (Help)............................................................................126
5.5.6 Printing a copy of an end label (Lab. Copy) ...................................127
5.5.7 Thread tension (Thr. tens.) .........................................................128
5.6 Check................................................................................................129
5.6.1 Structure of the Checks display.........................................................129
5.6.2 Opening the Checks display.............................................................132
5.6.3 Creating a system backup (Backup system) .................................133
5.6.4 Restoring data (Restore system) .................................................135
5.6.5 Creating a backup of the protocol database
(Backup protoc. DB) ...................................................................136
5.6.6 Printing a barcode label (Print BC label)...................................137
5.6.7 Data transfer......................................................................................138
5.6.8 Copying Dump Files..........................................................................138
5.6.9 Displaying connections......................................................................138
5.6.10 Setup.................................................................................................139
5.6.11 Opening the thread database (Threads) .........................................149
5.6.12 Printing the protocol database (DB print)......................................150
5.6.13 Opening the seam database (Show DB)...........................................151
5.6.14 Opening the bobbin database (Bobbins).........................................152
5.6.15 Needle database (Needle DB) ........................................................153
5.6.16 Calibrating the step motor (SM-Cali)...............................................155
5.6.17 Calibration database (T.Tens.-Cali)............................................156
5.6.18 Calibrating the stitch length (SM) .......................................................157
5.6.19 Checking input and output (I/O).......................................................160
5.6.20 Checking the scanners (Scanner) ...................................................161
5.6.21 Checking the sewing motor (Sew. Motor)......................................162
5.6.22 Thread tension (Thread tens.).....................................................163
5.6.23 Uninterrupted power supply (UPS).....................................................166
5.7 Protocol printer..................................................................................168
5.8 Uninstalling the barcode printer drivers.............................................168
5.9 Calibrating the end label printer ........................................................169
5.10 Barcodes...........................................................................................170
5.10.1 Barcodes at a glance.........................................................................170
5.10.2 Opening the Barcodes display ..........................................................171
5.10.3 Changing the barcode type ...............................................................174
5.10.4 Defining a barcode............................................................................175
5.10.5 Saving a barcode profile....................................................................176
5.10.6 Loading a barcode profile..................................................................177
5.11 Setting batch mode ...........................................................................178
5.12 Setting multi barcodes.......................................................................179
5.13 Preparing the end label (Label).......................................................180
5.13.1 Opening the End label display...........................................................180
5.13.2 Defining the end label text.................................................................181
5.13.3 Positioning the text on the end label .................................................182
5.13.4 Defining the format of the end label ..................................................183

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4 Operating Instructions 550-867 - 00.0 - 11/2016
5.13.5 Positioning the end label barcode.....................................................184
5.13.6 Defining the font size.........................................................................185
5.13.7 Defining an end label barcode type...................................................185
5.13.8 Defining the content of the end label barcode...................................186
5.13.9 Saving an end label...........................................................................189
5.13.10 Loading an end label.........................................................................190
5.13.11 Defining extended label printing........................................................191
5.14 Deleting a bobbin ..............................................................................194
5.15 Storage locations and automatic backups (Path+netw.)................196
5.15.1 Changing the storage location...........................................................196
5.15.2 Setting an automatic backup of the protocol database .....................198
5.16 Thread database ...............................................................................199
5.16.1 Creating a new thread.......................................................................200
5.16.2 Changing a thread.............................................................................202
5.16.3 Deleting a thread...............................................................................203
5.17 Creating a teach-in file ......................................................................203
5.18 Restarting the program (Reset) .......................................................208
5.19 Exiting the program...........................................................................209
5.20 Logging out of the system .................................................................210
5.21 Additional program Label Creator ..............................................212
5.21.1 Preparing the end label (example) ....................................................214
5.21.2 Default settings..................................................................................216
5.21.3 Adjusting the end label size...............................................................217
5.21.4 Opening the Toolbox ......................................................................218
5.21.5 Inserting contents..............................................................................220
5.21.6 Moving contents ................................................................................221
5.21.7 Creating a barcode............................................................................222
5.21.8 Adding an additional barcode............................................................225
5.21.9 Creating standard text.......................................................................225
5.21.10 Creating variable text ........................................................................226
5.21.11 Inserting a graphic.............................................................................227
5.21.12 Saving a label script file.....................................................................228
5.21.13 Printing a test end label.....................................................................229
5.22 Additional program SABSearch .......................................................230
5.22.1 Performing a search (example).........................................................231
5.22.2 Exiting SABSearch ..........................................................................235
6 Maintenance.....................................................................................237
6.1 Cleaning ............................................................................................238
6.2 Lubricating.........................................................................................240
6.3 Servicing the pneumatic system........................................................242
6.3.1 Setting the operating pressure..........................................................242
6.3.2 Draining the water condensation.......................................................243
6.3.3 Cleaning the filter element.................................................................245

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Operating Instructions 550-867 - 00.0 - 11/2016 5
6.4 Parts list.............................................................................................246
7 Setup ................................................................................................247
7.1 Checking the scope of delivery .........................................................247
7.2 Removing the transport locks............................................................247
7.3 Assembling the reel stand.................................................................248
7.4 Setting the working height.................................................................250
7.5 Setting the pedal ...............................................................................251
7.6 Assembling the control panel............................................................253
7.7 Electrical connection .........................................................................253
7.8 Connecting the control panel.............................................................254
7.9 Pneumatic connection.......................................................................255
7.9.1 Assembling the compressed air maintenance unit............................255
7.9.2 Setting the operating pressure..........................................................256
7.10 Lubricating.........................................................................................257
7.11 Putting the machine into operation....................................................259
7.12 Performing a test run.........................................................................260
7.13 Transporting the machine in house...................................................262
8 Decommissioning ...........................................................................263
8.1 Decommissioning the machine .........................................................263
8.2 Transporting the machine..................................................................264
9 Disposal ...........................................................................................265
10 Troubleshooting..............................................................................267
10.1 Customer Service..............................................................................267
10.2 Messages of the software .................................................................268
10.2.1 Information messages.......................................................................268
10.2.2 Error messages.................................................................................269
10.2.3 Editing error messages .....................................................................272
10.3 Errors in sewing process...................................................................274
11 Technical data .................................................................................277
11.1 Characteristics...................................................................................279
11.2 Technical features of the software ....................................................280
11.3 Data recording...................................................................................281
12 Appendix..........................................................................................283

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6 Operating Instructions 550-867 - 00.0 - 11/2016

About these instructions
Operating Instructions 550-867 - 00.0 - 11/2016 7
1 About these instructions
These instructions have been prepared with utmost care.
They contain informationandnotesintendedto ensure long-term
and reliable operation.
Should you notice any discrepancies or if you have improvement
requests,thenwewouldbegladtoreceiveyourfeedbackthrough
Customer Service (p. 267).
Consider the instructions part of the product and store them in a
place where they are readily available.
1.1 For whom are these instructions intended?
These instructions are intended for:
• Operators:
This group is familiar with the machine and has access
to the instructions. Specifically, chapter Operation
(p. 21) is important for the operators.
• Specialists:
This group has the appropriate technical training for
performing maintenance or repairing malfunctions.
Specifically, the chapter Setup (p. 247) is important for
specialists. Service Instructions are supplied separately.
With regard tominimum qualification and other requirements to be
metbypersonnel,pleasealsofollowthechapterSafety (p. 11).

About these instructions
8 Operating Instructions 550-867 - 00.0 - 11/2016
1.2 Representation conventions – symbols and
characters
Various information in these instructions is represented or high-
lighted by the following characters in order to facilitate easy and
quick understanding:
Proper setting
Specifies proper setting.
Disturbances
Specifiesthedisturbancesthatcanoccurfromanincorrectsetting.
Cover
Specifies which covers must be disassembled in order to access
the components to be set.
Steps to be performed when operating the machine (sewing
and equipping)
Steps to be performed for service, maintenance, and
installation
Steps to be performed via the software control panel
The individual steps are numbered:
First step
Second step
The steps must always be followed in the specified order.
Lists are marked by bullet points.
Result of performing an operation
Change to the machine or on the display/control panel.
Important
Specialattentionmustbepaidtothispointwhenperformingastep.
1.
2.
...
•


About these instructions
Operating Instructions 550-867 - 00.0 - 11/2016 9
Information
Additional information, e.g. on alternative operating options.
Order
Specifies the work to be performed before or after a setting.
References
 Reference to another section in these instructions.
Safety Important warnings for the user of the machine are specifically
marked.Since safetyisofparticularimportance,hazardsymbols,
levels of danger and their signal words are described separately
in the chapter Safety (p. 11).
Location
information Ifnootherclearlocationinformationisusedinafigure,indications
of right or left are always from the user's point of view.
1.3 Other documents
The machine includes components from other manufacturers.
Eachmanufacturerhasperformedahazardassessmentforthese
purchased parts and confirmed their design compliance with
applicable European and national regulations. The proper use of
the built-in components is described in the corresponding manu-
facturer's instructions.

About these instructions
10 Operating Instructions 550-867 - 00.0 - 11/2016
1.4 Liability
Allinformationandnotesintheseinstructionshavebeencompiled
in accordance with the latest technology and the applicable stan-
dards and regulations.
Dürkopp Adler cannot be held liable for any damage resulting
from:
• Breakage and damage during transport
• Failure to observe these instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved parts
Transport
Dürkopp Adler cannot be held liable for breakage and transport
damages. Inspect the delivery immediately upon receiving it.
Report any damage to the last transport manager. This also
applies if the packaging is not damaged.
Leave machines, equipment and packaging material in the con-
ditioninwhichtheywerefoundwhenthedamagewasdiscovered.
This will ensure any claims against the transport company.
Report all other complaints to Dürkopp Adler immediately after
receiving the product.

Safety
Operating Instructions 550-867 - 00.0 - 11/2016 11
2 Safety
This chapter contains basic information for your safety. Read the
instructions carefully before setting up or operating the machine.
Make sure to follow the information included in the safety instruc-
tions. Failure to do so can result in serious injury and property
damage.
2.1 Basic safety instructions
Themachinemayonlybeusedasdescribedintheseinstructions.
The instructions should be available at the machine's location at
all times.
Work on live components and equipment is prohibited.
Exceptions are defined in the DIN VDE 0105.
For the following work, switch off the machine at the main switch
or disconnect the power plug:
• Replacing the needle or other sewing tools
• Leaving the workstation
• Performing maintenance work and repairs
• Threading
Missingorfaultypartscouldimpairsafetyanddamagethemachine.
Only use original parts from the manufacturer.
Transport Usealiftingcarriageorforklifttotransportthemachine.Raisethe
machine max. 20 mm and secure it to prevent it from slipping off.
Setup The connecting cable must have a power plug approved in the
relevant country. The power plug may only be assembled to the
power cable by qualified specialists.
Obligations
of the operator Follow the country-specific safety and accident prevention regu-
lations and the legal regulations concerning industrial safety and
the protection of the environment.

Safety
12 Operating Instructions 550-867 - 00.0 - 11/2016
All the warnings and safety signs on the machine must always be
in legible condition. Do not remove!
Missing or damaged warnings and safety signs must be replaced
immediately.
Requirements
to be met by
the personnel
Only qualified specialists may:
• set up the machine
• perform maintenance work and repairs
• perform work on electrical equipment
Only authorized persons may work on the machine and must first
have understood these instructions.
Operation Check the machine during operating for any externally visible
damage. Stop working if you notice any changes to the machine.
Report any changes to your supervisor. Do not use a damaged
machine any further.
Safety
equipment Safety equipment should not be removed or deactivated. If it is
essential to remove or deactivate safety equipment for a repair
operation, it must be assembled and put back into operation
immediately afterward.
2.2 Signal words and symbols used in
warnings
Warnings in the text are distinguished by color bars.
The color scheme is based on the severity of the danger.
Signal words indicate the severity of the danger.
Signal words Signal words and the hazard they describe:
Signal word Meaning
DANGER (with hazard symbol)
If ignored, fatal or serious injury will result
WARNING (with hazard symbol)
If ignored, fatal or serious injury can result

Safety
Operating Instructions 550-867 - 00.0 - 11/2016 13
Symbols The following symbols indicate the type of danger to personnel:
CAUTION (with hazard symbol)
If ignored, moderate or minor injury can result
CAUTION (with hazard symbol)
If ignored, environmental damage can result
NOTICE (without hazard symbol)
If ignored, property damage can result
Symbol Type of danger
General
Electric shock
Puncture
Crushing
Environmental damage

Safety
14 Operating Instructions 550-867 - 00.0 - 11/2016
Examples Examples of the layout of warnings in the text:
This is what a warning looks like for a hazard that will result
in serious injury or even death if ignored.
This is what a warning looks like for a hazard that could
result in serious or even fatal injury if ignored.
This is what a warning looks like for a hazard that could
result in moderate or minor injury if the warning is ignored.
DANGER
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
WARNING
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Safety
Operating Instructions 550-867 - 00.0 - 11/2016 15
This is what a warning looks like for a hazard that could
result in property damage if ignored.
This is what a warning looks like for a hazard that could
result in environmental damage if ignored.
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Safety
16 Operating Instructions 550-867 - 00.0 - 11/2016

Machine description
Operating Instructions 550-867 - 00.0 - 11/2016 17
3 Machine description
3.1 Components of the machine
3.1.1 Complete overview
Fig. 1: Complete overview

Machine description
18 Operating Instructions 550-867 - 00.0 - 11/2016
3.1.2 Upper part of the machine
Fig. 2: Upper part of the machine
3.1.3 Lower part of the machine
Fig. 3: Lower part of the machine
(1) - Thread reel stand
(2) - External winder
(3) - End label scanner (optional)
(4) - Hand scanner
(5) - End label printer
(6) - Control panel with touchscreen
(1) - Uninterrupted power supply
(UPS)
(2) - Tray
(3) - Main switch
(4) - Pedal
(5) - Control
(6) - Sewing lamp transformer
(7) - Switch (height adjustment)
(8) - Switch (logging in and out)
(9) - Knee button
⑥
④
⑤
③
②
①
①
④
⑨⑦⑥⑤
③
⑧
②