DURKOPP ADLER 550-867 Operating instructions

550-867
Service Instructions

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Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents,
including extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG 2017
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Service Instructions 550-867 - 00.0 - 12/2017 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 Working basis ...................................................................... 15
3.1 Following the order of the settings ......................................... 15
3.2 Laying the cables ................................................................... 16
3.3 Flats on shafts........................................................................ 16
3.4 Setting the handwheel into position ....................................... 17
3.5 Locking the machine in place................................................. 18
3.6 Tilting and erecting the machine head ................................... 20
3.7 Removing and assembling covers ......................................... 21
3.7.1 Removing and placing the arm cover .................................... 21
3.7.2 Removing and placing the head cover................................... 23
3.7.3 Removing and placing the rear cover .................................... 24
3.7.4 Removing and placing the cover on the side ......................... 25
3.8 Removing and placing the handwheel ................................... 26
3.9 Opening and closing the hook cover...................................... 27
3.10 Disassembling and assembling the throat plate .................... 29
3.11 Disassembling and assembling the feed dog ........................ 30
4 Setting the handwheel scale............................................... 33
5 Positioning the arm shaft.................................................... 35
6 Toothed belt wheels ............................................................ 36
6.1 Positioning the upper toothed belt wheel ............................... 37
6.2 Positioning the lower toothed belt wheel................................ 38
7 Setting the mechanical stitch adjustment ......................... 39
8 Setting the eccentric for the forward and backward
stitches ................................................................................. 41
9 Presetting the step motor ................................................... 42
10 Setting the feed dog ............................................................ 43
10.1 Setting the feed dog position ................................................. 43
10.1.1 Moving the feed dog .............................................................. 44
10.1.2 Moving the feed dog carrier ................................................... 45
10.2 Setting the feed dog movement............................................. 47
10.2.1 Setting the feed movement for the feed dog.......................... 48
10.2.2 Setting the stroke movement of the feed dog ........................ 49
10.2.3 Setting the height of the feed dog at top dead center ............ 51
10.2.4 Setting the compensating weight ........................................... 52
11 Setting transmission lever .................................................. 54

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2Service Instructions 550-867 - 00.0 - 12/2017
12 Needle bar linkage ............................................................... 57
12.1 Aligning the needle bar linkage sideways .............................. 57
12.2 Aligning the needle bar linkage in the sewing direction ......... 59
13 Hook, loop stroke and needle bar height .......................... 61
13.1 Setting the loop stroke position.............................................. 61
13.2 Setting the height of the needle bar ....................................... 63
13.3 Setting the needle guard........................................................ 66
13.4 Setting the distance between hook tip and needle ................ 68
14 Bobbin case lifter................................................................. 70
14.1 Setting the lifting gap ............................................................. 70
14.2 Setting the timing for lifting..................................................... 73
15 Sewing feet ........................................................................... 74
15.1 Setting the stroke of feeding foot and presser foot ................ 74
15.2 Setting the stroke movement for the feeding foot .................. 75
15.3 Setting the sewing foot pressure............................................ 77
16 Sewing foot lift ..................................................................... 78
16.1 Setting the sewing foot lift mechanically ................................ 78
16.2 Setting the height of the mechanically raised sewing feet ..... 80
16.3 Setting the height of the pneumatically raised sewing feet .... 82
17 Thread-guiding parts ........................................................... 84
17.1 Setting the needle thread regulator........................................ 84
17.2 Setting the needle thread tension spring ............................... 85
17.3 Repairing the tensioning plate ............................................... 87
17.4 Replacing the thread force sensor ......................................... 87
18 Short thread cutter............................................................... 90
18.1 Locking latch for the thread-pulling knife ............................... 91
18.2 Setting the thread-pulling knife .............................................. 92
18.3 Setting the counter blade....................................................... 96
18.4 Setting the cutoff position....................................................... 98
19 Electrostatic discharge (ESD)........................................... 100
20 Potentiometer in the machine arm ................................... 101
20.1 Basic setting without control panel V810/V820.................... 101
20.2 Basic setting with control panel V810 or V820..................... 103
21 Connections of the circuit board...................................... 105
22 Setting the friction clutch.................................................. 107
23 Programming...................................................................... 109
23.1 Structure of the software...................................................... 109
23.1.1 Security levels (0-2) ............................................................. 109
23.1.2 Start screen - preparing the machine for operation ............. 111
23.1.3 Main screen ......................................................................... 114
23.1.4 Register screen.................................................................... 116
23.1.5 Recurring elements.............................................................. 117
23.1.6 Input window ........................................................................ 118

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Service Instructions 550-867 - 00.0 - 12/2017 3
23.2 Logging into the system ....................................................... 118
23.2.1 Logging in with the hand scanner ........................................ 119
23.2.2 Logging in via software ........................................................ 120
23.2.3 Logging in using the fingerprint scanner .............................. 122
23.3 Managing users ................................................................... 123
23.3.1 Opening the user database.................................................. 124
23.3.2 Printing a copy of the access code ...................................... 124
23.3.3 Opening the fingerprint database......................................... 125
23.3.4 Storing a user photo............................................................. 125
23.3.5 Creating a new user............................................................. 127
23.3.6 Deleting users ...................................................................... 133
23.3.7 Deleting the fingerprint database ......................................... 134
23.4 Seam record sets................................................................. 135
23.4.1 Opening the Seam record sets display.......................... 136
23.4.2 Creating a new seam record set .......................................... 137
23.4.3 Editing a seam record set (Edit seam parameter
record)............................................................................... 139
23.4.4 Copying a seam record set.................................................. 154
23.4.5 Deleting a seam record set .................................................. 155
23.4.6 Changing the thread (Change thread in seam
records)............................................................................. 157
23.4.7 Exporting a seam record set ................................................ 158
23.4.8 Importing a seam record set ................................................ 159
23.5 Database.............................................................................. 159
23.5.1 Opening the Database display........................................... 159
23.5.2 Opening the protocol database............................................ 160
23.5.3 Printing a protocol file .......................................................... 161
23.5.4 Copying a protocol file (Copy) ............................................. 161
23.5.5 Error codes (Help) .............................................................. 162
23.5.6 Printing a copy of an end label (Lab. Copy)...................... 162
23.5.7 Thread tension (Thr. tens.) ............................................ 163
23.6 Check................................................................................... 164
23.6.1 Structure of the Checks display ........................................... 164
23.6.2 Opening the Checks display ............................................... 166
23.6.3 Creating a system backup (Backup system) .................... 166
23.6.4 Restoring data (Restore system) .................................... 168
23.6.5 Creating a backup of the protocol database
(Backup protoc. DB)...................................................... 169
23.6.6 Printing a barcode label (Print BC label)...................... 169
23.6.7 Data transfer ........................................................................ 170
23.6.8 Copying Dump Files............................................................. 170
23.6.9 Displaying connections ........................................................ 171
23.6.10 Reducing the data volume of the protocol database
(Reduce protoc. DB)...................................................... 171
23.6.11 Setup.................................................................................... 172
23.6.12 Opening the thread database (Threads)............................ 181
23.6.13 Printing the protocol database (DB print)......................... 181
23.6.14 Opening the seam database (Show DB) ............................. 182
23.6.15 Opening the bobbin database (Bobbins) ........................... 182
23.6.16 Needle database (Needle DB) ........................................... 183
23.6.17 Calibrating the step motor (SM-Cali) ................................. 185
23.6.18 Opening the calibration database (T.Tens.-Cali)........... 186

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4Service Instructions 550-867 - 00.0 - 12/2017
23.6.19 Calibrating the stitch length (SM).......................................... 187
23.6.20 Checking input and output (I/O) ......................................... 189
23.6.21 Checking the scanners (Scanner)...................................... 190
23.6.22 Checking the sewing motor (Sew. Motor)......................... 191
23.6.23 Thread tension (Thread tens.)........................................ 192
23.6.24 Uninterrupted power supply (UPS) ....................................... 194
23.7 Protocol printer..................................................................... 195
23.8 Uninstalling the barcode printer drivers ............................... 195
23.9 Calibrating the end label printer ........................................... 198
23.10 Barcodes.............................................................................. 198
23.10.1 Barcodes at a glance ........................................................... 198
23.10.2 Opening the Barcodes display ............................................. 199
23.10.3 Changing the barcode type.................................................. 201
23.10.4 Defining a barcode............................................................... 202
23.10.5 Saving a barcode profile ...................................................... 203
23.10.6 Loading a barcode profile .................................................... 204
23.11 Setting batch mode.............................................................. 205
23.12 Setting multi barcodes ......................................................... 205
23.13 Preparing the end label (Label).......................................... 206
23.13.1 Opening the End label display ............................................. 207
23.13.2 Defining the end label text ................................................... 207
23.13.3 Positioning the text on the end label .................................... 208
23.13.4 Defining the format of the end label ..................................... 208
23.13.5 Positioning the end label barcode........................................ 209
23.13.6 Defining the font size ........................................................... 210
23.13.7 Defining an end label barcode type ..................................... 210
23.13.8 Defining the content of the end label barcode ..................... 211
23.13.9 Saving an end label ............................................................. 213
23.13.10 Loading an end label............................................................ 213
23.13.11 Defining extended label printing........................................... 214
23.14 Deleting a bobbin ................................................................. 216
23.15 Storage locations and automatic backups (Path+netw.)..218
23.15.1 Changing the storage location ............................................. 218
23.15.2 Setting an automatic backup of the protocol database ........ 219
23.16 Thread database.................................................................. 220
23.16.1 Creating a new thread.......................................................... 221
23.16.2 Changing a thread ............................................................... 222
23.16.3 Deleting a thread.................................................................. 223
23.17 Creating a teach-in file ......................................................... 223
23.18 Restarting the program (Reset) .......................................... 227
23.19 Exiting the program.............................................................. 228
23.20 Logging out of the system.................................................... 229
23.21 Additional program Label Creator ................................. 230
23.21.1 Preparing the end label (example)....................................... 231
23.21.2 Default settings .................................................................... 232
23.21.3 Adjusting the end label size ................................................. 233
23.21.4 Opening theToolbox ......................................................... 234
23.21.5 Inserting contents................................................................. 235
23.21.6 Moving contents................................................................... 236
23.21.7 Creating a barcode .............................................................. 237
23.21.8 Adding an additional barcode .............................................. 239
23.21.9 Creating standard text.......................................................... 239

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Service Instructions 550-867 - 00.0 - 12/2017 5
23.21.10 Creating variable text ........................................................... 240
23.21.11 Inserting a graphic ............................................................... 241
23.21.12 Saving a label script file ....................................................... 242
23.21.13 Printing a test end label ....................................................... 243
23.22 Additional program SABSearch ......................................... 243
23.22.1 Performing a search (example)............................................ 244
23.22.2 Exiting SABSearch ............................................................. 247
24 Maintenance ....................................................................... 249
24.1 Cleaning............................................................................... 250
24.2 Lubricating ........................................................................... 252
24.2.1 Checking the lubrication of the machine head ..................... 252
24.2.2 Checking the hook lubrication.............................................. 254
24.3 Servicing the pneumatic system .......................................... 256
24.3.1 Setting the operating pressure............................................. 256
24.3.2 Draining the water condensation ......................................... 257
24.3.3 Cleaning the filter element ................................................... 258
24.4 Parts list ............................................................................... 259
25 Decommissioning .............................................................. 261
25.1 Transporting the machine .................................................... 262
26 Disposal .............................................................................. 263
27 Troubleshooting................................................................. 265
27.1 Customer Service ................................................................ 265
27.2 Messages of the software .................................................... 265
27.2.1 Information messages.......................................................... 266
27.2.2 Error messages.................................................................... 266
27.2.3 Editing error messages ........................................................ 268
27.3 Errors in sewing process...................................................... 270
28 Technical data .................................................................... 271
28.1 Characteristics ..................................................................... 273
28.2 Technical features of the software ....................................... 274
28.3 Data recording ..................................................................... 275
29 Appendix............................................................................. 277

Table of Contents
6Service Instructions 550-867 - 00.0 - 12/2017

About these instructions
Service Instructions 550-867 - 00.0 - 12/2017 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. 265).
Consider the instructions part of the product and store them in a place
where they are readily available.
1.1 For whom are these instructions intended?
These instructions are intended for specialists. This group has the
appropriate technical training for performing maintenance or repairing
malfunctions.
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 setting.
Cover
Specifies which covers must be disassembled in order to access the com-
ponents to be set.
Steps to be performed when operating the machine (sewing and
equipping)
Steps to be performed for service, maintenance, and installation
Steps to be performed via the software control panel
The individual steps are numbered:
First step
Second step
The steps must always be followed in the specified order.
1.
2.
…

About these instructions
8Service Instructions 550-867 - 00.0 - 12/2017
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 a setting.
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.
•


About these instructions
Service Instructions 550-867 - 00.0 - 12/2017 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 damage during transport
• Failure to observe these instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved parts
Transport
Dürkopp Adler cannot be held liable for breakage and transport damages.
Check 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 Service Instructions 550-867 - 00.0 - 12/2017

Safety
Service Instructions 550-867 - 00.0 - 12/2017 11
2 Safety
This chapter contains basic information for your safety. Read the instruc-
tions carefully before setting up or operating the machine. Make sure to
follow the information included 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
disconnect 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 forklift 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:
• Setting up the machine
• Performing maintenance work and repairs
• Performing work on electrical equipment
Only authorized persons may work on the machine and must first have
understood these instructions.

Safety
12 Service Instructions 550-867 - 00.0 - 12/2017
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 removed or deactivated. If it is essential
to remove or deactivate safety equipment for a repair operation, it must be
assembled and put back into operation immediately afterward.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color scheme is
based on the severity of the danger. Signal words indicate the severity of
the danger.
Signal words Signal words and the hazard they describe:
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
Service Instructions 550-867 - 00.0 - 12/2017 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 Service Instructions 550-867 - 00.0 - 12/2017
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.

Working basis
Service Instructions 550-867 - 00.0 - 12/2017 15
3 Working basis
3.1 Following the order of the settings
Order
The setting positions for the machine are interdependent.
Always comply with the order of individual setting steps as specified.
It is absolutely essential that you follow all notices regarding prerequisites
and subsequent settings that are marked with in the margin.
Information
Some shafts of the machine have flat surfaces ( p. 16). These surfaces
makes it easier to set up the machine.
For all settings on the surface, the first screw in the direction of rotation is
screwed onto the surface.
WARNING
Risk of injury!
If setting operations on stitch-forming parts are not
performed with faultless needles, the machine may
produce faulty tearing seams. Faulty tearing seams
can cause serious injuries, including death.
Insert a new, faultless needle before all setting
operations on stitch-forming parts.
NOTICE
Property damage may occur!
Possible damage to the machine from using faulty needles for
setting operations on stitch-forming parts.
Insert a new, faultless needle before all setting operations on stitch-
forming parts.
NOTICE
Property damage may occur!
Risk of machine damage from incorrect order.
It is essential to follow the working order specified in these
instructions.

Working basis
16 Service Instructions 550-867 - 00.0 - 12/2017
3.2 Laying the cables
Ensure that all cables are laid in the machine such that the function of
moving parts is not hampered.
To lay the cables:
1. Lay any excess cabling neatly in proper cable snakes.
2. Bind together the cable loops with cable ties.
Important
Tie loops wherever possible to fixed parts.
The cables must be secured firmly.
3. Cut off any overlapping cable ties.
3.3 Flats on shafts
Fig. 1: Flats on shafts
Some shafts (2) have flat surfaces (1) at the points where the components
are screwed on. This stabilizes the connection and makes setting easier.
Important
Ensure that the screws are completely flush with the surface.
NOTICE
Property damage may occur!
Excess cables can impair the functioning of moving machine parts.
This impairs the sewing function and can result in damage.
Lay excess cable as described in these instructions.
(1) - Flat (2) - Shaft
①
②

Working basis
Service Instructions 550-867 - 00.0 - 12/2017 17
3.4 Setting the handwheel into position
Fig. 2: Setting the handwheel into position
Some settings require that the handwheel be moved to a certain position.
To set the handwheel to the desired position:
1. Turn the handwheel (2) until the desired degree number is parallel to
the marking (1).
(1) - Marking (2) - Handwheel
①
②

Working basis
18 Service Instructions 550-867 - 00.0 - 12/2017
3.5 Locking the machine in place
Fig. 3: Locking the machine in place (1)
For some settings, the machine must be locked in place. To do this,
the locking peg (4) is inserted into an arresting groove on the arm shaft
crank (1), blocking the arm shaft.
There are 2 securing positions:
•Position I: Loop stroke position
• 5 mm end in the large arresting groove (2)
• Setting the loop stroke and needle bar height
•Position II: Handwheel zero position
• 3 mm end in the small arresting groove (3)
• Setting the handwheel position and checking the top dead center
for the needle bar
(1) - Arm shaft crank
(2) - Large arresting groove (3) - Small arresting groove (4) - Locking peg
③
②
①
④