Duerkopp Adler | 650-16 | Operating instructions | Duerkopp Adler 650-16 Operating instructions

Duerkopp Adler 650-16 Operating instructions
DA_650-16_deen_05-2012.qxd:DA-6-pages.qxd
650-16
23.05.2012
10:05 Uhr
Seite 3
Operating IInstructions
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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 - 2014
Table of contents
1
About this operating instructions......................................................5
1.1
1.2
1.3
1.4
1.5
1.5.1
1.5.2
Scope ....................................................................................................5
For whom is this operating instructions intended? ................................5
Representation conventions – symbols and characters ........................6
Other documents ...................................................................................7
Liability...................................................................................................8
Transport ...............................................................................................8
Proper use .............................................................................................8
2
Technical Specifications...................................................................11
2.1
2.2
2.3
2.4
Characteristics.....................................................................................11
Declaration of conformity.....................................................................13
Additional equipment ...........................................................................13
Technical data .....................................................................................14
3
Safety instructions ............................................................................17
3.1
3.2
Basic safety instructions ......................................................................17
Signal words and symbols used in warnings.......................................19
4
Machine Description .........................................................................23
5
Operation............................................................................................25
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.8.1
5.9
5.10
5.11
Threading the needle...........................................................................25
Setting the needle thread tension........................................................26
Setting the thread regulator .................................................................27
Winding the hook thread......................................................................28
Replacing the hook thread bobbin.......................................................30
Setting the hook thread tension...........................................................32
Changing the needle ...........................................................................34
Raising the presser feet.......................................................................35
Functions of the optional additional pedal ...........................................36
Knee switch .........................................................................................36
Sewing.................................................................................................37
Customer Service ................................................................................38
6
Installation..........................................................................................39
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
Scope of delivery .................................................................................39
Removing the transport locks ..............................................................40
Assembling the frame..........................................................................41
Pre-assembling the table top...............................................................42
Attaching the table top and pedals to the frame ..................................43
Completing the table top......................................................................44
Setting the working height ...................................................................45
Inserting the machine upper part.........................................................46
Operating Instructions 650-16 - 01.0 - 06/2014
1
Table of contents
6.9
6.9.1
6.9.2
6.9.3
6.9.4
6.9.5
6.9.6
6.9.7
6.9.8
6.9.9
6.9.10
6.9.11
6.9.12
6.9.13
6.9.14
6.9.15
6.10
Electrical connection............................................................................47
Checking the mains voltage ................................................................47
Connecting the mains power supply....................................................48
Connecting the cables to the upper part..............................................49
Connecting the cables for the additional controller..............................50
Connecting the setpoint transducers to the controller .........................51
Connecting the equipotential bonding for the upper part.....................52
Connecting the equipotential bonding for the controller ......................53
Connecting the equipotential bonding for the additional controller......54
Connecting the equipotential bonding for the sewing head motor.......55
Connecting the equipotential bonding for the knee switch ..................56
Connecting the equipotential bonding for the setpoint transducers.....57
Connecting the knee switch.................................................................58
Connecting the control panel...............................................................59
Connecting the LED sewing light.........................................................60
Connect the additional sewing light (Waldmann) (optional) ................61
Sewing test ..........................................................................................61
7
Controller with the OP3000 control panel .......................................63
7.1
7.2
7.3
7.4
7.4.1
7.4.2
7.4.3
7.5
7.5.1
7.5.2
7.5.3
7.6
7.6.1
7.6.2
7.7
7.7.1
7.7.2
7.8
7.8.1
7.8.2
7.8.3
7.8.4
OP3000 control panel..........................................................................63
Switching the sewing machine on .......................................................64
Controller operating modes .................................................................65
Manual mode.......................................................................................66
Quick access function (softkey menu).................................................68
Menu for other settings........................................................................69
Sewing process ...................................................................................70
Automatic mode...................................................................................71
Before starting sewing Sewing process ...................................................................................73
Canceling the program ........................................................................74
Quick programming .............................................................................75
Creating a program by keyboard input ................................................77
Creating a program by sewing the seam.............................................78
Edit mode ............................................................................................79
Changing further parameters for the current step ...............................80
Changing further parameters for the selected program.......................81
Programming mode .............................................................................82
Creating a program..............................................................................82
Copying the program ...........................................................................84
Deleting a program ..............................................................................85
Mirroring the program ..........................................................................85
8
Controller with the OP7000 control panel .......................................87
8.1
8.2
OP7000 control panel..........................................................................87
Switching the sewing machine on .......................................................88
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Operating Instructions 650-16 - 01.0 - 06/2014
Table of contents
8.3
8.4
8.4.1
8.4.2
8.5
8.5.1
8.5.2
8.6
8.6.1
8.6.2
8.7
8.7.1
8.7.2
8.7.3
8.7.4
8.7.5
8.8
Controller operating modes .................................................................88
General operation................................................................................89
Inputting numeric values......................................................................89
Entering text ........................................................................................91
Manual mode MAN..............................................................................93
Parameters that can be set in MAN mode...........................................94
Sewing process ...................................................................................97
Automatic mode AUTO........................................................................98
AUTO parameters that can be set.......................................................99
Sewing process .................................................................................105
Programming mode ...........................................................................107
Editing existing programs (EDIT).......................................................108
Creating a new program (PROGRAMMING).....................................113
Copying the seam program ...............................................................121
Deleting the seam program ...............................................................121
Length correction (LENGTH CORRECTION)....................................122
Service mode SERVICE....................................................................123
9
Disposal............................................................................................125
10
Appendix ..........................................................................................127
Operating Instructions 650-16 - 01.0 - 06/2014
3
Table of contents
4
Operating Instructions 650-16 - 01.0 - 06/2014
About this operating instructions
1 About this operating instructions
This operating instructions for sewing machine 650-16 was compiled with the utmost care. It contains information and notes to
enable the machine to give many years of reliable service.
Please contact us if you find any discrepancies or have any
suggestions,  5.11 Customer Service, page 38.
Consider this operating instructions part of the product and keep
it on hand at all times. Be sure to read the manual completely
before using the product for the first time. If you pass the product
on to someone else, please be sure to give them the operating
instructions.
1.1 Scope
This operating instructions describes the set-up and intended use
of the 650-16 sewing machine.
1.2 For whom is this operating instructions
intended?
This operating instructions is intended for:
• Operators:
This group is familiar with the machine and has access to
the operating instructions. Specifically,  5 Operation,
page 25 is important for this group.
• Technicians:
This group has the appropriate technical training for performing maintenance on the sewing machine or repairing
malfunctions. Specifically,  6 Installation, page 39 is
intended for technical personnel.
A service manual will be provided separately.
With regard to minimum qualifications and other requirements to
be met by the personnel, please also observe  3 Safety instructions, page 17.
Operating Instructions 650-16 - 01.0 - 06/2014
5
About this operating instructions
1.3 Representation conventions – symbols and
characters
Various information in this operating instructions is represented
or highlighted by the following characters in order to facilitate easy
and quick understanding:
Correct setting
Indicates proper setting.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Steps to be performed when operating the machine
(sewing and setting up)
Steps to be performed for servicing, maintenance, and
installation
Steps to be performed via the software control panel
The individual steps are numbered:
1.
1. First step
2.
2. Second step
...
The sequence of the steps must always be followed.
•

Lists are identified by bullet points.
Result of performing an operation
Change to the machine or in the display.
Important
Special attention must be paid to this point when performing a step.
6
Operating Instructions 650-16 - 01.0 - 06/2014
About this operating instructions
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 the manual.
Safety Important warnings for the machine operator are specially designated. Since safety is of particular importance, hazard symbols,
levels of danger and their signal words are described separately
in  3 Safety instructions, page 17.
Orientation If the figure is unclear, indications of “right” and “left” are always
from the operator's point of view.
1.4 Other documents
This equipment includes components from other manufacturers.
Each manufacturer has performed a hazard assessment for these
purchased parts and confirmed their design compliance with applicable European and national regulations. The proper use of these
components is described in each manufacturer's manual.
Operating Instructions 650-16 - 01.0 - 06/2014
7
About this operating instructions
1.5 Liability
All information in this operating instructions was compiled with
consideration to the state of the art, and applicable standards and
regulations.
The manufacturer cannot be held liable for damages resulting
from:
• Breakage and transport damages
• Failure to observe operating instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
1.5.1
Transport
Dürkopp Adler cannot be held liable for breakage and transport
damages. Inspect the delivery immediately upon receiving it.
Report any damage to the last transport manager. This applies
even if the packaging is undamaged.
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 complains to Dürkopp Adler immediately after
receiving the product.
1.5.2
Proper use
The Dürkopp Adler 650-16 is intended for sewing light to moderately heavy material. Light to moderately heavy material requires
a needle strength of 70-120 Nm.
The machine is intended only for use with dry material. The
material must not contain any hard objects.
The stitching is produced using core spun threads, polyester
fibers, or cotton threads.
The sewing machine is intended for industrial use.
8
Operating Instructions 650-16 - 01.0 - 06/2014
About this operating instructions
The machine may only be set up and operated in dry conditions
on well-maintained premises. If the machine is operated on premises that are not dry and well-maintained, then further measures
may be required which must be compatible with EN 60204-31:
1999.
Only authorized/trained personnel may operate the machine.
The manufacturer cannot be held liable for damages resulting from
improper use.
WARNING
Risk of electric shock, crushing and pointed
objects!
Improper use can result in injury.
Please observe all instructions in the manual.
ATTENTION
Improper use can result in material damage.
Please observe all instructions in the manual.
Operating Instructions 650-16 - 01.0 - 06/2014
9
About this operating instructions
10
Operating Instructions 650-16 - 01.0 - 06/2014
Technical Specifications
2 Technical Specifications
The Dürkopp Adler 650-16 is a special sewing machine for programmed or manual sewing in of sleeves in ladies' and mens'
outerwear.
2.1 Characteristics
The sewing machine is equipped with an integral sewing head
drive, with a stepper motor which drives upper and lower belt
transport for gentle transport of the material, together with stepper
motor-driven curve support and an inclined base of improved
material handling.
The presser foot is powered by a stepper motor and the electromagnetically controlled needle thread tension permit programming of these parameters.
For the operation of the machine either the OP3000 control panel
or the OP7000 control panel must be selected.
The OP3000 control panel with graphical display permits easy
creation of programs and improved overview of the parameter
settings and the programmed seam.
The OP7000 control panel with touch screen displays the contour
to be sewn graphically and in color. In this mode the graduating
function is available. On the basis of a programmed size this
creates other sizes automatically and optimizes the programming
of further sizes by graduating the program. Programs can be saved
to a USB stick and transferred to other machines.
The optional, ergonomically shaped table top provides additional
assistance to working.
The further features are:
•
•
•
•
•
•
•
Single-needle integral column machine
Integral sewing head drive in the housing
Number of stitches max. 4000 rpm
Machine without lubrication
Integral LED sewing light
Oil-free horizontal hook
Stitch length from 1.0 to 5.5 mm adjustable and programmable
in 0.1 mm steps
• Presser foot pressure electronically controlled and programmable
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11
Technical Specifications
• Alternating belt upper transport (programmable), allowing
easy passage of the material past the needle. Maximum alternation height 2.5 mm (depending on the speed)
• Electronically regulated thread tension (programmable), for
different materials and for heavy gathering
• Patented curve support for easy material handling (programmable)
• Electromagnetic thread cutter
• Automatic bartack
• Raising the presser foot: 12 mm
• Built-in adjusting disc with positioning marks on the handwheel for quick checking of the machine setting.
• Edge stop stepping width from 7.5 mm
• OP3000 button bar with graphics display
• Within reach of the operator
• Gathering values between - 6 and 16, i.e. a maximum of
23 available gathering values.
• Graphics display allows easy creation of programs by
teaching, editing, copying and deletion
• Direct input of the gathering value by correction in automatic mode or in manual mode.
• OP7000 control panel
• 5.7” touch screen with 16-bit color depth
• USB connection type A (use only a USB stick with the part
number 9805 791113)
• the same scope of functionality as for OP3000
• the additional graduation function for automatic adaptation
of the program to different sizes
• graphical representation of the segments of the armhole
with concurrent progress display
• Optional second pedal
When the pedal is pushed forwards the fullness for a step is
increased by one gathering value; when it is pushed backwards it is decreased.
When the next step is called up the gathering value specified
in the program applies once again. Alternatively, depending
on the setting in the technician level the curve radius altered
in the same way.
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Operating Instructions 650-16 - 01.0 - 06/2014
Technical Specifications
2.2 Declaration of conformity
The machine complies with the European regulations specified in
the declaration of conformity or in the installation declaration.
2.3 Additional equipment
A flexible system of additional equipment allows the sewing
machine to be optimally equipped for any application at low cost.
 = Standard equipment
 = Optional enhancement
Order number
Additional equipment
650-16
0650 E00001
Equipment for normal material

0650 491054
OP3000 - button bar

0650 491074
OP7000 - control panel

9805 791113
USB stick (only for OP7000)

9822 510003
Halogen sewing light for machine upper part 
0798 500088
Transformer for sewing light

MG55 400504
Frame MG 55-3 and table top 1320x750

0650 400014
Additional pedal set for altering the fullness
and curve radius

MG55 007914
Rollers retrofit set

9880 650003
Attachment set for sewing light

0650 590014
Initial set of spare parts

Operating Instructions 650-16 - 01.0 - 06/2014
13
Technical Specifications
Order number
Additional equipment
650-16
0791 650400
Set of seam templates (for demonstration
purposes)

0650 E00002
Equipment for heavy material

2.4 Technical data
Noise levels
Workplace-specific emission value as per DIN EN ISO 10821:
LC = 79 dB (A) ± 0.83 dB(A) at
• Stitch length: 3.0 mm
• Number of stitches: 2900 rpm
• Material: 2-layer material G1 DIN 23328
Technical data
Stitch type
Double top-stitching 301
Hook type
Horizontal hook, oil-free
Number of needles
1
Needle system
134-35
Needle thickness [Nm]
70 – 120
Sewing thread thickness [Nm]
max. 50 / 3
Stitch length (programmable) [mm]
1.0 – 4.0
Number of stitches (programmable)
[stitches/min]
max. 4000
Bartack sewing (programmable)
14
650-16
Start bartack/ end bartack
Clearance under the raised presser foot
[mm]
max. 12
Sewed material thickness [mm]
max. 4
Operating Instructions 650-16 - 01.0 - 06/2014
Technical Specifications
Technical data
Table height (steplessly adjustable)
[mm]
650-16
780 – 900
Width, height, depth [mm]
(machine installed on the frame)
1320/1300/750
Weight [kg]
(machine installed on the frame)
115
Rated voltage [V/Hz]
Rated voltage on delivery [V/Hz]
Rated power [kVA]
Operating Instructions 650-16 - 01.0 - 06/2014
190 – 240V
50/60Hz
1 x 230V
50Hz
1.0
15
Technical Specifications
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Operating Instructions 650-16 - 01.0 - 06/2014
Safety instructions
3 Safety instructions
This section contains basic information for your safety. Read the
instructions carefully before setting up or operating the machine.
Make sure to follow the information included in this section. Failure
to do so can result in serious injury and damage to the machine.
3.1 Basic safety instructions
The machine may be used only as described in this operating
instructions.
The operating instructions should be available at the machine's
location at all times.
Work on live components and equipment is prohibited. Exceptions
are defined in the specifications in DIN VDE 0105.
For the following work, the machine must be disconnected from
the power supply using the main switch or by disconnecting the
power plug:
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing maintenance work and repairs
• Threading
Missing or faulty spare parts could impair safety and damage the
machine. Make sure you only use original replacement parts from
the manufacturer.
Transport Use a sturdy lifting carriage or forklift for transporting the machine.
Raise the machine max. 20 mm and secure it against slipping off.
Operating Instructions 650-16 - 01.0 - 06/2014
17
Safety instructions
Installation The power cable must have a plug authorized for the country in
which the machine is being used. The power plug may only be
connected to the power cable by a qualified specialist.
Obligations Observe the country specific safety and accident prevention regof the operator ulations and the legal regulations concerning industrial safety and
the protection of the environment.
All warnings and safety signs on the machine must always be in
legible condition and may not be removed. Missing or damaged
labels should be replaced immediately.
Requirements to The machine should only be set up by qualified technicians.
be met by the
personnel
Maintenance work and repairs should only be carried out by
qualified technicians.
Work on electrical equipment may only be carried out by qualified
specialists.
Only authorized persons may work on the machine. Every person
who works on the machine must first have understood the operating instructions.
Operation Inspect the machine while in use for any externally visible damage.
Stop working if you notice any changes to the machine. Report
any changes to your supervisor. A damaged machine should no
longer be used.
Safety Safety equipment should not be removed or deactivated. If this
equipment cannot be avoided for a repair operation, the safety equipment
must be refitted and put back into service immediately afterwards.
18
Operating Instructions 650-16 - 01.0 - 06/2014
Safety instructions
3.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color
scheme is oriented towards the severity of the danger. Signal
words indicate the degree of risk:
Signal words Signal words and the hazard that they describe:
Signal word
Hazard
DANGER
Will result in serious injury or death.
WARNING
Can result in serious injury or death.
CAUTION
Can result in minor or moderate injury.
ATTENTION
Can result in property damage.
Symbols The following symbols indicate the type of risk to personnel:
Symbol
Type of danger
General risk
Risk of electric shock
Risk of puncturing
Risk of crushing
Operating Instructions 650-16 - 01.0 - 06/2014
19
Safety instructions
Examples Examples of the layout of the warnings in the text:
DANGER
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
will result in serious injury or even death if ignored.
WARNING
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
could result in serious injury or even death if
ignored.
CAUTION
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
could result in moderate or minor injury if the warning is ignored.
ATTENTION
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that could
result in material damage if ignored.
20
Operating Instructions 650-16 - 01.0 - 06/2014
Safety instructions
CAUTION
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is a warning note for a hazard that could result
in environmental damage if ignored.
Operating Instructions 650-16 - 01.0 - 06/2014
21
Safety instructions
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Operating Instructions 650-16 - 01.0 - 06/2014
Machine Description
4 Machine Description
Figure 1: General view of the 650 sewing machine
཰
ི
(1) - Machine upper section
(2) - Thread reel holder
Operating Instructions 650-16 - 01.0 - 06/2014
ཱ
ཱི
(3) - Foot pedal
(4) - Main switch
23
Machine Description
24
Operating Instructions 650-16 - 01.0 - 06/2014
Operation
5 Operation
5.1 Threading the needle
WARNING
Risk of injury from the point of the needle and
moving parts
Turn off the sewing machine before threading the
thread.
Steps
1. Plug the thread reels on to the thread reel holders and feed
the needle and hook threads through the unwinding bracket.
Important: The unwinding bracket must be horizontal and
be positioned above the thread reels.
2. Thread the needle thread as shown in the following figure.
Figure 2: Threading the needle
Operating Instructions 650-16 - 01.0 - 06/2014
25
Operation
Threads with Figure 3: Threading the needle with threads of high elasticity
high elasticity
5.2 Setting the needle thread tension
Correct setting
The main tension (1) should be set as low as possible.
The thread interlacing should be exactly in the middle of the
material being sewn.
With thin sewn material, excessive thread tension can lead to
undesired gathering and thread breakages.
Figure 4: Interlacing
Correct thread interlacing in the
middle of the material being sewn
Needle thread tension too weak or
hook thread tension too strong
Needle thread tension too strong
or
hook thread tension too weak
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Operating Instructions 650-16 - 01.0 - 06/2014
Operation
Figure 5: Main tensioner
(1) - Main tensioner
1
Steps
1. Set the main tensioner (1) via the control panel so that a even
stitch pattern is achieved.
Opening When the thread is cut, the main tensioner (1) is opened automatautomatic ically.
5.3 Setting the thread regulator
WARNING
Risk of crushing by moving parts
Switch the sewing machine off before setting the
thread regulator.
The thread regulator regulates the amount of needle thread
required for forming the stitch. An optimum sewing result is possible only when the thread regulator is exactly adjusted.
Correct setting
With the correct setting the needle thread loop must slide over the
thickest part of the hook at low tension.
When the largest thread quantity is required then the thread
tension spring (3) must be pulled approx. 0.5 mm down from its
upper end position. This occurs when the needle thread loop
matches the maximum hook diameter.
Operating Instructions 650-16 - 01.0 - 06/2014
27
Operation
Figure 6: Setting the thread regulator
1
2
3
(1) - Screw
(2) - Thread regulator
(3) - Thread tensioning spring
Steps
1. Loosen the screw (1).
2. Change the setting of the thread regulator (2).
3. Tighten the screw (1).
5.4 Winding the hook thread
ATTENTION
Possible machine damage through moving the bobbin
without performing sewing
Moving the bobbin without performing sewing can cause damage to the presser foot and the bobbin case in the hook.
Activate bobbin mode if you wish to wind the hook thread without performing sewing.
28
Operating Instructions 650-16 - 01.0 - 06/2014
Operation
Figure 7: Winding the hook thread
1
2
3
(1) - Winder flap
(2) - Bobbin
(3) - Cutter
Steps
1. Fit the bobbin (2) on the bobbin shaft.
2. Thread the hook thread as shown in the following figure.
3. Wind the hook thread clockwise on to the bobbin core.
4. Swing the bobbin winder flap (1) against the bobbin.
5. Switch the main switch on.
6. Start sewing.
7. Once the bobbin is full, the winder switches off automatically
( Service manual section 16.1).
8. Pull off the bobbin, clamp the thread under the cutter (3) and
tear it off.
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29
Operation
5.5 Replacing the hook thread bobbin
WARNING
Risk of injury from moving parts
Switch off the sewing machine before replacing the
hook thread bobbin.
Figure 8: Replacing the hook thread bobbin
6
7
1
2
3
(1) - Bobbin housing flap
(2) - Hook cover
(3) - Bobbin
(4) - Slot
4
5
(5) - Tension spring
(6) - Hole
(7) - Bobbin housing upper section
Steps
Removing an empty bobbin
1. Push the hook cover (2) downwards.
2. Move the needle to the up position.
3. Lift the bobbin housing flap (1).
4. Remove the bobbin housing upper section (7) with the
bobbin (3).
5. Remove the empty bobbin (3) from the bobbin housing upper
section (7).
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Operating Instructions 650-16 - 01.0 - 06/2014
Operation
Inserting a full bobbin
1. Insert the full bobbin (3) into the bobbin housing upper
section (7).
2. Feed the hook thread through the slot (4) under the tensioning
spring (5) into the hole (6).
3. Pull the hook thread approx. 5 cm out of the bobbin
housing (7).
4. The bobbin must rotate in the direction of the arrow when pulling out the thread.
5. Insert the bobbin housing (7) again.
6. Push the hook cover (2) upwards.
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31
Operation
5.6 Setting the hook thread tension
WARNING
Risk of injury from moving parts
Switch off the sewing machine before replacing the
hook thread bobbin.
Correct setting
The hook thread tension must be set so that the resulting stitch
pattern looks like the figure in  5.2 Setting the needle thread
tension, page 26.
At the recommended hook thread tension of e.g. 25 g (measured
with a full bobbin), 12.5 g should be generated by the braking
spring and 12.5 g by the tensioning spring.
The basic setting for the tensioning spring is performed as follows:
When the bobbin housing contains a full bobbin it must sink slowly
under its own weight.
Figure 9: Bobbin housing sinking
The braking spring prevents the bobbin running on when the
thread has been cut.
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Operating Instructions 650-16 - 01.0 - 06/2014
Operation
Figure 10: Setting the hook thread tension
1
(1) - Braking spring
(2) - Tension spring
2
3
(3) - Regulating screw
Steps
1. Turn back the adjusting screw (3) so far that the tension on
the tensioning spring (2) is completely removed.
2. Bend the braking spring (1) such that half the recommended
hook thread tension value is applied through the braking
spring.
3. Insert the bobbin into the bobbin housing upper section and
thread in the hook thread  5.4 Winding the hook thread,
page 28.
4. Insert the bobbin housing together with the bobbin into the
hook.
5. Hold the free thread end tightly with one hand.
6. Turn the handwheel until the sewing machine performs one
stitch.
7. Pull the hook thread on to the upper side of the needle hole
using the needle thread.
8. Remove the hook thread in the direction of sewing at an angle
of 45°. About half the tension value should be evident.
9. Then tighten the adjusting screw (3) up to the recommended
tension value.
Operating Instructions 650-16 - 01.0 - 06/2014
33
Operation
5.7 Changing the needle
WARNING
Risk of injury from the point of the needle and
moving parts
Turn the sewing machine off before replacing the
needle.
Figure 11: Changing the needle
1
2
3
4
(1) - Needle bar
(2) - Screw
(3) - Groove
(4) - Hook tip
Steps
1. Loosen the screw (2) and remove the needle.
2. Insert the new needle into the hole in the needle bar (1) until
it reaches the end stop.
Important: The groove (3) must face towards the hook tip (4).
3. Tighten the screw (2).
Order
After changing to a different needle thickness, always adjust the
clearance between the hook and the needle
( Service manual section 6.1).
Malfunctions
An incorrect hook distance can cause the following malfunctions:
• Changing to a thinner needle: Missing stitches
Thread damage
• Changing to a thicker needle: Damage to the hook tip
Damage to the needle
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Operating Instructions 650-16 - 01.0 - 06/2014
Operation
5.8 Raising the presser feet
WARNING
Risk of crushing by the presser feet
Do not reach under the raised presser feet.
The presser feet (1) can be raised by an electric motor, by depressing the pedal (3).
Figure 12: Raising the presser feet
2
1
(1) - Presser feet
(2) - Additional pedal (optional)
2
3
(3) - Foot pedal
Steps
1. Push the pedal halfway backwards.
2. Raise the presser feet.
or
1. Push the pedal fully backwards.
2. Activate the thread cut-off and raise the presser feet.
Operating Instructions 650-16 - 01.0 - 06/2014
35
Operation
5.8.1
Functions of the optional additional pedal
The left pedal (2) has a dual function. Depending on the setting
of the technician level it either alters the fullness or the curve
support ( Service manual section 17.3.3).
• In automatic mode:
The value for fullness or curve support is corrected for the current step.
• In manual mode:
The value for fullness or curve support is selected.
Steps
1. Depress the additional pedal:
• Push the pedal forwards: Increase the value
• Push the pedal backwards: Decrease the value
5.9 Knee switch
The knee switch (1) is used to switch the seam programs from
one step to the next, both in automatic mode and also in programming mode.
Figure 13: Knee switch
1
(1) - Knee switch
Steps
1. Depress the knee switch.
 The next step is called up.
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Operating Instructions 650-16 - 01.0 - 06/2014
Operation
5.10 Sewing
Before starting sewing
Initial situation
• Pedal is in the rest position.
 Sewing machine is at a standstill.
 Needle is up. Presser foot is down.
Position material at the start of
the seam
• Push the pedal half backwards.
 The presser foot rises.
• Position the sewing material.
• Release the pedal.
 The presser foot descends on to the sewing
material.
At the start of the seam
Starting bartack and sewing
the seam
• Push the pedal forwards and keep it there.
 Starting bartack is sewn (if specified).
Then the machine sews along the seam at the
speed determined by the pedal.
In the middle of the seam
Stopping sewing
• Release the pedal (position 0).
 The machine stops in the 1st position (needle
down) or in the needle up position (depending on
the setting chosen).
The presser foot is down or raised
(depending on the setting chosen).
Continue sewing
(after releasing the pedal)
• Press the pedal forwards.
 The machine continues to sew at the specified
speed.
Intermediate raising
• Push the pedal half backwards.
 The presser feet are raised.
• Correct the material.
• Release the pedal.
 The presser feet are lowered.
Altering the fullness
• Press the fullness button or the left pedal.
 The selected fullness value is activated.
At the end of the seam
Operating Instructions 650-16 - 01.0 - 06/2014
37
Operation
Remove the material to be sewn • Push the pedal fully backwards and keep it there.
 The end bartack is sewn (if activated).
 The thread is cut off (if activated).
 The machine stops in the 2nd position.
 The needle is up. The presser feet are raised.
• Remove the sewn material.
• Release the pedal.
 The presser feet are lowered.
5.11 Customer Service
Contact for repairs if machine is damaged:
Dürkopp Adler AG
Potsdamer Str. 190
33719 Bielefeld, Germany
Tel. +49 (0) 180 5 383 756
Fax +49 (0) 521 925 2594
E-mail: service@duerkopp-adler.com
Internet: www.duerkopp-adler.com
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6 Installation
WARNING
Risk of injury
The machine may be installed only by trained
specialists.
Wear safety gloves and safety shoes when
unpacking and installing.
6.1 Scope of delivery
The scope of delivery depends on your specific order.
Check that all parts required are present before installing the
machine.
Figure 14: Scope of delivery
1
12
13
2
3
4
11
10
5
6
9
Operating Instructions 650-16 - 01.0 - 06/2014
8
7
39
Installation
This description applies to a special sewing machine whose individual components are all supplied by Dürkopp Adler:
• Upper part of the machine, including the LED sewing
light (2)
• Control panel (optional) (3)
Dürkopp Adler accessory pack with:
• Thread reel holders (1)
• Main switch (4)
• Transformer for the LED sewing light (5)
• Protective cover (not illustrated)
• Fastening material
• Knee switch (6)
Controller parts set, complete:
• DAC 3 controller (7)
• Additional controller (13)
Additional equipment:
• Support frame (10) with table (12), drawer (11),
rodding and pedal (8)
• Additional pedal and rodding (9)
6.2 Removing the transport locks
When you have installed the special sewing machine which you
bought, you must remove the following transport locks:
• Lashing straps and wooden blocks from the upper part of the
machine, the table and the support frame
• Restrain block and lashing straps from the sewing head
40
Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.3 Assembling the frame
Figure 15: Assembling the frame
6
7
8
4
5
3
(1) - Cross strut
(2) - Main pedal
(3) - Additional pedal
(4) - Setpoint transducer for the
additional pedal
2
1
(5) - Frame brace
(6) - Cable duct
(7) - Setpoint transducer for the main
pedal
(8) - Adjusting screw
Steps
1. Attach the pedal (2) to the cross brace (1).
2. Attach the additional pedal (3) (optional) to the cross brace (1).
3. Attach the cross brace (1) to the frame.
4. After the machine has been fully assembled, align the pedals,
 6.5 Attaching the table top and pedals to the frame,
page 43.
5. Screw the setpoint transducers (4) and (7) on to the frame
brace (5). Distance between the floor and the upper edge of
the frame brace (5): 290 mm.
6. Screw the cable duct (6) (30 x 30 x 250 mm) for the setpoint
transducer cables on to the frame brace (5).
7. Turn the adjusting screw (8) to ensure that the frame stands
securely. The frame must stand with all four feet on the floor.
Operating Instructions 650-16 - 01.0 - 06/2014
41
Installation
6.4 Pre-assembling the table top
Figure 16: Pre-assembling the table top
7
8
9
10
6
5
4
3
2
1
Steps
1. Use the table top (1).
2. Screw on the drawer (2) and its brackets
(chipboard screws 3.5 x 17).
3. Screw on the knee switch (3).
4. Screw on the sewing light transformer (4).
5. Screw on the main switch (5)
(chipboard screws 5 x 30).
6. Screw on the cable duct (6) (40 x 40 x 200 mm long)
(chipboard screws 3.5 x 17).
7. Screw on the strain relief (7)
(chipboard screws 3.5 x 17).
8. Screw on the additional controller (8)
(chipboard screws 5 x 30).
9. Screw on the DAC motor controller incl. protective plate (9)
(chipboard screws 5 x 30).
10. Screw on the cable duct (40 x 40 x 250 mm long) (10)
(chipboard screws 3.5 x 17).
11. Fit the electric cables,  6.9 Electrical connection, page 47.
Larger scale diagrams can be found at the end of the manual,
 10 Appendix, page 127.
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.5 Attaching the table top and pedals to the
frame
Figure 17: Attaching the table top and aligning the pedals
1
8
5
2
7
(1) - Thread reel
holder
(2) - Table top
(3) - Frame brace
(4) - Frame
6
4
(5) - Lever
(6) - Main pedal
(7) - Additional pedal
(8) - Screws
3
Steps
1. Using wood screws (6 x 30), attach the frame (4) to the table
top (2). Drill pilot holes for the wood screws.
2. Use the center marks to position the pilot holes.
3. Turn the frame (4) the right way up.
4. Align the pedals.
5. For ergonomic reasons, align the pedals laterally so that the
center of the main pedal (6) is directly beneath the needle.
The frame brace (3) is provided with slotted holes to allow
alignment of the pedal.
6. Loosen the screws (8).
7. Adjust the height of the pedal rodding so that in the home
position the pedal slope is about 10°.
The lever (5) on the setpoint transducer can be adjusted to suit.
8. Tighten the screws (8).
9. Insert the thread reel holder (1) into the hole in the table top,
and secure it with a nut and washer.
10. Fit and align the thread reel holders and unwinding bracket.
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43
Installation
Important: The unwinding bracket must be vertically above
the thread reel holders.
6.6 Completing the table top
Figure 18: Completing the table top
3
2
1
4
5
(1) - Rubber corners
(2) - Upper part support
(3) - Hinge mountings
(4) - Edge strips
(5) - Oblique fittings
Steps
1. Insert the oblique fittings (5).
2. Insert the rubber corners (1) into the table top.
3. Using 4.5 x 15 (4x) screws, screw on the hinge mountings (3).
4. Using 4.5 x 55 (8x) screws, screw the edge strips (4) to the
table top.
5. Insert the upper part support (2).
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.7 Setting the working height
The working height can be adjusted between 780 and 900 mm
(measured to the upper edge of the table plate).
Figure 19: Setting the working height
1
1
(1) - Screws
Steps
1. Slacken the screws (1) on the frame bars.
2. Set the table top to the desired working height.
3. To avoid jamming, slide the table top in or out evenly at both
sides.
4. Tighten the screws (1).
Operating Instructions 650-16 - 01.0 - 06/2014
45
Installation
6.8 Inserting the machine upper part
Figure 20: Inserting the machine upper part
1
2
(1) - Transport eye
(2) - Clamping plate
Steps
1. Using the transport eye (1), lift the machine upper part and
insert it into the cut-out on the table top.
2. After the upper part has been placed in position, immediately
connect the bracket (2) which prevents the upper part coming
loose if the table top is tipped.
The bracket is included in the accessories pack for the upper part.
If the machine is supplied ready assembled, the transport eye is
included in the accessories pack.
WARNING
Risk of injury due to the upper part tipping
When transporting the machine, secure the upper
part against tipping.
46
Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.9 Electrical connection
DANGER
Danger of life-threatening electric shock
The machine may be connected only by trained
electricians.
Disconnect the power plug before starting to work
on the electrical equipment.
Make sure the machine cannot be accidentally
switched back on.
6.9.1
Checking the mains voltage
The voltage on the type plate of the sewing drive must correspond
to the mains voltage.
DANGER
Danger of life-threatening electric shock
Make sure that the voltage listed on the type plate of
the sewing drive corresponds to the mains supply
voltage.
Operating Instructions 650-16 - 01.0 - 06/2014
47
Installation
6.9.2
Connecting the mains power supply
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before connecting the
mains power supply to the main switch.
Make sure the machine cannot be accidentally
switched back on.
Figure 21: Connecting the control cabinet, additional controller and LED
1
2
(1) - Switch knob
(2) - Screw
(3) - Bracket
3
4
5
(4) - Hole
(5) - Switch
transformer
Steps
1. Undo the screw (2) in the knob and take off the switch knob (1).
2. Remove the cover (3) from the main switch. Unlock this, using
a screwdriver to push the bar out of the hole (4).
3. Lay the cables for the control cabinet, the additional controller
and the LED transformer in cable duct.
4. Insert the cables into the main switch.
5. Connect the cable cores from the control cabinet to the screw
terminals “T1” and “T2” on the switch (5).
6. In addition, connect the additional controller to the screw
terminals “T1” and “T2”.
7. Connect the LED transformer leads to “L1” and “L2”
(in addition to the mains supply cable).
8. Connect the protective earth conductors of the control cabinet
and the additional controller to the main switch.
48
Operating Instructions 650-16 - 01.0 - 06/2014
Installation
9. Replace the cover (3) on the main switch.
10. Fit the switch knob (1) and screw it tight.
11. Place the cable duct cover on the cable duct.
6.9.3
Connecting the cables to the upper part
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before connecting the
cables to the upper part.
Make sure the machine cannot be accidentally
switched back on.
Figure 22: Connecting the cables to the upper part
1
2
3
(1) - Connections, side 1
(2) - Connections, side 2
(3) - Bridge plug 9850 001208
All cables are color coded.
Important: The bridge plug 9850 001208 (3) must be plugged
into the controller, otherwise the controller will not
work.
Operating Instructions 650-16 - 01.0 - 06/2014
49
Installation
Steps
1. Lay the cables to the control cabinet and bundle them together
with cable ties.
2. Plug the motor cables to the corresponding plugs on the connection side (2).
3. Plug the other cables to the corresponding plugs on the connection side (1).
4. Connect the LED light to the transformer,  6.9.14 Connecting the LED sewing light, page 60.
6.9.4
Connecting the cables for the additional
controller
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before connecting the
cables to the additional controller.
Make sure the machine cannot be accidentally
switched back on.
Figure 23: Connecting the cables for the additional controller
1
(1) - Cable
2
(2) - Underside of the casing
Steps
1. Connect the 15-pin plug to the correspondingly marked connector on the side of the control cabinet (2), as shown in
 6.9.3 Connecting the cables to the upper part, page 49.
2. Lay the cable (1) for the stepper motor in the underside of the
casing (2) and plug it into the connection plug.
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.9.5
Connecting the setpoint transducers to the
controller
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before connecting the
setpoint transducers to the controller.
Make sure the machine cannot be accidentally
switched back on.
Figure 24: Connecting the setpoint transducers to the controller
1
2
Steps
1. Connect the setpoint transducer for the main pedal to the
“Speed” plug (1) (X120b).
2. Connect the setpoint transducer for the additional pedal to the
“Fullness” plug (2) (X120t).
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51
Installation
6.9.6
Connecting the equipotential bonding for the
upper part
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before connecting the
equipotential bonding for the upper part.
Make sure the machine cannot be accidentally
switched back on.
The protective earth conductor (2) (350 mm long) is included in
the accessories pack for the machine. The protective earth conductor (2) dissipates static charges which build up on the upper
part of the machine to earth via the additional control cabinet.
Figure 25: Connecting the upper part equipotential bonding
1
2
3
(1) - Upper part attachment
(2) - Protective earth conductor
(3) - Tab connector
Steps
1. Screw the protective earth conductor (2) to the upper part (1),
lay it to the additional control cabinet and plug it on the flat
plug (3).
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.9.7
Connecting the equipotential bonding for the
controller
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before starting to
Connecting the equipotential bonding for the
controller.
Make sure the machine cannot be accidentally
switched back on.
Figure 26: Connecting the equipotential bonding for the controller
4
5
3
1
2
(1) - Attachment to control cabinet (4) - Protective earth conductor
(2) - Plug
(5) - Attachment to the frame
(3) - Protective earth conductor
Steps
1. Screw the protective earth conductor (3) of the plug (2) on to
the control cabinet (1).
2. Screw the protective earth conductor (4) (150 mm long) on to
the frame (5) using a toothed shakeproof washer.
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53
Installation
6.9.8
Connecting the equipotential bonding for the
additional controller
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before starting to
establish equipotential bonding to the additional
controller.
Make sure the machine cannot be accidentally
switched back on.
Figure 27: Connecting the equipotential bonding for the additional controller
1
2
3
(1) - Protective earth conductor
(2) - Tab connector
(3) - Attachment to control cabinet
Steps
1. Plug the protective earth conductor (1) into the flat plug (2) on
the additional control cabinet.
2. Lay the cable (2) (300 mm long) to the control cabinet (3) and
screw it on.
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.9.9
Connecting the equipotential bonding for the
sewing head motor
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before starting to
connect the equipotential bonding for the sewing
head motor.
Make sure the machine cannot be accidentally
switched back on.
Figure 28: Connecting the sewing head motor equipotential bonding
1
2
3
(1) - Earthing point on the control
cabinet
(2) - Protective earth conductor
(3) - Plug for the sewing head drive
The protective earth conductor (2) for the sewing head motor is
connected in the plug (3) for sewing head drive.
Steps
1. Screw the protective earth conductor (2) to the earthing point
on the control cabinet (1).
Operating Instructions 650-16 - 01.0 - 06/2014
55
Installation
6.9.10 Connecting the equipotential bonding for the
knee switch
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before starting to
connect the equipotential bonding for the knee
switch.
Make sure the machine cannot be accidentally
switched back on.
Figure 29: Connecting the equipotential bonding for the knee switch
1
3
2
(1) - Mounting clip
(2) - Cable duct
4
(3) - Protective earth conductor
(4) - Tab connector
Steps
1. Screw the protective earth conductor (3) (650 mm long) to the
attachment clip (1) on the knee switch.
2. Lay the cable in the cable duct (2) and plug the additional controller on to the flat plug (4).
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Installation
6.9.11 Connecting the equipotential bonding for the
setpoint transducers
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before starting to
connect the equipotential bonding for the setpoint
transducers.
Make sure the machine cannot be accidentally
switched back on.
Figure 30: Connecting the equipotential bonding for the setpoint transducers
1
6
2
3
4
(1) - Protective earth conductor
(2) - Setpoint transducer connection
(main pedal)
(3) - Cable duct
5
(4) - Protective earth conductor
(5) - Setpoint transducer connection
(additional pedal)
(6) - Attachment to control cabinet
Steps
1. Screw the protective earth conductor (4) (500 mm long) on to
the setpoint transducer (5) (optional).
2. Lay the cable (4) through the cable duct (3) to the setpoint
transducer (2) and screw it on (optional).
3. Screw the protective earth conductor (1) (650 mm long) on to
the setpoint transducer (2) and to the control cabinet (6).
Operating Instructions 650-16 - 01.0 - 06/2014
57
Installation
6.9.12 Connecting the knee switch
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before starting to
connect the knee switch.
Make sure the machine cannot be accidentally
switched back on.
Figure 31: Connecting the knee switch
1
(1) - Plug
(2) - Cable
2
3
2
(3) - Knee switch
Steps
1. Lay the cable (2) for the knee switch (3) through the cable duct
to the controller and connect it to the plug (1).
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.9.13 Connecting the control panel
DANGER
Danger of life-threatening electric shock
Disconnect the power plug before starting to
connect the control panel.
Make sure the machine cannot be accidentally
switched back on.
Figure 32: Connecting the control panel
3
1
2
(1) - Cable
(2) - Table top opening
4
(3) - Retainer
(4) - Control panel
Steps
1. Screw the control panel (4) on the bracket (3) and align it.
2. Plug the plug for the cable (1) on to the control panel, through
the opening in the table top (2) to the control cabinet, and connect it to the socket (X170 Panel).
Operating Instructions 650-16 - 01.0 - 06/2014
59
Installation
6.9.14 Connecting the LED sewing light
DANGER
Danger of life-threatening electric shock
The sewing light switch is connected directly to the
mains supply and is live even when the main switch
is switched off.
Disconnect the power plug without fail before connecting the sewing light.
Make sure the power plug cannot be accidentally
plugged back in.
Figure 33: Connecting the LED sewing light
3
2
1
(1) - Sewing light controller
(2) - Main switch
(3) - Plug
Steps
1. Fit the sewing light controller (1) next to the main switch (2),
 6.4 Pre-assembling the table top, page 42.
2. Connect the supply cable for the sewing light controller within
the main switch,  6.9.2 Connecting the mains power supply,
page 48.
3. Connect the plug (3) for the LED light to the black plug of the
sewing light controller output cable.
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Operating Instructions 650-16 - 01.0 - 06/2014
Installation
6.9.15 Connect the additional sewing light
(Waldmann) (optional)
See the installation manual 0791 100702. This manual is supplied
with the sewing light.
6.10 Sewing test
Perform a sewing test after completing the installation work.
WARNING
Risk of injury from pointed and moving parts
Switch off the sewing machine before threading the
needle thread or hook thread.
Steps
1. Insert the mains plug.
2. Wind on the hook thread,  page 28.
3. Switch the main switch on.
4. Activate winder mode.
5. Fill the bobbin at medium speed.
6. Switch off the main switch.
7. Thread the needle and hook threads,  page 25 and
 page 30.
8. Switch the main switch on.
9. Select the material to be sewn.
10. Perform a sewing test, first at low speed and then at continually
increasing speeds.
11. Check that the seams conform to the desired requirements.
12. If the requirements are not satisfied:
Alter the thread tension,  page 26 and  page 32.
If necessary, also check the settings listed in the service manual
and correct them as required.
Operating Instructions 650-16 - 01.0 - 06/2014
61
Installation
62
Operating Instructions 650-16 - 01.0 - 06/2014
Controller with the OP3000 control panel
7 Controller with the OP3000 control panel
7.1 OP3000 control panel
Figure 34: Control unit panel
A
B
All settings in the controller for the 650-16 are performed using
the OP3000 control panel.
Key
Function
0 to 16
Setting the fullness
Inputting the parameter value (if the field for the parameters
is activated)
Selection of a parameter that is shown in the display
• Press the key under the desired symbol.
 The function is selected.
ESC
Cancel the function
Exit the menu
OK
Confirm the settings
Activate the input
P
Function is different for each menu
S
Function is different for each menu
F
Function is different for each menu

Selection to the right

Selection to the left
Back one menu level

Increase the value
Scroll through the list (upwards)

Decrease the value
Scroll through the list (downwards)
Operating Instructions 650-16 - 01.0 - 06/2014
63
Controller with the OP3000 control panel
Key
Function
A
Upper softkey - 1
Assignment is different for each menu
B
Upper softkey - 2
Assignment is different for each menu
+/-
Switch between increase and decrease the fullness
7.2 Switching the sewing machine on
Figure 35: Display of the firmware and software version
1. Switch the main switch on.
 The software version appears on the display:
• On the left of the screen the control panel firmware
• On the right of the screen the controller software version
 The machine performs a reference run:
The display shows the program last used, or manual mode.
Figure 36: Display of the program last used
Figure 37: Display in manual mode
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Operating Instructions 650-16 - 01.0 - 06/2014
Controller with the OP3000 control panel
7.3 Controller operating modes
The 650-16 controller has 4 available
operating modes:
• Manual mode (program 000)
Manual mode is the simplest operating mode.
There are no sewing programs and no inputs
for individual sewing steps.
Changes to the fullness, stitch length, thread tension, curve
support and also the activation of other functions are always
implemented immediately.
Thus all the major sewing parameters can be changed manually during the sewing process.
• Automatic mode (program 001 - 999)
Automatic mode allows sewing programs to be executed.
The seams are divided into individual sections (steps) within
the sewing programs. Each step is assigned its own individual sewing parameters such as fullness, curve support etc.
• Quick programming
Quick programming allows very quick and simple creation of
new sewing programs.
• Programming mode
Programming mode allows new sewing programs to be created, edited, deleted, copied, and mirrored (left sleeve / right
sleeve).
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7.4 Manual mode
Figure 38: Parameters in manual mode
The following table shows the individual symbols (parameters) in
the display and the functions of the keys on the control panel.
When a parameter is selected, its color on the display changes.
When a parameter is changed, its new value is loaded immediately.
Symbol
Meaning
(depending on the assignment)
Quick programming
• Press the upper softkey
Quick access function (softkey menu)
• Press the lower softkey,  7.4.1 Quick access function (softkey menu), page 68.
Program number
Value range: 000 to 999
Program 000 indicates that the controller is in
“Manual mode”.
• Use / to select the “Program” parameter.
• Use / to change the program number.
Or:
• Input the program number directly using the keys
“0” to “9” and confirm with “OK” as required.
 This takes you into “Automatic mode”.
Fullness
Value range: Upper fullness: 0 to 16
Lower fullness: 0 to -6
• Use the keys “0” to “16” to select the desired value.
• Use the “+/-” key to select upper or lower fullness.
Or:
• Use the second pedal to select the fullness, if fitted.
Stitch length
Value range: 1.0 to 5.5 mm
• Use / to select the “Stitch length” parameter.
• Use / to change the stitch length
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Symbol
Meaning
Thread tension
Value range: 1 to 99
• Use / to select the “Thread tension” parameter.
• Use / to change the thread tension
Curve support
Value range: 0 to 6
• Use / to select the “Curve support” parameter.
• Use / to change the curve support
Other parameters
 7.4.2 Menu for other settings, page 69
Seam length in mm
After the thread has been cut off, the display is
retained. Measurement restarts when sewing starts
again.
P
Creating a program
 7.8.1 Creating a program, page 82
+/-
Switch between upper
and lower fullness
ESC, F and S No function assigned
0 – 16
Fullness values
OK
No function assigned
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7.4.1
Quick access function (softkey menu)
Here you have quick access to functions during the sewing
process and can also assign a function to the upper softkey.
1. Press the lower softkey
.
 The following information is shown on the display:
Figure 39: Softkey menu
2. Call up a function:
• Press the numeric key under the designed function.
or
Assigning a function to the upper softkey:
• Press the numeric key under the designed function and
at the same time press the upper softkey.
 The function is assigned to the upper softkey and can be
called up by pressing the key.
3. Press ESC to exit the menu.
Symbol
Meaning
Manual bartack
• Press the key “1” and keep it pressed for a manual
bartack.
Bartack suppression on/off
• Press the key “2”.
 The bartacks are switched on or off.
Needle position up / down
• Press the key “3”.
 If sewing is stopped within the seam, the needle is
positioned up or down.
Automatic step progression on/off
(available only in Automatic mode)
• Press the key “4”.
Automatic step progression is enabled/disabled
whilst sewing a seam.
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Symbol
Meaning
Quick programming
 Press the key “5”.
Quick programming starts.
Bobbin mode
• Press the key “6”.
• Push the pedal halfway backwards.
 Bobbin mode is ended.
7.4.2
Menu for other settings
1. Use / to select the “Other parameters”.
2. Press the “OK” key.
3. Use / to select the desired parameter.
4. Select the parameter using the “OK” key.
5. Change values using the / keys.
6. Click on the “OK” button to confirm.
7. Press or “ESC” to exit the menu.
Symbol
Meaning
Alternate (foot alternation)
Value range: 0.0 to 2.5 mm
Foot Press. (presser foot pressure)
Value range: 1 – 15
Start Tack (bartack at the start of a seam)
Value range: on/off
End Tack (bartack at the end of a seam)
Value range: on/off
Thread Trim (thread cutoff)
Value range: on/off
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7.4.3
Sewing process
Sewing without fullness
1. Input values for stitch length, thread tension, curve support
and foot alternation.
2. Push the pedal forwards and sew.
Sewing with fullness
1. Change the fullness with the left pedal (optional)
(if set at the technician level).
Or:
1. Alter the fullness using the “0” to “16” and “+/-” keys.
Altering parameters whilst within the seam
1. Move the pedal to the “0” position.
2. Change the desired parameter on the control panel.
3. Push the pedal forwards again and sew.
 The seam will be sewn using the altered parameter value.
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7.5 Automatic mode
Program numbers 001 to 999.
1. Use / to select the “Program” parameter.
2. Use / to select the program number “1” or another one if
available.
 The controller switches to automatic mode and the following
information appears in the display:
Figure 40: Display in Automatic mode
The following table shows the individual symbols in the display
and the functions of the keys on the control panel.
7.5.1
Symbol
Before starting sewing
Meaning
Quick programming (depending on the assignment)
• Press the upper softkey
Quick access function (softkey menu)
• Press the lower softkey
Program number
Value range: 000 to 999
• Use / to select the “Program” parameter.
• Use / to change the program number.
Or:
• Input the program number using the 0 - 9 keys
and confirm with “OK” as required.
If you select program 000, the controller selects
Manual mode
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Symbol
Meaning
Right sleeve / left sleeve
The machine can sew only right sleeves, only left
sleeves, or right and left sleeves alternately
• Use / to select a right sleeve or a left sleeve
(if programs exist for both).
Steps
Number of steps contained in the current program.
Stitch length
Value range: 1.0 to 5.5 mm
The stitch length can be altered before starting sewing.
The altered value applies throughout the entire sewing
program.
• Use / to select the “Stitch length” parameter.
• Use / to adjust the stitch length.
Thread tension
Value range: 1 to 99
The thread tension can be altered before starting
sewing.
The altered value applies throughout the entire sewing
program.
Use / to select the “Thread tension” parameter.
• Use / to change the thread tension
Other parameters
Foot Press. (presser foot pressure)
Fulln.Corr. (fullness correction)
• Use / to select the “Other parameters”
parameter.
• Press the “OK” key.
• Use / to select the fullness correction or the
presser foot pressure.
• Select the parameter using the “OK” key.
• Change values using /.
• Click on the “OK” button to confirm.
• Press or “ESC” to exit the menu.
Program bar
Length per step in mm,
or a dash (-) if no automatic step
progression
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Symbol
Meaning
P
Programming mode
Switches into programming mode.
ESC, F, S
No function assigned
1. Sew, press the knee switch or press the “OK” key.
 The program switches to the 1st step.
7.5.2
Sewing process
1. Push the pedal forwards and sew.
 The following information is shown on the display:
Figure 41: Display when sewing in Automatic mode
1
2
(1) - Program bar
(2) - Current step
The parameter values for the current step are shown in the display.
The program bar (1) shows the progress of the seam.
The number under the current step shows the outstanding length
of the step.
The program bar shows half the current step in bold.
Figure 42: Current step
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Completed steps are shown fully in bold.
Figure 43: Completed step
The following table lists the functions that can be performed in the
course of the seam.
Key/Pedal
Function
+/and
0 - 16
Temporary correction of the fullness value
(valid only for the current step)
2nd pedal
(optional)
Temporary correction of the fullness value or the
curve support (depending on the setting in the
technician level)
(valid only for the current step)
Knee switch
Next program step
/
Stop forward/back or to the start of the step
3
Switch the sleeve side (if programmed) in the
1st step at the start of the step
/
Correction of the thread tension
The value is saved.
ESC, P, F, S,
OK
No function assigned
Pedal halfway Raise the presser foot
back
Pedal fully
back
Cut off the thread
The program remains stopped at the cutoff point.
Lower softkey Softkey menu
 7.4 Manual mode, page 66
7.5.3
Canceling the program
1. Cut off (push the pedal fully back).
2. Press the “ESC” key.
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Or:
Push the pedal fully back
 The program is interrupted.
7.6 Quick programming
If
is assigned to the upper softkey:
1. Press the upper softkey
.
 The following display appears:
Figure 44: Quick programming
2. Continue with handling step 3.
If
is not assigned to the upper softkey:
1. Press the
key.
 The softkey menu appears.
Figure 45: Softkey menu
2. Press the key “5”.
3. Use / or the keypad keys 0 – 9 to select a program number.
4. Press the “OK” key.
 The following information is shown on the display,
the “P” in the program number field flashes:
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Figure 46: Quick programming display
The following table shows the individual symbols in the display
and the functions of the keys on the control panel.
Symbol
Meaning
Automatic step progression on/off
• Press the upper softkey
Activates / deactivates automatic step progression for
the current step.
Current program to be created
Current sleeve side to be created
(pre-set at the technician level)
Current step
• Use / to select the “Step” parameter.
• Use /to switch to the next/previous step.
• Press the “OK” key to edit other parameters for the
step,  7.7 Edit mode, page 79.
Fullness
Value range: -6 to 16
• Use the keys “0” to “16” to select the desired value.
Or:
• Use the second pedal to select the fullness, if fitted.
• Use the “+/-” key to select upper (+) or lower (-) fullness.
Stitch length for the current step
Value range: 1.0 to 5.5 mm
• Use / to select the “Stitch length” parameter.
• Use / to change the stitch length.
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Symbol
Meaning
Thread tension
Value range: 0 to 99
• Use / to select the “Thread tension” parameter.
• Use / to change the thread tension.
Curve support
Value range: 0 to 6
• Use / to select the “Curve support” parameter.
• Use / to change the curve support.
Length of the current step in mm
7.6.1
Creating a program by keyboard input
1. Set all the parameters for each step.
2. Step through to the next step using the knee switch.
Cancel with ESC
Before the “S” key is pressed, program creation can be canceled
at any time by pressing the “ESC” key.
Once all steps are complete:
3. Press the “S” key.
 The program is saved.
Depending on the settings at the technician level
• The sleeve side that was created is mirrored
• The sleeve side that was created is not mirrored
• The teach-in for the 2nd sleeve side is opened
• The selection screen for the action of creating the
2nd sleeve side is opened
 The machine switches to Automatic mode.
The program that was just created is selected.
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Figure 47: Displaying the newly created program
7.6.2
Creating a program by sewing the seam
1. Insert the material to be sewn.
2. Input the parameters for the 1st step (fullness, stitch length,
thread tension and curve support).
3. Sew the first step.
4. Operate the knee switch.
 The program switches to the next step.
Cancel with ESC
Before the “S” key is pressed, program creation can be canceled
at any time by pressing the “ESC” key.
If a section of seam has already been sewn the program will have
been saved and must if necessary be deleted,  7.8.3 Deleting
a program, page 85.
Once all steps are complete:
5. Press the “S” key.
 The program is saved.
The following display appears:
Figure 48: Display after creating a program by sewing the seam
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6. Sew the overlap.
7. Push the pedal fully back.
 The sleeve that was created is mirrored, depending on the
settings at the technician level.
The machine switches to Automatic mode.
The program that was just created is selected.
Figure 49: Displaying the newly created program
7.7 Edit mode
Edit mode allows existing programs to be edited or deleted.
Programming mode should be used to create new programs,
 7.8 Programming mode, page 82.
1. In Automatic mode, press the “P” key.
 The controller switches to Edit mode.
The program previously selected can now be edited.
The following information is shown on the display,
the “P” in the program number field flashes:
Figure 50: Display in Edit mode
1. Use / to select the program to be edited, the sleeve side
and the step; and use / to deselect them.
The step to be edited can also be selected using the knee
switch.
 The selected step is shown bold in the program bar.
2. Use / to select the parameter to the changed for the
respective step, and use / to change it.
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7.7.1
Changing further parameters for the current
step
1. Use /to select the field
.
2. Press the “OK” key.
 The submenu opens.
3. Use / to select the desired parameter.
4. Press the “OK” key to activate or deactivate the parameter,
or use / to change its value and press “OK” to confirm it.
Symbol
Meaning
Step. Len. (step length)
Auto Forward
(automatic step progression)
Alternate (sewing foot alternation)
Foot Press (presser foot pressure)
5. Exit the submenu using “ESC” or 
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7.7.2
Changing further parameters for the selected
program
This menu allows further parameters for the current sewing
program to be changed.
1. Use /to select the field
.
2. Press the “OK” key.
 The submenu opens.
3. Use / to select the desired parameter.
4. Press the “OK” key to activate or deactivate the parameter,
or use / to change its value and press “OK” to confirm it.
Symbol
Meaning
Thr. Tens (thread tension)
Stitchlen. (stitch length)
Foot Press. (presser foot pressure)
Fulln. Corr. (fullness correction)
Start Tack (bartack at the start of a seam)
End Tack (bartack at the end of a seam)
Thread Trim (thread cutoff)
5. Exit the submenu using “ESC” or 
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7.8 Programming mode
7.8.1
Creating a program
1. In Edit mode, press the
key.
 The softkey menu appears.
Figure 51: Softkey menu
2. Press the
key.
 The following display appears:
Figure 52: Select the program number
The controller displays the next free program number.
3. Press “OK” to load the program number.
Or:
Select another program number using / or input a program number using the keypad keys “0 - 9” and then press
“OK”.
 The program number is loaded.
The following display appears, with “P” flashing:
Figure 53: Display after specifying the program number
4. If necessary change the sleeve side or other parameters, 
7.7 Edit mode, page 79.
5. Press the
82
key.
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 The following display appears, with “P” flashing:
Figure 54: Inputting parameters when creating a new program
The rest of the procedure is as described in the section<reference>
Quick programming,  7.6 Quick programming, page 75.
6. Select whether progression to the individual steps to be programmed should be by using the knee switch or by automatic
progression.
7. Press the
key.
Once the creation of the program is complete and the “S” key has
been pressed or after the thread cutoff has been entered, the
following query window appears:
Figure 55: Query window after creation of a program
8. Select whether
• the sleeve side that was programmed should be mirrored
• the sleeve side that was programmed should not be mirrored
• the teach-in for the 2nd sleeve side should be opened.
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7.8.2
Copying the program
The selected program is copied into a new program number.
1. Press the
key.
 The softkey menu appears.
Figure 56: Softkey menu
2. Press the
key.
 The following display appears:
Figure 57: Copying the program
 The controller displays the next free program number.
3. Press “OK” to load the program number.
Or:
Select another program number using / or input a program number using the keypad keys “0 - 9” and then press
“OK”.
 The program number is loaded.
The following display appears, with the program number
flashing:
Figure 58: Display after specifying the program number
4. Load the desired changes into the new program.
5. Press the “ESC” key.
 The controller exits Programming mode and reverts to Automatic mode.
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7.8.3
Deleting a program
The selected program is deleted.
1. Press the
key.
 The softkey menu appears.
Figure 59: Softkey menu
2. Press the
key.
3. Press the “ESC” key.
 The controller exits Programming mode and reverts to
Automatic mode.
7.8.4
Mirroring the program
The sleeve side already programmed is mirrored over to the other
sleeve side.
1. Press the
key.
 The softkey menu appears.
Figure 60: Softkey menu
2. Press the
key.
3. Press the “ESC” key.
 The controller exits Programming mode and reverts to
Automatic mode.
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8 Controller with the OP7000 control panel
8.1 OP7000 control panel
All settings for the 650 sewing machine are performed using the
OP7000 control panel.
Figure 61: OP7000 control panel
The activation of the sewing motor and the stepper motors is
performed by the DAC3 controller in conjunction with the OP7000
control panel with the user interface in symbolic representation.
The program automation permits either manual or automatic control of fullness, optionally upper or lower, curve support and also
the programming of sewing steps with individual parameters.
Up to 999 sewing programs can be saved.
Each sewing program can contain up to 30 sewing steps.
Each sewing step can be assigned various parameters such as
stitch length, fullness values, curve support, thread tension,
segment length etc.
The seam programs are displayed continuously whilst sewing is
in progress. Programs can be mirrored for the other side of the
sewing material.
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8.2 Switching the sewing machine on
1. Switch the main switch on.
 The OP7000 control panel is switched on.
• The machine class is shown on the left of the display, the
firmware is shown on the right.
• The machine performs a reference run.
• The control panel starts in the mode that was active when
it was switched off - MAN or AUTO.
8.3 Controller operating modes
The controller has four operating modes available:
• Manual mode MAN
Manual mode is the simplest operating mode.
There are no sewing programs and no inputs for individual
sewing steps.
Changes to the fullness, stitch length, thread tension, curve
support and also the activation of other functions are implemented immediately.
Thus all the major sewing parameters can be changed manually during the sewing process.
• Automatic mode AUTO
Automatic mode allows sewing programs to be executed.
The seams are divided into individual sections within the sewing programs. Each step is assigned its own individual sewing parameters such as fullness etc.
• Programming mode
In Programming mode, new seam programs can be created
(PROGRAMMING), existing seam programs can be edited,
deleted, copied and mirrored (EDIT) and also optimized
(Length Correction).
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• Service mode SERVICE
Service mode contains functions for use during service work.
Service mode is password-protected, to avoid accidentally
changing the machine settings.
8.4 General operation
Operation is performed using the control panel. All functions and
inputs are triggered by touching the screen.
Numeric values for the individual parameters and text for the
program names can be input in the individual operating modes.
The inputs are performed using separate user interfaces.
8.4.1
Inputting numeric values
Figure 62: Inputting numeric values
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The user interface for inputting numeric values consists of the
following elements:
Header, consisting of:
• Symbol of the selected parameter
• Name of the parameter
• Value range of the parameter
• Symbol for exiting the user interface
Input line for the value
Keypad
Meaning of the buttons
Symbols/buttons
Meaning
Value input
Change of plus/minus sign
Input of a decimal point for values that
permit places of decimals
Changing the value incrementally up or
down
Delete the input value
Exit the user interface without inputting or
saving any values
Save the value that was input and exist the
user interface
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8.4.2
Entering text
Figure 63: Entering text
The user interface for inputting text consists of the following
elements:
Header, consisting of:
• Symbol for a new seam program
• Symbol for exiting the user interface
Input line for the text
Keypad
Meaning of the buttons
Symbols/buttons
Meaning
Input of numbers in the text
Input of text
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Symbols/buttons
Meaning
Input of a hyphen
Input of a underscore
Exit the user interface without inputting or
saving any text
Input of a space
Switching between upper case/lower case
Delete letters/digits from the input line
Save the value that was input and exist the
user interface
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8.5 Manual mode MAN
Figure 64: Manual mode MAN
཰
ཱ
ི
ཱི
Header (1)
Operating mode MAN is displayed.
Left pane (2)
Buttons for manually inputting the fullness and the curve support
are displayed here.
Middle pane (3)
The symbols for all the parameters that can be set are displayed
here. The gray fields above the parameter symbols show the
respective current values.
Right pane (4)
Another user interface or another operating mode can be selected
here.
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8.5.1
Parameters that can be set in MAN mode
The following table lists the parameters that can be set in MAN
programming mode.
Symbols
Meaning
Setting the fullness,  page 95
setting the curve support.
Other program parameters in manual mode MAN,
 page 96
Inputting the needle thread tension
Inputting the stitch length in mm
1. Press the desired button.
 The user interface for setting the parameter is displayed.
For some parameters the setting is more than just a numerical
value. These parameters are described below.
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MAN mode Setting the fullness
The following table lists the symbols and buttons for manually
setting the fullness.
Symbols/buttons
Meaning
Inputting the fullness
The fullness setting is displayed by
a button highlighted in red.
Select the type of fullness:
• Upper (upper transport)
• Lower (lower transport)
The fullness selected is displayed in an
activated control field.
Display of further buttons for inputting the
fullness. The buttons 0 to 16 are available
for input.
1. Select the type of fullness.
 The type of fullness selected is displayed in an activated
control field within the symbol.
2. If a higher or lower degree of fullness is required, use the arrow
keys to display more buttons.
3. Input the fullness using the buttons 0 to 16.
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Setting the curve support
The following table lists the symbols and buttons for manually
setting the curve support.
The default setting is a value of 2.
Symbols/buttons
Meaning
Inputting the curve support
The curve support is displayed by a button
highlighted in red.
1. Input the curve support using the buttons 1 to 6.
MAN mode Other program parameters
After the Other program parameters button has been pressed,
an overview of all the available parameters is displayed.
Figure 65: Other program parameters in MAN mode
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Parameters
Meaning
Needle Stop Position Up
When sewing stops the needle position is
up (activated) or down (not activated)
Foot Stroke Alternation
Presser foot alternation whilst the needle is
in the seam
Value range: 0 ... 2.5 mm
Foot Pressure
Presser foot pressure
Value range: 1 ... 10
Backtack at Start
Backtack at start of the seam on
(activated) or off (not activated)
Backtack at End
Backtack at end of the seam on (activated)
or off (not activated)
Thread Trim
Thread cutoff at end of the seam on
(activated) or off (not activated)
8.5.2
Sewing process
1. Set the fullness ( page 95).
2. Set the curve support.
3. Input the values for needle thread tension and stitch length.
4. Push the pedal forwards and sew.
 The length in mm sewn in the seam is displayed.
When the thread is cut off, the display is reset.
Changing parameters during the seam
1. Move the pedal to the 0 position.
2. Change the desired parameter on the control panel ( page
94).
3. Push the pedal forwards and sew.
 The seam will be sewn using the altered parameter value.
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8.6 Automatic mode AUTO
Figure 66: Automatic mode AUTO
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Header (1)
The AUTO operating mode is displayed. The buttons + F%
and - F% offer quick access for setting the fullness values in %.
Left pane (2)
The graphical representation of the entire seam, divided into the
number of programmed sewing steps, is displayed here. A red bar
with an arrowhead indicates the direction of sewing and progress
of the sewn seam.
Middle pane (3)
The number and the name of the selected seam program are
displayed here, together with the symbols for all the parameters
that can be set. The gray fields above the parameter symbols
show the respective current values.
Right pane (4)
Another user interface or another operating mode can be selected
here.
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8.6.1
AUTO parameters that can be set
The following table lists the parameters that can be edited in AUTO
programming mode.
Symbols
Meaning
Program selection,  page 100
Select the right or left piece to be sewn
Set the sewing material size,  page 101
Other program parameters in AUTO
automatic mode,  page 104
Temporarily setting the fullness value until
the next sewing step,  page 102
Applying a % correction to the fullness
values of all sewing steps,  page 103
Setting the needle thread tension.
If the value is changed in AUTO Automatic
mode it is permanently saved in the
program.
Setting the stitch length in mm.
If the value is changed in AUTO Automatic
mode it is permanently saved in the
program.
1. Press the desired button.
 The user interface for setting the desired parameter is displayed.
For some parameters the setting is more than just a numerical
value. These extended parameters are described in detail below.
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AUTO mode Program selection
Figure 67: Program selection parameter
1. Press on the desired seam program.
 The seam program selected is displayed in an activated control field within the line.
2. Press the OK button.
 The seam program selected is loaded in Automatic mode
AUTO.
3. Press the Abort button to cancel the selection of the program.
 If necessary the seam program selected is discarded and the
user interface for the Automatic mode AUTO is displayed.
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AUTO mode Setting the sewing material size
Figure 68: Setting the sewing material size parameter
The following information is displayed:
• The currently selected size is indicated by a double
arrow (>>).
• The sizes highlighted in red represent the reference sizes
for the graduation logic.
1. Press on the desired sewing material size.
 The user interface for the Automatic mode AUTO is displayed.
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AUTO mode Temporarily correcting the fullness value until the next
sewing step
Figure 69: Parameter for temporarily correcting the fullness value
Buttons for manually inputting the fullness are displayed in the left
pane.
Symbols/buttons
Meaning
Input the fullness
The fullness setting is displayed by a
button highlighted in red.
Select the type of fullness:
• Upper (upper transport)
• Lower (lower transport)
The fullness selected is displayed in an
activated control field.
Display of further buttons for inputting the
fullness. The buttons 0 to 16 are available
for input.
1. Select the type of fullness.
 The type of fullness selected is displayed in an activated
control field within the symbol.
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2. If a higher or lower degree of fullness is required, use the arrow
keys to display more buttons.
3. Input the fullness using the buttons 0 to 16.
The fullness value remains active until the next sewing step.
AUTO mode Correcting the fullness ratio
The fullness ratio can be set either by the buttons + F% and - F%
or the fullness correction parameter.
Figure 70: Fullness correction parameter in %
1. Input the correction value for the fullness in percent.
Information for inputting numeric values:  page 89.
2. Press the OK button.
 The correction value is saved and the previous user interface
is displayed.
If the correction value is changed in AUTO Automatic mode
it remains active until the controller changes to the next program.
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AUTO mode Other program parameters
After the Other program parameters button has been pressed,
an overview of all the available parameters is displayed.
Figure 71: Other program parameters in AUTO mode
104
Parameters
Meaning
Foot Pressure
Presser foot pressure
Value range: 1 ... 10
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8.6.2
Sewing process
1. Select the seam program,  page 100.
 The program number and name of the seam program are
displayed on the user interface. If no name has been saved
for the seam program, <No Name> is displayed.
2. Select the right or left piece to be sewn.
3. Select the size of the piece to be sewn,  page 101.
4. Push the pedal forwards and sew the seam.
 The sewing progress is displayed graphically in the left pane
as a red bar.
Figure 72: Sewn sewing steps and sewing step in progress
 The remaining sewing length per sewing step is displayed.
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Changing parameters during the seam
1. Move the pedal to the 0 position.
2. Change the desired parameter on the control panel.
3. Push the pedal forwards and sew.
 The seam will be sewn using the altered parameter value.
Correcting the fullness before or during the seam
1. Move the pedal to the 0 position.
2. Change the fullness correction using the buttons + F% or - F%.
3. Push the pedal forwards and sew.
 The changed fullness value is applied and displayed.
Cancel the seam program
1. Push the pedal fully back.
 The seam program is canceled.
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8.7 Programming mode
Figure 73: Programming mode
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Header (1)
The EDIT operating mode is displayed.
Left pane (2)
The graphical representation of the entire seam, divided into the
number of programmed sewing steps, is displayed here.
Middle pane (3)
Existing seam programs can be edited here  page 108. The
number and the name of the selected seam program are displayed, together with the symbols for all the parameters that can
be set. The gray fields above the parameter symbols show the
respective current values.
Right pane (4)
Here new seam programs can be created  page 113, existing
seam programs can be deleted  page 121, copied  page 121
and optimized  page 122 (Length Correction).
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8.7.1
Editing existing programs (EDIT)
The following table lists the parameters that can be edited in EDIT
programming mode.
Symbols
Meaning
Changing the program name
There is only one display in the EDIT
mode. A new program is automatically
assigned the next free program slot.
Select the right or left piece to be sewn
Set the sewing material size,  page 109
Other program parameters in EDIT
programming mode,  page 111
Set the fullness in the current sewing step,
 page 118
Set the curve support in the current sewing
step
Set the needle thread tension in the current
sewing step
Set the stitch length in mm in the current
sewing step
Switch the seam length measurement in
the current sewing step on or off
Other sewing step parameters in EDIT
programming mode,  page 112
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1. Press the desired button.
 The user interface for setting the desired parameter is displayed.
For some parameters the setting is more than just a numerical
value. These extended parameters are described in detail below.
EDIT mode Setting the sewing material size
Figure 74: Setting the sewing material size parameter
The following information is displayed:
• The currently selected size is indicated by a double
arrow (>>).
• The sizes highlighted in red represent the reference sizes
for the graduation logic.
1. Press on the desired sewing material size.
 The EDIT user interface of the programming mode is displayed.
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EDIT mode Correcting the fullness in the current sewing step
Figure 75: Correcting the fullness parameter
Buttons for manually inputting the fullness are displayed in the left
pane.
Symbols/buttons
Meaning
Input the fullness.
The fullness setting is displayed by a
button highlighted in red.
Select the type of fullness:
• Upper (upper transport)
• Lower (lower transport)
The fullness selected is displayed in an
activated control field.
Display of further buttons for inputting the
fullness. The buttons 0 to 16 are available
for input.
1. Select the type of fullness.
 The type of fullness selected is displayed in an activated
control field within the symbol.
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2. If a higher or lower degree of fullness is required, use the arrow
keys to display more buttons.
3. Input the fullness using the buttons 0 to 16.
EDIT mode Other program parameters
After the Other program parameters button has been pressed,
an overview of all the available parameters is displayed.
Figure 76: Other program parameters in EDIT programming mode
Parameters
Meaning
Backtack at Start
Backtack at start of the seam on/off
Value range: 0, 1
Backtack at End
Backtack at end of the seam on/off
Value range: 0, 1
Thread Trim
Thread cutoff on/off
Value range: 0, 1
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EDIT mode Other sewing step parameters
After the Other sewing step parameters button has been
pressed, an overview of all the available parameters is displayed.
Figure 77: Other sewing step parameters in the EDIT programming mode
112
Parameters
Meaning
Foot Stroke Alternation
Presser foot alternation whilst the needle is
in the seam.
Value range: 0 ... 2.5 mm
Foot Pressure
Presser foot pressure.
Value range: 1 ... 10
Maximum Speed
Sewing speed/rotational speed.
Value range: 100 ... 4000
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8.7.2
Creating a new program (PROGRAMMING)
Prerequisite:
• Operating mode EDIT is displayed.
1. Press the PNEW button.
 The PROGRAMMING user interface is displayed. Pressing
the P button displays the number of the next free program
slot.
Figure 78: Programming mode PROGRAMMING
2. Press <No Name> and input a name.
Information for inputting text:  page 91.
If no name is input for the seam program, <No Name>
continues to be displayed.
 The first sewing step is displayed with its number in the left
pane.
3. Input all the parameters for the first sewing step.
4. Sew the first sewing step, or manually input the length of the
sewing step using the seam length measurement parameter.
5. Select the next sewing step, either by pressing on the number
of the first sewing steps or by using the knee switch.
 The second sewing step is displayed with its number in the
left pane.
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Figure 79: Programming mode progress PROGRAMMING
6. Repeat step 2 until all the sewing steps have been programmed.
7. Press the END button or cut off the threads.
 There are three variants for the program response - depending on the user's input method:
Variant
Program display
The last programmed sewing step was sewn
but not cut off, then ended with END.
continue with step 8
The last programmed sewing step was sewn
and threads cut off.
continue with step 9
All sewing steps were input manually and
ended with END.
continue with step 9
8. If the threads were not cut off after sewing, a message appears.
Cut off the threads.
 The message is cleared.
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Figure 80: Selection after programming
9. Select whether the new seam program should be mirrored for
the other side of the sewing material (mirror programmed side
to other side), the other side of the sewing material should be
programmed (program other side) or the programming should
be ended (finish).
10. Select the desired function.
 The selected function is indicated by an activated control
field.
11. Press the OK button.
 The seam program is saved. Depending on which function is
selected, different buttons are displayed:
Function
Button
Mirror programmed side to other side
AUTO mode
Program other side
PROGRAMMING-mode
Finish
AUTO mode
 Pressing the Abort button closes the window, the AUTO
user interface is then displayed. All the data that were input
are deleted by this!
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Parameters that can be set
The following table describes the parameters that can be set in
programming mode PROGRAMMING.
Symbols
Meaning
Input the program name.
There is only one display in the
PROGRAMMING mode. A new program is
automatically assigned the next free
program slot.
Select the right or left piece to be sewn
Set the sewing material size,  page 117
Other program parameters in programming
mode PROGRAMMING,  page 119
Set the fullness in the current sewing step,
 page 118
Set the curve support in the current sewing
step
Set the needle thread tension in the current
sewing step
Set the stitch length in mm in the current
sewing step
Switch the seam length measurement in
the current sewing step on or off
Other sewing step parameters in
programming mode PROGRAMMING,
 page 120
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1. Press the desired button.
 The user interface for setting the desired parameter is displayed.
For some parameters the setting is more than just a numerical
value. These extended parameters are described in detail below.
Mode Setting the sewing material size
PROGRAMMING
Figure 81: Setting the sewing material size parameter
The following information is displayed:
• The currently selected size is indicated by a double
arrow (>>).
1. Select the size system in the right pane.
2. Press on the desired sewing material size.
 The PROGRAMMING user interface of the programming
mode is displayed.
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Mode Setting the fullness
PROGRAMMING
Figure 82: Fullness setting parameter
Buttons for manually inputting the fullness are displayed in the left
pane.
Symbols/buttons
Meaning
Input the fullness.
The fullness setting is displayed by a
button highlighted in red.
Select the type of fullness:
• Upper (upper transport)
• Lower (lower transport)
The fullness selected is displayed in an
activated control field.
Display of further buttons for inputting the
fullness. The buttons 0 to 16 are available
for input.
1. Select the type of fullness.
 The type of fullness selected is displayed in an activated
control field within the symbol.
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2. If a higher or lower degree of fullness is required, use the arrow
keys to display more buttons.
3. Input the fullness using the buttons 0 to 16.
Mode Other program parameters
PROGRAMMING
After the Other program parameters button has been pressed,
an overview of all the available parameters is displayed.
Figure 83: Other program parameters
Parameters
Meaning
Backtack at Start
Backtack at start of the seam on/off
Value range: 0, 1
Backtack at End
Backtack at end of the seam on/off
Value range: 0, 1
Thread Trim
Thread cutoff on/off
Value range: 0, 1
Grading Factor
Grading factor
Value range: 0.0 ... 6.0 (% per size)
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Mode Other sewing step parameters
PROGRAMMING
After the Other sewing step parameters button has been
pressed, an overview of all the available parameters is displayed.
Figure 84: Other sewing step parameters
120
Parameters
Meaning
Foot Stroke Alternation
Presser foot alternation whilst the needle is
in the seam
Value range: 0 ... 2.5 mm
Foot Pressure
Presser foot pressure
Value range: 1 ... 10
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Controller with the OP7000 control panel
8.7.3
Copying the seam program
Prerequisite:
• Operating mode EDIT is displayed.
1. Select the seam program,  page 100.
2. Press the PCOPY button.
 The seam program is copied and saved in the next free program slot. An appropriate message is displayed.
8.7.4
Deleting the seam program
Prerequisite:
• Operating mode EDIT is displayed.
1. Select the seam program,  page 100.
2. Press the PDEL button.
 A message is displayed asking whether you really wish to
delete the active seam program.
3. To delete the program, confirm by pressing the Yes button.
 The seam program is deleted. An appropriate message is
displayed.
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8.7.5
Length correction (LENGTH CORRECTION)
All the sewing steps are graded with the same factor.
In some sewing steps it is important for the quality of the result
that the grading is greater or less than this.
You can use the length correction to achieve these local adjustments.
Prerequisite:
• Operating mode EDIT is displayed.
1. Press the PLEN button.
 The length correction user interface is displayed.
Figure 85: Length correction interface
2. Sew the sewing step.
3. Switch to the next sewing step either manually at the control
panel or using the knee switch.
 The sewing progress is displayed graphically.
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Figure 86: Length correction progress
4. Do the same with all further sewing steps.
5. After the last sewing step press the END button.
 This closes the length correction, EDIT programming mode
then opens.
8.8 Service mode SERVICE
Service mode contains functions for use during service work.
Service mode is password-protected, to avoid accidentally changing the machine settings.
More information on the contents of Service mode can be found
in the  Service manual 650.
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Disposal
9 Disposal
Do not dispose of the machine in the general household waste.
The machine must be disposed of in an appropriate and proper
manner according to national regulations.
ATTENTION
Risk of environmental damage due to incorrect
disposal!
Improper disposal of the machine can result in
serious environmental damage.
ALWAYS observe the legally prescribed regulations for disposal of oil.
When disposing of the machine, be aware that it consists of a
range of different materials (steel, plastic, electronic components,
etc.). Observe the applicable national regulations for disposal.
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Disposal
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Appendix
10Appendix
Dimensions for manufacturing a table top
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Appendix
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Appendix
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Appendix
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Operating Instructions 650-16 - 01.0 - 06/2014
23.05.2012
DÜRKOPP ADLER AG
Potsdamer Straße 190
33719 Bielefeld
GERMANY
Phone +49 (0) 521 / 925-00
E-mail service@duerkopp-adler.com
www.duerkopp-adler.com
10:04 Uhr
Seite 2
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Original Instructions - 0791 650740 EN - 01.0 - 06/2014
DA_650-16_deen_05-2012.qxd:DA-6-pages.qxd
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