Dürkopp Adler 550-D800 User manual

550-D800
Operating Instructions

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Property of Dürkopp Adler GmbH and protected by copyright. Any reuse of these contents,
including extracts, is prohibited without the prior written approval of Dürkopp Adler GmbH.
Copyright © Dürkopp Adler GmbH 2023
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Operating Instructions 550-D800 - 01.0 - 05/2023 1
1 About these instructions ........................................................... 7
1.1 For whom are these instructions intended?.................................. 7
1.2 Representation conventions – symbols and characters ............... 7
1.3 Other documents .......................................................................... 9
1.4 Liability.......................................................................................... 9
2 Safety......................................................................................... 11
2.1 Basic safety instructions ............................................................. 11
2.2 Signal words and symbols used in warnings.............................. 12
3 Machine description................................................................. 15
3.1 Components of the machine....................................................... 15
3.2 Proper use .................................................................................. 15
3.3 Declaration of Conformity ........................................................... 16
4 Operation................................................................................... 17
4.1 Preparing the machine for operation .......................................... 17
4.1.1 Switching on the machine........................................................... 17
4.1.2 Scanning barcodes..................................................................... 18
4.1.3 Inserting or changing the needle ................................................ 22
4.1.4 Feeding needle and hook thread................................................ 24
4.1.5 Threading the needle thread ...................................................... 26
4.1.6 Winding the hook thread............................................................. 29
4.1.7 Inserting/changing the bobbin .................................................... 32
4.1.8 Threading the hook thread ......................................................... 34
4.2 Thread tension............................................................................ 36
4.2.1 Adjusting the needle thread tension ........................................... 37
4.2.2 Adjusting the hook thread tension .............................................. 37
4.3 Adjusting the needle thread regulator......................................... 38
4.4 Locking the sewing foot in top dead center ................................ 39
4.5 Adjusting the sewing foot stroke................................................. 40
4.6 Adjusting the sewing foot pressure............................................. 41
4.7 Adjusting the stitch length........................................................... 41
4.8 Quick functions on the push buttons .......................................... 41
4.8.1 Activating/deactivating function keys.......................................... 41
4.8.2 Assigning a function to the favorite buttons................................ 43
4.8.3 Switching the function of a favorite button on and off................. 43
4.9 LEDs on the machine arm .......................................................... 44
4.10 Skip Stitch Detection (SSD)........................................................ 44
4.11 Quick stroke adjustment ............................................................. 48
4.12 Switching on and off the sewing light ......................................... 49
4.13 Additional equipment .................................................................. 50
4.13.1 End label scanner....................................................................... 50
4.13.2 Barcode scanner for needle and hook thread ............................ 51
4.13.3 Bobbin identification ................................................................... 52
4.13.4 Needle cooling from above......................................................... 53
4.13.5 Needle cooling from below ......................................................... 53
4.13.6 Operation lock ............................................................................ 53
4.14 Sewing........................................................................................ 54
4.14.1 Pressing the pedal...................................................................... 56
4.14.2 Sewing in the end label .............................................................. 58
4.15 Disruption of the power supply ................................................... 61

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2Operating Instructions 550-D800 - 01.0 - 05/2023
4.16 Switching off the machine........................................................... 62
5 Programming ............................................................................ 65
5.1 Structure of the software ............................................................ 65
5.1.1 Security levels (0-2).................................................................... 65
5.1.2 Start screen - preparing the machine for operation .................... 68
5.1.3 Main screen ................................................................................ 71
5.1.4 Register screen .......................................................................... 73
5.1.5 Recurring elements .................................................................... 74
5.1.6 Input window............................................................................... 75
5.2 Logging into the system.............................................................. 75
5.2.1 Logging in with the hand scanner............................................... 76
5.2.2 Logging in with a password ........................................................ 77
5.2.3 Logging in using the fingerprint scanner..................................... 80
5.3 Managing users .......................................................................... 82
5.3.1 Opening the user database ........................................................ 82
5.3.2 Printing a copy of an access barcode......................................... 82
5.3.3 Opening the fingerprint database ............................................... 83
5.3.4 Storing a user photo ................................................................... 83
5.3.5 Creating a new user ................................................................... 85
5.3.6 Deleting users............................................................................. 91
5.3.7 Deleting the fingerprint database................................................ 93
5.4 Seam record sets ....................................................................... 94
5.4.1 Opening the Seam record sets display ................................ 94
5.4.2 Creating a new seam record set................................................. 95
5.4.3 Editing a seam record set (Edit seam parameter record)97
5.4.4 Copying a seam record set....................................................... 113
5.4.5 Deleting a seam record set....................................................... 114
5.4.6 Changing the thread (Change thread in seam records)116
5.4.7 Exporting a seam record set..................................................... 117
5.4.8 Importing a seam record set..................................................... 117
5.5 Database .................................................................................. 118
5.5.1 Opening the Database display................................................ 118
5.5.2 Opening the protocol database ................................................ 119
5.5.3 Printing a protocol file ............................................................... 120
5.5.4 Copying a protocol file (Copy) .................................................. 120
5.5.5 Error codes (Help) ................................................................... 121
5.5.6 Printing a copy of an end label (Lab. Copy) .......................... 121
5.5.7 Thread tension (Thr. tens.)................................................. 122
5.6 Check ....................................................................................... 123
5.6.1 Structure of the Checks display................................................ 123
5.6.2 Opening theChecks display..................................................... 125
5.6.3 Creating a system backup (Backup system)......................... 125
5.6.4 Restoring data (Restore system)......................................... 127
5.6.5 Creating a backup of the protocol database
(Backup protoc. DB)........................................................... 128
5.6.6 Printing a barcode label (Print BC label) .......................... 129
5.6.7 Data transfer............................................................................. 129
5.6.8 Copying dump files ................................................................... 129
5.6.9 Reducing the volume of the protocol database
(Reduce protoc. DB)........................................................... 130
5.6.10 DACFleXCommander............................................................... 130

Table of Contents
Operating Instructions 550-D800 - 01.0 - 05/2023 3
5.6.11 Setup ........................................................................................ 130
5.6.12 Opening the thread database (Threads)................................. 140
5.6.13 Printing the protocol database (DB print) ............................. 140
5.6.14 Opening the seam database (Show DB) .................................. 141
5.6.15 Opening the bobbin database (Bobbins) ................................ 141
5.6.16 Needle database (Needle DB)................................................ 142
5.6.17 Calibrating the stepper motor (SM-Cali)................................. 144
5.6.18 Opening the calibration database (T.Tens.-Cali)................ 145
5.6.19 Checking the scanners (Scanner)........................................... 147
5.6.20 Thread tension (Thread tens.) ............................................ 148
5.6.21 Uninterrupted power supply(UPS)............................................. 151
5.7 Protocol printer ......................................................................... 152
5.8 Uninstalling the barcode printer drivers .................................... 152
5.9 Calibrating the end label printer................................................ 154
5.10 Barcodes .................................................................................. 154
5.10.1 Barcodes at a glance................................................................ 155
5.10.2 Opening the Barcodes display.................................................. 156
5.10.3 Changing the barcode type ...................................................... 158
5.10.4 Defining a barcode ................................................................... 159
5.10.5 Saving a barcode profile........................................................... 160
5.10.6 Loading a barcode profile ......................................................... 161
5.11 Setting batch mode................................................................... 162
5.12 Setting multi barcodes .............................................................. 162
5.13 Preparing the end label (Label) .............................................. 163
5.13.1 Opening the End label display.................................................. 164
5.13.2 Defining the end label text ........................................................ 164
5.13.3 Positioning the text on the end label......................................... 165
5.13.4 Defining the format of the end label.......................................... 166
5.13.5 Positioning the end label barcode ............................................ 167
5.13.6 Defining the font size ................................................................ 167
5.13.7 Defining the end label barcode type ......................................... 168
5.13.8 Defining the content of the end label barcode .......................... 168
5.13.9 Saving an end label .................................................................. 170
5.13.10 Loading an end label .............................................................. 171
5.13.11 Defining extended label printing ............................................. 172
5.14 Deleting a bobbin...................................................................... 174
5.15 Storage locations and automatic backups (Path+netw.)....... 175
5.15.1 Changing the storage location.................................................. 175
5.15.2 Setting an automatic backup of the protocol database............. 177
5.16 Thread database ...................................................................... 178
5.16.1 Creating a new thread .............................................................. 178
5.16.2 Changing a thread .................................................................... 180
5.16.3 Deleting a thread ...................................................................... 180
5.17 Creating a teach-in file.............................................................. 181
5.18 Restarting the program (Reset)............................................... 186
5.19 Exiting the program .................................................................. 187
5.20 Logging out of the system ........................................................ 188
5.21 Additional program Label Creator ...................................... 189
5.21.1 Preparing the end label (example) ........................................... 190
5.21.2 Default settings......................................................................... 192
5.21.3 Adjusting the end label size...................................................... 192
5.21.4 Opening the Toolbox............................................................. 194

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4Operating Instructions 550-D800 - 01.0 - 05/2023
5.21.5 Inserting contents ..................................................................... 195
5.21.6 Moving contents ....................................................................... 196
5.21.7 Creating a barcode ................................................................... 197
5.21.8 Adding an additional barcode ................................................... 199
5.21.9 Creating standard text .............................................................. 200
5.21.10 Creating variable text.............................................................. 201
5.21.11 Inserting a graphic .................................................................. 202
5.21.12 Saving a label script file .......................................................... 203
5.21.13 Printing a test end label .......................................................... 204
5.22 Additional program SABSearch ............................................... 204
5.22.1 Performing a search (example) ................................................ 205
5.22.2 Exiting SABSearch .................................................................. 209
6 Maintenance............................................................................ 211
6.1 Cleaning ................................................................................... 212
6.2 Lubricating ................................................................................ 213
6.2.1 Lubricating the machine head .................................................. 214
6.2.2 Lubricating the hook ................................................................. 215
6.3 Servicing the pneumatic system............................................... 216
6.3.1 Adjusting the operating pressure.............................................. 216
6.3.2 Draining the water-oil mixture................................................... 217
6.3.3 Cleaning the filter element........................................................ 218
6.4 Parts list.................................................................................... 219
7 Setup........................................................................................ 221
7.1 Checking the scope of delivery................................................. 221
7.2 Transport .................................................................................. 221
7.3 Removing the transport locks ................................................... 221
7.4 Adjusting the working height..................................................... 222
7.5 Adjusting the pedal ................................................................... 222
7.6 Electrical connection................................................................. 223
7.7 Pneumatic connection .............................................................. 224
7.7.1 Assembling the compressed air maintenance unit ................... 224
7.7.2 Adjusting the operating pressure.............................................. 224
7.8 Checking the lubrication ........................................................... 225
7.9 Putting the machine into operation ........................................... 227
7.10 Performing a test run ................................................................ 227
8 Decommissioning................................................................... 229
9 Disposal................................................................................... 231
10 Troubleshooting ..................................................................... 233
10.1 Customer Service ..................................................................... 233
10.2 Messages of the software......................................................... 233
10.2.1 Information messages .............................................................. 233
10.2.2 Error messages ........................................................................ 234
10.2.3 Editing error messages............................................................. 255
10.3 Errors in sewing process .......................................................... 257
11 Technical data......................................................................... 259
11.1 Data and characteristic values ................................................. 259
11.2 Requirements for fault-free operation....................................... 259

Table of Contents
Operating Instructions 550-D800 - 01.0 - 05/2023 5
12 Appendix ................................................................................. 261

Table of Contents
6Operating Instructions 550-D800 - 01.0 - 05/2023

About these instructions
Operating Instructions 550-D800 - 01.0 - 05/2023 7
1 About these instructions
These instructions have been prepared with utmost care. They contain in-
formation and notes intended to ensure long-term and reliable operation.
Should you notice any discrepancies or if you have improvement requests,
then we would be glad to receive your feedback through Customer
Service (p. 233).
Consider these instructions as part of the product and keep it easily
accessible.
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. 17) is important
for the operators.
• Specialists:
This group has the appropriate technical training for performing
maintenance or repairing malfunctions. Specifically, the chapter
Setup (p. 221) is important for specialists.
Service Instructions are supplied separately.
With regard to minimum qualification and other requirements to be met by
personnel, please also follow the chapter Safety (p. 11).
1.2 Representation conventions – symbols and characters
Various information in these instructions is represented or highlighted by
the following characters in order to facilitate easy and quick understanding:
Proper setting
Specifies proper setting.
Disturbances
Specifies the disturbances that can occur from an incorrect adjustment.
Cover
Specifies which covers must be disassembled in order to access the com-
ponents to be set.

About these instructions
8Operating Instructions 550-D800 - 01.0 - 05/2023
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
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating options.
Order
Specifies the work to be performed before or after an adjustment.
References
 Reference to another section in these instructions.
Safety Important warnings for the user of the machine are specifically marked. Since
safety is of particular importance, hazard symbols, levels of danger and their
signal words are described separately in the chapter Safety (p. 11).
Location
information If no other clear location information is used in a figure, indications of right
or left are always from the user's point of view.
1.
2.
…
•


About these instructions
Operating Instructions 550-D800 - 01.0 - 05/2023 9
1.3 Other documents
The machine includes components from other manufacturers. Each man-
ufacturer has performed a hazard assessment for these purchased parts
and confirmed their design compliance with applicable European and na-
tional regulations. The proper use of the built-in components is described
in the corresponding manufacturer's instructions.
1.4 Liability
All information and notes in these instructions have been compiled in
accordance with the latest technology and the applicable standards and
regulations.
Dürkopp Adler cannot be held liable for any damage resulting from:
• Breakage and transport damages
• 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 condition in
which they were found when the damage was discovered. This will ensure
any claims against the transport company.
Report all other complaints to Dürkopp Adler immediately after receiving
the product.

About these instructions
10 Operating Instructions 550-D800 - 01.0 - 05/2023

Safety
Operating Instructions 550-D800 - 01.0 - 05/2023 11
2 Safety
This chapter contains basic information for your safety. Read the instruc-
tions carefully before setting up or operating the machine. Be sure to fol-
low the information in the safety instructions. Failure to do so can result in
serious injury and property damage.
2.1 Basic safety instructions
The machine may only be used as described in these instructions.
These instructions must be available at the machine's location at all times.
Work on live components and equipment is prohibited. Exceptions are de-
fined in the DIN VDE 0105.
For the following work, switch off the machine at the main switch or discon-
nect the power plug:
• Replacing the needle or other sewing tools
• Leaving the workstation
• Performing maintenance work and repairs
• Threading
Missing or faulty parts could impair safety and damage the machine.
Only use original parts from the manufacturer.
Transport Use a lifting carriage or stacker to transport the machine. Raise the 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 regulations and
the legal regulations concerning industrial safety and the protection of the
environment.
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 be used for:
• Setting up the machine/putting the machine into operation
• Performing maintenance work and repairs
• Performing work on electrical equipment
Only authorized persons may work on the machine and must first have un-
derstood these instructions.

Safety
12 Operating Instructions 550-D800 - 01.0 - 05/2023
Operation Check the machine during operating for any externally visible damage.
Stop working if you notice any changes to the machine. Report any chang-
es to your supervisor. Do not use a damaged machine any further.
Safety
equipment Safety equipment should not be disassembled or deactivated. If it is essen-
tial to disassemble 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:
Symbols The following symbols indicate the type of danger to personnel:
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
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

Safety
Operating Instructions 550-D800 - 01.0 - 05/2023 13
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 seri-
ous 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.
Puncture
Crushing
Environmental damage
Symbol Type of danger
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
14 Operating Instructions 550-D800 - 01.0 - 05/2023
This is what a warning looks like for a hazard that could result in envi-
ronmental damage if ignored.
This is what a warning looks like for a hazard that could result in
property damage if ignored.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Machine description
Operating Instructions 550-D800 - 01.0 - 05/2023 15
3 Machine description
3.1 Components of the machine
Fig. 1: Components of the machine
3.2 Proper use
(1) - Control panel
(2) - End label scanner (optional)
(3) - Tray
(4) - Pedal
(5) - Control
(6) - Uninterrupted power supply
(7) - Main switch
(8) - Hand scanner
(9) - End label printer
(10) - Reel stand
WARNING
Risk of injury from live, moving and cutting
parts as well as from sharp parts!
Improper use can result in electric shock, crushing,
cutting and punctures.
Follow all instructions provided.
NOTICE
Non-observance will lead to property damage!
Improper use can result in material damage at the machine.
Follow all instructions provided.
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①
③④⑤
⑧
⑥
⑦
⑨
⑩

Machine description
16 Operating Instructions 550-D800 - 01.0 - 05/2023
The machine may only be used with sewing material that satisfies the re-
quirements of the specific application at hand.
The machine is intended only for use with dry sewing material. The sewing
material must not contain any hard objects.
The needle thicknesses permissible for the machine are listed in the Tech-
nical data (p. 259) chapter.
The seam must be completed with a thread that satisfies the requirements
of the specific application at hand.
The machine is intended for industrial use.
The machine may only be set up and operated in dry conditions on well-
maintained premises. If the machine is operated on premises that are not
dry and well-maintained, then further measures may be required which
must be compatible with DIN EN 60204-31.
Only authorized persons may work on the machine.
Dürkopp Adler cannot be held liable for damages resulting from improper
use.
3.3 Declaration of Conformity
The machine complies with European regulations ensuring health, safety,
and environmental protection as specified in the declaration of conformity
or in the declaration of incorporation.

Operation
Operating Instructions 550-D800 - 01.0 - 05/2023 17
4 Operation
The operating sequence consists of several different steps. Fault-free op-
eration is necessary in order to achieve a good sewing result.
4.1 Preparing the machine for operation
Complete the following steps in preparation of sewing before starting to
work:
• Scan codes (p. 18)
• Log in user (p. 75)
• Insert or change the needle(p. 22)
• Feed the needle thread through the hose guide (p. 24)
• Thread the needle thread (p. 26)
• Thread the hook thread (p. 34)
• Edit the seam record set if necessary (p. 94)
4.1.1 Switching on the machine
Information
When switching on the machine for the first time, proceed as described in
the Setup chapter (p. 221).
WARNING
Risk of injury from moving, cutting and sharp
parts!
Crushing, cutting and punctures are possible.
If possible, make all preparations only when the
machine is switched off.
WARNING
Risk of injury from moving, cutting and sharp
parts!
Crushing, cutting and punctures are possible.
Do not sew unless the machine is fully assembled
and includes all safety devices.

Operation
18 Operating Instructions 550-D800 - 01.0 - 05/2023
Fig. 2: Switching on the machine
To switch on the machine:
1. Set the main switch (2) to position 1(On).
2. Press the switch (1) to switch on the uninterrupted power supply (UPS).
The PC boots up, and the software launches. The machine is
checked and initialized.
Information
It may also be necessary to switch on the control and the printer, which
would be indicated by the machine on the control panel.
4.1.2 Scanning barcodes
To prepare the machine for sewing, the following barcodes need to be
scanned:
• Barcode of the needle thread reel (p. 51)
• Barcode of the hook thread reel (p. 51)
• Barcode of the bobbin
These three barcodes are requested / scanned automatically as soon as
the machine is switched on.
(1) - Switch (2) - Main switch
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①