DURKOPP ADLER 540 - 100 User manual

Manual, complete
540 - 100
CNC double lockstitch buttonholer
Operating Instructions
Installation Instructions
Service Instructions
Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Phone + 49 (0) 5 21 / 9 25-00 • Fax + 49 (0) 5 21 / 9 25 24 35 • www.duerkopp-adler.com
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Ausgabe / Edition: 04/2006 Printed in Federal Republic of Germany Teile-Nr./Part.-No.: 0791 540001

540 - 100
Manual, complete
Contents
Operating Instructions
Installation Instructions
Service Instructions
Interconnection-diagram
9890 540001 B
Software version
A04.1
B04.1

Foreword
This instruction manual is intended to help the user to become familiar
with the machine and take advantage of its application possibilities in
accordance with the recommendations.
The instruction manual contains important information on how to
operate the machine securely, properly and economically. Observation
of the instructions eliminates danger, reduces costs for repair and
down-times, and increases the reliability and life of the machine.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the
machine/sewing unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
– Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
– Service (maintenance, inspection, repair and/or
– Transport.
The user also has to assure that only authorized personnel work on
the machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including
the performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be
remounted directly after completion of the maintenance and repair
work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

General safety instructions
The non-observance of the following safety instructions can cause
bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the
instruction book and operated by persons with appropriate
training.
2. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe
all the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot,
needle plate, feed dog and bobbin) when threading, when the
workplace is left, and during service work, the machine must be
disconnected from the mains by switching off the master switch or
disconnecting the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance
unit.
Exceptions to this are only adjustments and functions checks
made by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time
as the entire sewing unit is found to comply with EC directives.
It is absolutely necessary to respect
the safety instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.

Index Page:
Part 3: Service Instructions Class 540-100
1. Elements of the control panel
1.1 Alteringparametervalues......................................... 4
1.1.1 Numericalvalues.............................................. 4
1.1.2 Selectionofaparameter.......................................... 4
2. Menu structure technician mode (overview)
2.1 Submenumachineconfiguration(overview).............................. 6
3. Calling up the technician mode and entering the code ..................... 7
4. Main menu of the technician mode
4.1 Submenumachineconfiguration..................................... 7
4.1.1 Submenuuser................................................ 8
4.1.2 Submenuforsoftstartsetting....................................... 8
4.1.3 Submenu for determining the equipment ................................ 8
4.1.4 Submenuforthreadmonitorconfiguration............................... 9
4.1.5 Submenu for the configuration of condensed stitches ........................ 10
4.1.6 Submenuforenteringmachinetimes.................................. 11
4.2 Submenu for the configuration of the operating elements ...................... 11
4.2.1 Submenu for selecting the menu language............................... 11
4.2.2 Submenuforsettingdateandtime ................................... 11
4.3 Submenufortestfunctions........................................ 12
4.3.1 SubmenuMultitest ............................................. 12
4.3.1.1 Submenuoutputtest............................................ 13
4.3.1.2 Submenu input test ............................................. 13
4.3.1.3 Submenu automatic input test ...................................... 14
4.3.1.4 Submenusewingmotortest........................................ 14
4.3.1.5 Submenustepmotortest ......................................... 14
4.4.1.6 SubmenuRAMtest............................................. 14
4.4.1.7 SubmenuEPROMtest........................................... 14
4.4.2 SubmenuDACIII.............................................. 15
4.4.3 Submenu memo-dongle .......................................... 15
4.4.3.1 Dongle contents ............................................... 15
4.4.3.2 Submenu loading .............................................. 16
4.4.3.3 Submenusaving .............................................. 17
4.4.3.4 Formatting.................................................. 18
5. Knife setting
5.1 Aligningtheknifeandadjustingtheknifeheight ........................... 19
5.2 Settingoftheknifeincisiondamper................................... 20
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Index Page:
6. Hook and needle bar
6.1 Needle position ............................................... 21
6.2 Reference position of the needle bar .................................. 21
6.3 Setting the adjusting sheet ........................................ 22
6.4 Loop formation stroke position and distance between hook and needle ............. 23
6.5 Needle bar height .............................................. 24
6.6 Needle protection .............................................. 25
6.7 Alignment of the bobbin case holder................................... 25
7. Aligning the throat plate as to the needle .............................. 26
8. Thread tension plate
8.1 Threadpulleradjustment ......................................... 26
8.2 Thread controller spring and thread regulator ............................. 27
9. Sewing basket
9.1 Settingoftheclothpresserblock(liftingstroke) ........................... 28
9.2 Lifting / Lowering speed of the sewing basket ............................. 28
9.3 Alignmentofthesewingbasketastothethroatplate ........................ 29
9.4 Referencepositionofthesewingbasket................................ 30
10. Bobbin thread scissors
10.1 Settingoftheclosingpath......................................... 31
10.2 Adjusting the spring sheet of the thread rest.............................. 32
11. Needle thread scissors
11.1 Function sequence ............................................. 33
11.2 Removal and check of the needle thread scissors .......................... 34
11.3 Alignmentofthescissorsblock...................................... 35
11.4 Scissorsswivelledin............................................ 37
11.5 Heightadjustment.............................................. 38
11.6 Scissorsswivelledout........................................... 38
11.7 Distance to the needle ........................................... 39
11.8 Opening the scissors ............................................ 39
11.9 Settingoftheclosingpath......................................... 40
11.10 Setting the time for opening the scissors ................................ 40
12. Machine stop position .......................................... 41
13. Bobbin winder ............................................... 42
14. Solenoid valves .............................................. 43
15. Exchange of the sewing basket .................................... 44
16. Stretching the drive belts ........................................ 45

1. Elements of the control panel
Key Function
If no text field is activated:
–Change to the parent menu.
If a text field is activated:
–Change between the figures tenth, unit, ten etc.
–Change between the lines in the menus. The selected line is
always dark-shadowed.
If a text field is activated:
–Increase or reduce the value of the respective figure by one or
change between the parameters in case of functions with several
choices, e.g. between “Push button on“ and “Push button off“.
–Activate the text field. The value can be altered with the keys “ñ“
and “ò“.
If a text field is activated:
–The set value is taken over.
–You get back to the main menu from a submenu.
If a text field is activated:
–An input is aborted. The previous value remains unchanged.
–The control changes from the sewing mode to the programming
mode. The buttonhole parameters can be altered in this mode.
–The control changes from the sewing mode or programming mode
to the sequence programming mode.
–The control changes from the sewing mode to the technician mode.
This mode can only be activated by entering a code 25483.Inthis
operating state it is possible to set basic machine parameters and
to call up diagnosis and adjusting programs.
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1.1 Altering parameter values
1.1.1 Numerical values
Numerical values can be altered as follows:
–Selectthelinewiththevaluetobealteredwiththecursorkeysñ
and ò.
–Actuate the OK key.
The cursor flashes under a digit of the numerical value.
–Change between the digits with the cursor keys ïand ð.
–Increase or reduce the value of the selected digit with the cursor
keys ñand ò.
In case of parameters which cannot optionally be altered another
possible parameter value is indicated by actuating the cursor keys
ñand ò.
–Actuate the OK key.
The set value is taken over.
–If the set value is not to be taken over, actuate the ESC key.
The initially set value is restored
1.1.2 Selection of a parameter
Some parameters allow to choose between several possibilities.
The parameter can be altered as follows:
–Selectthelinewiththevaluetobealteredwiththecursorkeysñ
and ò.
–Actuate the OK key.
–Change between the possibilities with the cursor keys ñand ò.
The selected parameter is displayed.
–Actuate the OK key. The set parameter or value is taken over.
–If the set parameter or value is not to be taken over, actuate the
ESC key.
The initially set parameter or value is restored.
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2. Menu structure technician mode (overview)
Parameter
Soft start
Equipment
X- /Y- Correction Submenu: Machine configuration
Thread monitor
Condensed stitches
Subclasses
Times
Counter (totalizer) : Display Selection: German, English,
Italian, Parameter
Hour : Input
Minute: Input
Machine Language Day: Input
Set date/time Month: Input
User configuration Lock P: Selection Year: Input
Hand switch: Selection
Service
Output test
Input test
Auto input
Sewing motor test
Multitest Step motor test
Events RAM test
DAC III EPROM test
Data reset
Memo dongle Time/Date: Display
Temperature DAC III: Display
Interm. circuit voltage: Display
Buttonhole data
Machine compl.
Content
Loading
Save
Format
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2.1 Submenu machine configuration (overview)
Max. speed: Input
Speed basting stitches: Input
Scissors is moved out: Input
n-stitches b. u. bartack/bartack tension on: Input
n-stitches b. l. bartack/bartack tension on: Input
n-stitches b. lip there/lip tension on: Input
n-stitches b. lip back/lip tension on: Input
n-stitches b. seam beginning/lip tension on: Input
Number of stitches: Input
Speed: Input
Cage length: Selection
Parameter Free cage length: Input
Soft start Cage width: Selection
Equipment Free cage width: Input
Thread monitor Knife length: Input
Condensed stitches Pressure monitor: Input
Times
Counter (totalizer)
Repair mode: Selection
Needle thread mon. on/off: Selection
Number of stitches: Input
Stitch length x: Input
Stitch length y: Input
Position last stitch: Input
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3. Calling up the technician mode and entering the code
In order to get into the technician mode a code has to be entered. For
this purpose please proceed as follows:
–Press the Fkey in the sewing mode.
A window for entering the code appears.
–Enter the technician code 25483.
Confirm with the OK key.
Note
If a wrong code has been entered, the automate returns to
the sewing mode.
4. Main menu of the technician mode
No. Parameter name Symbol Description
T1 Machine Selection of the submenu for the machine
configuration
T2 User configuration Selection of the submenu for the configuration
of the control elements
T3 Service Selection of the submenu for test functions
4.1 Submenu Machine configuration
No. Parameter name Symbol Range Description
T1.1 Parameter - Selection of the submenu for
parameter setting
T1.2 Soft start - Selection of the submenu for soft
start setting
T1.3 Equipment - Selection of the submenu for
equipment definition
T1.4 Thread monitor - Selection of the submenu for thread
monitor options
T1.5 Condensed stitches - Selection of the submenu for setting
of condensed stitches
T1.7 Times - Selection of the submenu for
entering machine times
T1.8 Counter (totalizer) -
buttonholes ever sewn
0 … 99.999.999 Display of the counter of all
buttonholes ever sewn
The value cannot be selected or
edited.
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4.1.1 User submenu
No. Parameter name Symbol Range Description
T1.1.1 Max. speed 200 … 4000 Setting of the maximum speed in the
sewing mode.
The speed can be altered in steps of
100.
T1.1.2 Speed basting stitches 200 … 4000 Setting of the speed for the basting
stitches
T1.1.3 Move out the scissors 0 … 10 Number of stitches after which the
scissors moves out and releases the
clamped needle thread
T1.1.4 Lip tension before the
upper bartack
0…10 Number of stitches before the upper
bartack with the bartack tension
switched on
T1.1.5 Lip tension before the
lower bartack
0…10 Number of stitches before the lower
bartack with the bartack tension
switched on
T1.1.6 Lip tension before the
lip back
0…10 Number of stitches before the lip
back with the lip tension switched on
T1.1.7 Lip tension before the lip
there
0…10 Number of stitches before the lip
there with the lip tension switched
on
T1.1.8 Lip tension after the
seam beginning
0…10 Number of stitches after the seam
beginning after which the lip tension
is switched on.
Only valid for taper bars.
4.1.2 Submenu for soft start setting
No. Parameter name Symbol Range Description
T1.2.1 Number of stitches 0 … 10 Number of stitches of the soft start
T1.2.2 Speed 200 … max.
sewing speed
according to T1.1.1
Speed for the soft start
4.1.3 Submenu for determining the equipment
No. Parameter name Symbol Range Description
T1.3.1 Cagewidth 3,4,6,Xmm Selection of the cage width
T1.3.2 Free cage width 1,0 … 6,0 mm Only visible if cage width X has been
selected for T1.4.1.
Enter value for cage width.
T1.3.3 Cage length 17, 22, 35, 48,
70, X mm
Selection of the cage length
T1.3.4 Free cage length 10,0 … 70,0 mm Only visible if cage length X has
been selected for T1.4.3.
Enter value for cage length.
T1.3.5 Knife length 1,0 … 70,0 mm Length of the knife used.
(Default-Value: 3.5 mm)
T1.3.6 Pressure monitor 0 / 1 Pressure monitor available
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4.1.4 Submenu for the thread monitor configuration
No. Parameter name Symbol Range Description
T1.4.1 Repair mode A, B, C Selection of the repair mode to be
used.
T1.4.2 Needle thread monitor 0 … 10 Number of stitches not registered by
the thread breakage monitor before
an error message is displayed.
At the value 0 the thread breakage
monitor is switched off.
Description repair modes T1.4.1
Method A:
The buttonhole has to be unstitched and sewn again.
–After switching the automate on again the sewing basket lifts and
releases the material.
The automate is ready for a new sewing cycle.
Method B:
The buttonhole is completely stitched around anew.
–After switching the automate on again the sewing basket remains
lowered. The material under the sewing basket remains in its
position.
–Step the pedal forward (2nd step). The sewing cycle is started.
–After the sewing cycle the automate runs in reference position and
the sewing basket is lifted.
–The material can be taken out.
The automate is ready for a new sewing cycle.
Method C:
The buttonhole is continued to be sewn from the recognized point of
thread breakage.
–After switching the automate on again the sewing basket remains
lowered. The material under the sewing basket remains in its
position.
–Step the pedal forward (2nd step). The sewing basket moves to the
recognized point of thread breakage with the material.
–With the cursor keys ñand òyou can move - not sewing - to the
position to continue the sewing cycle.
–Step the pedal forward (2nd step). The sewing cycle is started.
–After the sewing cycle the automate runs in reference position and
the sewing basket is lifted.
–The material can be taken out.
The automate is ready for a new sewing cycle.
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4.1.5 Submenu for the configuration of condensed stitches
No. Parameter name Symbol Range Description
T1.5.1 Number of stitches 0 … 9 Enter the number of condensed
stitches
T1.5.2 Stitch length X 0,3 … 2,0 mm Enter the stitch distance of the
condensed stitches in direction X
T1.5.3 Stitch length Y 0,0 … 0,8 mm Enter the stitch distance of the
condensed stitches in direction Y
T1.5.4 Position last stitch -4 … 4 Enter the position of the last knotting
stitch according to fig. 1
Lip there Lip back
Fig. 1
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4.1.6 Submenu for entering machine times
No. Parameter name Symbol Range Description
T1.7.1 PedðStart 0 … 9000 ms Delay time between stepping down
the pedal position 2 and the sewing
motor start
T1.7.2 EndðCage 0 … 9000 ms Delay time between sewing end and
lifting of the cage
T1.7.3 CageðRef 0 … 9000 ms Delay time between lifting of the
cage and reference start
4.2 Submenu for the configuration of the operating elements
No. Parameter name Symbol Range Description
T2.1 Language - Select the submenu for the choice
of the menu language
T2.2 Set date/time - Select the submenu for setting date
and time
T2.3 Locking P on / off Switch the keyboard blocking for the
Pkey on or off. If the key blocking is
switched on, no buttonhole
programs can be established or
altered.
T2.4 Push-button on / off Select the push-button instead of
the foot pedal or in addition to the
foot pedal.
4.2.1 Submenu for selecting the menu language
You can choose among the following languages:
–German
–English (Default setting)
–Parameter display
(e.g.: T2.1 instead of Language,T2.3 instead of Locking P ,
T1.4.1 instead of Repair mode)
4.2.2 Submenu for setting date and time
No. Parameter name Symbol Range Description
T2.2.1 Minutes - 1 … 59 min Time:
Input of the minutes
T2.2.2 Hours - 1 … 23 h Time:
Input of the hours
T2.2.3 Day - 1 … 31 Date:
Input of the day
T2.2.4 Month - 1 … 12 Date:
Input of the month
T2.2.5 Year - 0 … 99 Date:
Input of the year
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4.3 Submenu for test functions
No. Parameter name Symbol Description
T3.1 Multitest Select the submenu Multitest
T3.2 Events Select the event display
T3.3 DAC III Select the submenu DAC III Parameter
T3.4 Data reset Submenu Reset
T3.5 Memo dongle Select the submenu Memo dongle
4.3.1 Submenu Multitest
No. Parameter name Symbol Description
T3.1.1 Outputs Select the submenu Output test
T3.1.2 Inputs Select the submenu Input test
T3.1.3 Auto input Select the submenu of the automatic input test
T3.1.4 Sewing motor Select the submenu Sewing motor test
T3.1.5 Step motor Select the submenu Step motor test
T3.1.6 RAM Select the submenu RAM test
T3.1.7 EPROM Select the submenu EPROM test
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4.3.1.1 Submenu Output test
–Select the output to be tested with the cursor keys ñand ò.
–Press the OK key. The selected output is switched on / off.
–The switching state of the output is indicated in the display.
Outputs Function
Y1 Control cylinder
- Main tension is opened
- Needle thread scissors is closed
- Bottom thread scissors is closed
- Sewing basket lifts
Y2 Scissors cylinder
Y3 Lip tension
Y4 Knife cylinder
Caution: Danger of injury!
Do not reach into the running machine when checking the output
elements.
4.3.1.2 Submenu Input test
–Select the input to be tested with the cursor keysñand ò.
–The switching state of the input and its alterations are indicated.
Inputs Function
S1 Push-button (optional)
S2 Pedal step 1+2 forwards
S4 Pedal step 2 forwards
S5 Push-button (optional)
S7 Needle thread monitor
S8 Pedal back
S17 Proximity switch X
S18 Proximity switch Y
S19 Proximity switch 180°-disc
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4.3.1.3 Submenu Automatic input test
The changes of the state of all inputs are displayed automatically.
4.3.1.4 Submenu Sewing motor test
–Press the OK key in order to start the sewing motor. The sewing
motor speed is displayed.
–With the cursor keys ñand òthe speed can be altered in steps of
100 r/min within the speed limits.
–Press the ESC key in order to stop the sewing motor.
4.3.1.5 Submenu Step motor test
No. Parameter name Symbol Range Description
T3.1.4.1 X-axis -50 … 50 With the cursor keys ïand ðthe
step motor is moved in the
corresponding direction by 5 ticks
each.
T3.1.4.2 Y-axis -50 … 50 With the cursor keys ñand òthe
step motor is moved in the
corresponding direction by 5 ticks
each.
–Press the ESC key in order to quit the menu item again.
The step motor is referenced anew.
4.4.1.6 Submenu RAM test
When selected the SRAM is tested for errors. The result is indicated in
the display.
4.4.1.7 Submenu EPROM test
When selected the EPROM is tested. The following values are
displayed:
–ROM size
–Machine class
–Software version
–Software date
–Check sum
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4.4.2 Submenu DAC III
No. Parameter name Symbol Description
T3.3.1 Date/Time Submenu for setting the time and
the date ðsee chapter 4.2 (T2.2) of
this instruction manual
T3.3.2 Temperature Display of the current temperature
inside the DAC III in °C
T3.3.3 Intermediate circuit
voltage
Display of the current intermediate
circuit voltage in V
4.4.3 Submenu Reset
No. Parameter name Symbol Description
T3.4.1 Buttonholes Selection ®Confirmation
Reset to default the buttonhole
geometry.
T3.4.2 Complete Selection ®Confirmation
Reset to default the buttonhole
geometry and the machine
parameters.
4.4.3 Submenu Memo dongle
The dongle can be inserted into the socket x110 (test interface) of the
control DAC III or pulled off again when the automate is running.
No. Parameter name Symbol Description
T3.5.1 Dongle content It is automatically recognized
whether a data or machine software
dongle has been plugged in. The
corresponding menu is displayed.
T3.5.2 Loading The submenu Loading is displayed.
Buttonhole, sequence or machine
data can be loaded from the dongle.
T3.5.3 Saving The submenu Saving is displayed.
Buttonhole, sequence or machine
data can be stored onto the dongle.
T3.5.4 Formatting Format the data dongle
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4.4.3.1 Dongle contents
Data dongle connected
If a data dongle is plugged in, all 50 buttonhole programs or all 16 free
contours respectively are displayed.
Buttonhole programs are named as follows:
Upper bartack type-Cutting length-Lower bartack type.
The corresponding bartack shape is shown in the display.
e.g.: A14.2A
(“A” means straight bartack and “14.2" the cutting length)
In case of free contours the name is given when programming the
contour on the PC.
–Press the ðkey in order to switch between buttonhole programs
and free contours.
Machine dongle connected
The following machine software data are displayed:
Class, subclass, version and date.
e.g.:
Class: 540
Subclass: 100
Version: A01
Date: 01/01/04
4.4.3.2 Submenu Loading
No. Parameter name Description
T3.5.2.1 Machine data After a confirmation all machine data are
loaded.
-
All global parameters (except:
Reference switch position x+y, cage length and
width, knife length, calibration values thread
tension)
- All buttonhole data
- All sequences
- Free contours (automatically the first two free
contours on the dongle.
Selection of the further 14 free contours
via menu item “Free contours” T3.5.2.4)
T3.5.2.2 All buttonhole data After a confirmation the following is loaded:
- All buttonhole data
- All sequences
Free contours are not loaded!
T3.5.2.3 Individual buttonholes The 50 buttonhole program locations of the
dongle are displayed.
- Select the buttonhole program to be loaded
with the cursor keys ñand ò. When selected
the buttonhole number can be given on the
machine(1to50).Pressthekey
-Pin order to copy the selected buttonhole
program to the machine.
Confirmation:
“Yes” - the buttonhole program is copied
“No” - back to the submenu Loading
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