Dürkopp Adler 650-16 User manual

650-16
Operating Manual

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Property of Dürkopp Adler AG and subject to copyright. Any use of this
content, or parts of it, is prohibited without express prior permission
from Dürkopp Adler AG.
Copyright © Dürkopp Adler AG - 2013

Content
Operating manual 650-16 Version 00.0 - 07/2013 1
1 General Information ............................................................................3
1.1 Scope of this guide................................................................................3
1.2 Declaration of conformity.......................................................................3
1.3 Applicable documents ...........................................................................3
1.4 Transport damage .................................................................................3
1.5 Limited liability .......................................................................................4
2 Safety instructions ..............................................................................5
2.1 General safety instructions....................................................................5
2.2 Marking of safety instructions................................................................7
3 Environmental protection notes ........................................................9
3.1 General environmental protection notes................................................9
3.2 Highlighting of environmental protection notes......................................9
4 Legend................................................................................................10
5 Product description...........................................................................11
6 Intended use ......................................................................................13
7 Technical data....................................................................................14
8 Operation............................................................................................15
8.1 Threading the needle thread ...............................................................15
8.2 Adjusting the needle-thread tension....................................................16
8.3 Adjusting the thread regulator .............................................................17
8.4 Winding on the hook thread.................................................................18
8.5 Changing the hook thread bobbin .......................................................19
8.6 Adjusting the hook thread tension .......................................................20
8.7 Changing needles................................................................................22
8.8 Lifting the sewing feet..........................................................................23
8.9 Function of the optional additional pedal.............................................24
8.10 Knee switch .........................................................................................24
8.11 Sewing.................................................................................................25
9 Operating and programming the control unit.................................26
9.1 Control panel OP3000.........................................................................26
9.2 Switching on the sewing machine .......................................................27
9.3 Operating modes of the control unit ....................................................28
9.4 Manual mode.......................................................................................29
9.4.1 Quick access function (softkey menu).................................................31
9.4.2 Menu for additional settings.................................................................32
9.4.3 Sewing process ...................................................................................33
9.5 Automatic mode...................................................................................33
9.5.1 Before sewing......................................................................................34
9.5.2 Sewing process ...................................................................................36
9.5.3 Terminating a program ........................................................................37
9.6 Quick programming .............................................................................38

Content Content
2 Operating manual 650-16 Version 00.0 - 07/2013
9.6.1 Programming via keypad input............................................................ 40
9.6.2 Programming by sewing...................................................................... 41
9.7 Editing mode ....................................................................................... 42
9.7.1 Changing other parameters for the current step ................................. 43
9.7.2 Changing other parameters for the selected program ........................ 44
9.8 Programming mode............................................................................. 45
9.8.1 Creating a program ............................................................................. 45
9.8.2 Copying a program.............................................................................. 47
9.8.3 Deleting a program.............................................................................. 48
9.8.4 Mirroring a program............................................................................. 48
10 Maintenance ...................................................................................... 49
11 Installation ......................................................................................... 50
11.1 Scope of delivery................................................................................. 50
11.2 Removing the security devices ........................................................... 51
11.3 Assembling the stand.......................................................................... 52
11.4 Pre-assembling the table top .............................................................. 53
11.5 Attaching the table top and the pedals to the frame............................ 54
11.6 Completing the table top ..................................................................... 55
11.7 Adjusting the working height ............................................................... 56
11.8 Inserting the machine head................................................................. 57
11.9 Electrical connections ......................................................................... 58
11.9.1 Check the mains voltage..................................................................... 58
11.9.2 Mains voltage distribution.................................................................... 59
11.9.3 Connecting the lines for the machine head......................................... 60
11.9.4 Connecting auxiliary control unit cables.............................................. 61
11.9.5 Connecting the encoder to the control unit ......................................... 62
11.9.6 Establishing equipotential bonding for the machine head................... 63
11.9.7 Establishing equipotential bonding for the control unit........................ 64
11.9.8 Establishing equipotential bonding for the auxiliary control unit.......... 65
11.9.9 Establishing equipotential bonding for the sewing drive ..................... 66
11.9.10 Establishing equipotential bonding for the knee switch....................... 67
11.9.11 Establishing equipotential bonding for encoders................................. 68
11.9.12 Connecting the knee switch ................................................................ 69
11.9.13 Connecting the control panel .............................................................. 70
11.9.14 Connecting the LED sewing lamp....................................................... 71
11.9.15 Connecting the auxiliary sewing lamp (Waldmann - optional) ............ 71
11.10 Sewing test.......................................................................................... 72
12 Appendix............................................................................................ 73

General Information
Instruction manual 650-16 Version 00.0 - 07/2013 3
1 General Information
1.1 Scope of this guide
This guide describes the intended use and assembly of the special
purpose sewing machine 650-16 for sewing sleeves.
1.2 Declaration of conformity
The machine conforms with the European regulations stated in
the declaration of conformity or incorporation.
1.3 Applicable documents
The appliance contains components by other manufacturers, e.g.,
drive motors. The respective manufacturers have performed a risk
analysis for these supply parts and declared the conformity of their
design to be compliant with valid European and national require-
ments. The intended use of the incorporated components is de-
scribed in the respective third-party manufacturer's guides.
1.4 Transport damage
Dürkopp Adler is not liable for breakage and transport damage.
Please check the deliver carefully immediately on receipt. Claim
against the forwarder for damage. This also applies if the pack-
aging is undamaged.
Leave the machine device and packaging material in the state it
was in when you ascertained the damage. This will help you assert
your claim against the forwarder.
Report all other complaints without delay after receipt of delivery
to Dürkopp Adler.

General Information
4 Instruction manual 650-16 Version 00.0 - 07/2013
1.5 Limited liability
All information and instructions for use in this guide were compiled
taking account the latest state of the art, and applicable standards
and regulations.
The manufacturer accepts no liability in case of damage due to:
• failure to observe this guide
• unintended use
• unauthorized modifications to the machine
• use of untrained staff
• breakage and transport damage
• use of non-approved spare parts

Safety instructions
Instruction manual 650-16 Version 00.0 - 07/2013 5
2 Safety instructions
This chapter contains basic instructions for your safety. Read
these instructions carefully before you install, program, maintain
or operate the machine.
Always follow the provisions in the safety instructions. Failure to
observe can lead to severe injury and damage to property.
2.1 General safety instructions
Unauthorizedpersonsmust not workon or with themachine. Every
person working on or with the machine must read the Operating
Guide before doing so.
The machine must only be used as described in this guide.
The Operating Guide must be kept at the machine's place of use.
Please observe all general safety and accident prevention regu-
lations and the legal requirements on occupational safety and
environmental protection.
Observethesafetyinstructions and the operating manualprovided
by the motor manufacturer for the drive.
All warning signs on the machine must always be kept in legible
state and must not be removed. Missing or damaged signs must
be replace immediately.
In the following situations, always de-energize the machine at the
main switch or by unplugging the mains plug:
• Threading
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing maintenance work and repairs

Safety instructions
6 Instruction manual 650-16 Version 00.0 - 07/2013
During use, check the machine for signs of visible damage. Stop
working if you notice any changes to the machine's behavior.
Report all changes to the appropriate supervisor. You must not
continue using a damaged machine.
Machines or machine parts that have reached the end of their
service life must not be operated. Dispose of these machines in
line with environmental legislation.
Only qualified and trained staff are allowed to install the machine.
Only qualified and trained staff are allowed to perform servicing,
maintenance and repairs.
Safety devices must not be removed or disabled. If this is unavoid-
able for repairs, the safety devices must be refitted and re-enabled
immediately after completing the repairs.
Work on the machine's electrical equipment must be performed
by a qualified electrician.
The power cable must have a country-specific, approved plug.
Only a qualified electrician is permitted to connect the plug to the
power cable.
Work on live parts and assemblies is prohibited.
Exceptions are governed by the regulations in DIN VDE 0105.
Only use original spare parts by the manufacturer. Incorrect or
faulty spare parts can impair safety and damage the machine.

Safety instructions
Instruction manual 650-16 Version 00.0 - 07/2013 7
2.2 Marking of safety instructions
Colored bars highlight the safety instructions in the text.
Signal words indicate the severity of the risk:
•Danger:
Certainty of serious or fatal injury.
•Warning:
Risk of serious or fatal injury.
•Caution:
Risk of moderate or minor injury.
•Attention:
Risk of damage.
In case of dangers for persons, these symbols indicate the type
of danger:
General danger
Danger due to pointed objects
Danger due to electric shock
Danger due to crushing

Safety instructions
8 Instruction manual 650-16 Version 00.0 - 07/2013
Examples for marking of safety instructions in the text:
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe will lead to
fatal or serious injury.
DANGER
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to
fatal or serious injury.
WARNING
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to
moderate or minor injury.
CAUTION
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to damage to
property.
CAUTION

Environmental protection notes
Instruction manual 650-16 Version 00.0 - 07/2013 9
3 Environmental protection notes
3.1 General environmental protection notes
Dispose of machines or machine parts that have reached the end
of their service life responsibly, observing the legal requirements
on environmental protection.
Use consumables conservatively and dispose of them responsi-
bly, observing the legal requirements on environmental protection.
3.2 Highlighting of environmental protection
notes
Green bars mark environmental protection notes in the text.
The following symbols state the type of environmental measure:
Example of layout for environmental protection instruc-
tions:
Note on responsible disposal
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
This is what environmental protection instructions
for compliant disposal look like.
Failure to observe can lead to environmental dam-
age.
ENVIRONMENTAL

Legend
10 Instruction manual 650-16 Version 00.0 - 07/2013
4 Legend
Correct setting
Indicates the correct setting.
Malfunctions
Indicates malfunctions that can occur in case of incorrect settings.
Steps for operation (sewing and set up)
Steps for servicing, maintenance and installation
Steps via the software control panel
The individual steps are numbered:
1. First operating step
2. Second operating step
Always follow the order of the steps as stated.
Results of an action
Change to the machine or the display.
Important
Pay particular attention to this step.
Information
Additional information, e. g. regarding alternative operating op-
tions.
Order
States which work you must perform before or after the setting.
References
 This is followed by a reference to another part of the text.
1.
2.
...


Product description
Instruction manual 650-16 Version 00.0 - 07/2013 11
5 Product description
The Dürkopp Adler 650-16 is a special purpose sewing machine
for programmed or manual sewing in of sleeves in ladies and gents
clothing.
The sewing machine is equipped with an integrated sewing drive,
a step-motor driven upper and lower belt transport for gentle
feeding of the material, step-motor driven curve support and an
sloping pedestal for improved material handling.
The step motor-driven sewing foot pressure and the electromag-
netically controlled needle thread tension support programming
of these parameters.
The OP3000 with graphic display supports easy programming and
an improved overview of the configured parameters and the pro-
grammed seam.
The option, ergonomically shaped table top also simplifies the
working process.
Other features include:
• Single needle, integrated column machine
• Sewing drive integrated in housing
• Max. stitches 4000 rpm
• Lubrication-free machine
• Integrated LED sewing lamp
• Oil-free horizontal hook
• Stitch length adjustable and programmable in steps of
0.1 mm from 1.0 to 5.5 mm
• Electronically controlled and programmable sewing foot
pressure
• Alternating top belt transport (programmable), thus allowing
for easy rotating of the material about the needle. Maximum
alternating height 2.5 mm (depending on speed)
• Electronically control threading (programmable), for different
materials and excessive gathering
• Patented curve support for easy material handling (program-
mable)
• Electromagnetic thread-cutter
• Automatic backtacking
• Sewing foot lifting: 12 mm

Product description
12 Instruction manual 650-16 Version 00.0 - 07/2013
• Integrated adjusting disc with position marks on the hand-
wheel for fast checking of the machine settings.
• Edge stop stitch width as of 7.5 mm
• OP3000 key bar with graphical display
• In the operator's reach
• Gathering values between - 6 and 16, that is, a maximum
of 23 gathering values.
• Easy creating of programs through teach-in, easy
processing, copying and deletion of programs via
the graphical display
• Direct entry of the gathering value in automatic mode,
during correction, or in manual mode.
• Second foot pedal optional
The current fullness is increased by
one gathering value by pushing the pedal forwards, and de-
creased by pushing the pedal back.
On retrieving the next step, the gathering value stored
in the program again applies. Alternatively, depending
on the presetting at technician level, the curve radius can be
changed in the same way.

Intended use
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6 Intended use
The 650-16 is a special purpose sewing machine that is intended
for sewing light to medium-weight material. Such material is usu-
ally composed of textile fibers. This material is used in the clothing
industry.
This special purpose sewing machine can also be used to produce
so-called technical seams.
However, the operator must perform a risk assessment to cover
the potential hazards (Dürkopp Adler AG is pleased to cooperate
with you in this), as this kind of use case is quite rare on the one
hand, and the range of options is difficult to keep track of. Depend-
ing on the results of this assessment, it may be necessary to
introduce appropriate safety measures.
As a general rule, only dry material may be processed on this
machine. The material must not be thicker than 4 mm when com-
pressed by the lowered foot. The material must not contain any
hard objects as the eye protection is required when operating the
machine otherwise. This eye protection cannot be supplied at the
current time.
The seam is generally created using yarns of textile fiber of di-
mensions up to 50/3 Nm. If you intend to use a different yarn, you
must also assess the risks this entails and introduce safety mea-
sures where appropriate.
This special purpose sewing machine must only be installed and
operated in dry and clean rooms. If the sewing machine is used
on premises that are not dry and clean, additional measures may
be needed; please consult us to agree on these measures (see
EN 60204-31: 1999).
As manufacturers of industrial sewing machines, we proceed on
the assumption that personnel who work with our products will
have received training that is at least sufficient to acquaint them
with all of the normal operations and with any hazards that these
may involve.

Technical data
14 Instruction manual 650-16 Version 00.0 - 07/2013
7 Technical data
Noise
Workplace-related emission value as per DIN EN ISO 10821:
LC= 79 dB (A) ± 0.83 dB (A) at
• Stitch length: 3.0 mm
• Stitch speed 2900 rpm
• Material: 2-ply material G1 DIN 23328
Type of stitch Double backstitch 301
Hook type Horizontal hook, oil-free
Number of needles 1
Needle system 134-35
Needle thickness [Nm] 70 – 120
Thread thickness [Nm] max. 50 / 3
Stitch length (programmable) [mm] 1.0 – 5.5
Number of stitches (programmable)
[min-1]
max. 4000
Tack (programmable) Start tack, end tack
Clearance under lifted sewing foot
[mm] max. 12
Material thickness [mm] max. 4
Table top height (infinitely adjustable)
[mm]
780 – 900
Width, depth, height [mm]
(machine resting on frame)
1320 / 750 / 1300
Weight [kg]
(machine resting on frame)
112
Rated voltage[V/Hz] 190 – 240V
50/60Hz
Rated voltage at factory setting[V/Hz] 1 x 230V
50Hz
Power rating[kVA] 1.0

Operation
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8 Operation
8.1 Threading the needle thread
Steps
1. Put the thread reel on the thread stand and guide the needle
thread and the hook thread through the unwinder arm.
Important: The unwinder arm must be horizontally above the
thread bobbin.
2. Thread as shown in the following figure.
Fig. 1: Threading the needle thread
Stretching
threads
Fig. 2: Threading with stretching threads
Risk of injury due to the needle tip and moving
parts
Switch off the sewing machine before threading.
WARNING

Operation
16 Instruction manual 650-16 Version 00.0 - 07/2013
8.2 Adjusting the needle-thread tension
Correct setting
Set the main tensioner (1) as low as possible.
The cross-over point of the thread should be in the center of the
material.
When using thin material, excessive thread tension can cause
unwanted gathering and thread breakage.
Fig. 3: interlacing
Fig. 4: Main tensioner
Steps
1. Use the OP 3000 to set the main tensioner (1) so that a uniform
stitch pattern is produced (Chap. 9.4, p. 29).
Automatic
opening
The main tensioner (1) is opened automatically when trimming
the thread.
Fig. a: Correct thread interlacing in
the center of the material
Needle-thread tension too strong or
hook thread tension too weak
Needle-thread tension too strong
or
hook thread tension too weak
(1) - Main tensioner
1

Operation
Instruction manual 650-16 Version 00.0 - 07/2013 17
8.3 Adjusting the thread regulator
The thread regulator controls the quantity of needle thread re-
quired for stitch formation. The thread regulator must be precisely
adjusted for an optimum result.
Correct setting
With correct setting the needle-thread loop must slide with low
tension over the thickest point of the hook.
If the maximum amount of thread is required, the thread tension
spring (3) must be pulled downwards approximately 0.5 mm from
its upper end position. This is the case if the needle thread loop
passes the maximum hook diameter.
Fig. 5: Adjusting the thread regulator
Steps
1. Release the screw (1).
2. Adjust the position of the thread regulator (2).
3. Tighten the screw (1).
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the
thread regulator.
WARNING
(1) - Screw
(2) Thread regulator
(3) - Thread tensioning spring
1
2
3

Operation
18 Instruction manual 650-16 Version 00.0 - 07/2013
8.4 Winding on the hook thread
Fig. 6: Winding on the hook thread
Steps
1. Place the bobbin (2) on the winder shaft.
2. Thread the hook thread as illustrated.
3. Wind the hook thread clockwise onto the bobbin.
4. Swivel the bobbin case flap (1) against the bobbin.
5. Switch on the main switch.
6. Start sewing.
7. After reaching the set bobbin fill quantity, the bobbin winder
switches off automatically (Service Manual Chap. 16.1).
8. Remove the full bobbin, clamp the thread under blade (3) and
cut.
Damage to machine possible due to winding without sew-
ing.
Winding on without sewing can cause damage to the sewing
feet and bobbin case in the hook.
Enable winding on mode (Chap. 9.4, p. 29) if you need to
CAUTION!
(1) - Bobbin case flap
(2) - Bobbin
(3) - Blade
1
23