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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