Page 1 550-D800 Operating Instructions...
Page 2 IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE All rights reserved. Property of Dürkopp Adler GmbH and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the prior written approval of Dürkopp Adler GmbH. Copyright © Dürkopp Adler GmbH 2023...
Page 3: Table Of Contents
4.13.5 Needle cooling from below ............53 4.13.6 Operation lock ................53 4.14 Sewing ..................54 4.14.1 Pressing the pedal ..............56 4.14.2 Sewing in the end label .............. 58 4.15 Disruption of the power supply ........... 61 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 4 5.6.6 Printing a barcode label (Print BC label) ......129 5.6.7 Data transfer ................129 5.6.8 Copying dump files ..............129 5.6.9 Reducing the volume of the protocol database (Reduce protoc. DB)............130 5.6.10 DACFleXCommander ............... 130 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 5 5.21 Additional program Label Creator ........189 5.21.1 Preparing the end label (example) ........... 190 5.21.2 Default settings ................. 192 5.21.3 Adjusting the end label size ............192 5.21.4 Opening the Toolbox............. 194 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 6 10.2.2 Error messages ................ 234 10.2.3 Editing error messages............. 255 10.3 Errors in sewing process ............257 Technical data................. 259 11.1 Data and characteristic values ..........259 11.2 Requirements for fault-free operation ........259 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 7 Table of Contents Appendix ................. 261 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 8 Table of Contents Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 9: About These Instructions
Proper setting Specifies proper setting. Disturbances Specifies the disturbances that can occur from an incorrect adjustment. Cover Specifies which covers must be disassembled in order to access the com- ponents to be set. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 10 Safety ( p. 11). If no other clear location information is used in a figure, indications of right Location information or left are always from the user's point of view. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 11: Other Documents
Leave machines, equipment and packaging material in the condition in which they were found when the damage was discovered. This will ensure any claims against the transport company. Report all other complaints to Dürkopp Adler immediately after receiving the product. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 12 About these instructions Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 13: Safety
• Setting up the machine/putting the machine into operation • Performing maintenance work and repairs • Performing work on electrical equipment Only authorized persons may work on the machine and must first have un- derstood these instructions. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 14: Signal Words And Symbols Used In Warnings
If ignored, environmental damage can result NOTICE (without hazard symbol) If ignored, property damage can result The following symbols indicate the type of danger to personnel: Symbols Symbol Type of danger General Electric shock Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 15 Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 16 NOTICE Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in property damage if ignored. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 17: Machine Description
Improper use can result in electric shock, crushing, cutting and punctures. Follow all instructions provided. NOTICE Non-observance will lead to property damage! Improper use can result in material damage at the machine. Follow all instructions provided. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 18: Declaration Of Conformity
Dürkopp Adler cannot be held liable for damages resulting from improper use. 3.3 Declaration of Conformity The machine complies with European regulations ensuring health, safety, and environmental protection as specified in the declaration of conformity or in the declaration of incorporation. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 19: Operation
Do not sew unless the machine is fully assembled and includes all safety devices. Information When switching on the machine for the first time, proceed as described in the Setup chapter ( p. 221). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 20: Scanning Barcodes
• Barcode of the needle thread reel ( p. 51) • Barcode of the hook thread reel ( p. 51) • Barcode of the bobbin These three barcodes are requested / scanned automatically as soon as the machine is switched on. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 21 Information If barcode scanners have been assembled for the needle thread and the hook thread, the barcodes will be scanned automatically.  The display switches to: Fig. 4: Scanning barcodes (2) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 22 7. Do not slide the hook cover (2) any further than up to the proximity switch (4).  The barcode on the bobbin / the bobbin number is visible. Fig. 6: Scanning barcodes (4) ⑤ ④ (4) - Proximity switch (5) - Bobbin Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 23 Sewing will not be released until the system could be booted and the scan- ning of all barcodes could be completed without error. Otherwise, an error message will be displayed ( p. 233). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 24: Inserting Or Changing The Needle
4. Insert the new needle into the hole in the needle bar (1) until it reaches the end stop. Important Align the needle in such a way that the groove (3) faces the hook (4). 5. Tighten the screw (2). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 25 An incorrect hook side clearance can cause the following disturbances: • Changing to a thinner needle: • Skip stitches • Thread damage • Changing to a thicker needle: • Damage to the hook tip • Damage to the needle Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 26: Feeding Needle And Hook Thread
Fig. 8: Feeding needle and hook thread (1) ① (1) - Thread reel Fig. 9: Feeding needle and hook thread (2) ② ③ (2) - Needle/hook thread barcode (3) - Barcode scanner (for the barcodes of needle and hook thread) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 27 3. Tie on the needle/hook thread and pull it through the hose guide manually. You can now thread the needle/hook thread ( p. 26 and  p. 34) and set the thread tension ( p. 36). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 28: Threading The Needle Thread
2. Feed the thread counterclockwise from the tube (1) around the pretension (7). 3. Feed the thread clockwise through the rear tension (6). 4. Feed the thread clockwise around the pin (4) and keep feeding it clock- wise through the front tension (5). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 29 7. Insert the thread from the right to the left through the lower guide of the thread lever (14). 8. Insert the thread through the BTSR sensor. 9. Insert the thread through the upper thread guide (10). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 30 If the loose thread end is too long, the thread may be caught by the hook and cause a disturbance. If the loose thread end is too short, the machine cannot start sewing. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 31: Winding The Hook Thread
The hook thread can be wound on when it has been fed correctly through the hose guide ( p. 24). Fig. 15: Winding the hook thread (1) ③ ① ② (1) - Pretension (3) - Thread guide (2) - Thread guide Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 32 Screw loosened far - small filling quantity Screw loosened slightly - large filling quantity  The winding process starts and ends automatically when the bobbin is full. The winder lever (4) returns to its lower position. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 33 - without a scanner, the following window will be displayed: Fig. 17: Winding the hook thread (4) 16. Enter the bobbin number. Information Verify that the bobbin number (6) you entered is correct before you press button. 17. Confirm with Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 34: Inserting/Changing The Bobbin
Fig. 18: Inserting/changing the bobbin (1) ② ③ ① (1) - Supply groove (3) - Bobbin barcode (2) - Bobbin number Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 35 4. Open the bobbin case retainer (8) and, if applicable, remove the empty bobbin. 5. Clean the sensor of the remaining thread monitor or of the skip stitch detection using compressed air ( p. 47). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 36: Threading The Hook Thread
Damage and malfunction of the sensor. Every time you change the bobbin, use compressed air to remove sewing dust from the area around the bobbin case and the sensor of the remaining thread monitor. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 37 (7) - Cutout 5. Feed the hook thread through the cutout (7) between throat plate (6) and hook cover (8). 6. Cut off the hook thread so that it sticks out 1-2 cm. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 38: Thread Tension
If the tension of needle thread and hook thread is identical, the thread interlace lies in the middle of the sewing material. Adjust the needle thread tension so that the desired seam pattern is achieved with the lowest possible tension. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 39: Adjusting The Needle Thread Tension
Dürkopp Adler’s service department before the year runs out (www.duerkopp-adler.com). 4.2.2 Adjusting the hook thread tension WARNING Risk of injury from needle tip and moving parts! Puncture, cutting and crushing possible. Switch off the machine before adjusting the hook thread tension. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 40: Adjusting The Needle Thread Regulator
With the correct setting the needle thread loop must slide over the thickest part of the hook at low tension. Proper setting The loop of the needle thread slides at low tension over the thickest point of the hook. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 41: Locking The Sewing Foot In Top Dead Center
WARNING Risk of injury from moving parts! Crushing possible. Do NOT reach into the area of the sewing foot. Fig. 27: Locking the sewing foot in top dead center ① (1) - Lever Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 42: Adjusting The Sewing Foot Stroke
This function will be locked in documented seam sections. Sewing foot stroke and speed are interdependent. The control detects the set sewing foot stroke using a potentiometer and limits the speed. The values are preset on the control side. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 43: Adjusting The Sewing Foot Pressure
Needle thread tension (4) - Bartack suppression (7) - fully customizable button Activating a function To activate a function key: 1. Press the desired button.  Function is activated. The button lights up. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 44 Forced canceling of the tearing seam. Stroke quick adjustment Fully customizable The button is fully customizable. The machine comes configured so that a press of the button will switch on the underarm lighting. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 45: Assigning A Function To The Favorite Buttons
 The button lights up; the function is switched on. To switch the function of a button off: 1. Press the button whose function is switched on.  The button is no longer lit; the function is switched off. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 46: Leds On The Machine Arm
Crushing, cutting and punctures are possible. Only change the bobbin with the machine switched off. Fig. 32: Skip stitch detection (1) ① ② ③ (1) - Skip stitch detection (3) - Supply groove (2) - Flat Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 47 SDÜ sensor will be active (the bobbin will not start rotating immediately even though the machine is already sewing). The value is based on experience and may vary with the bobbin, the thread and the thread tension (preset value = 25). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 48  You can start sewing a new seam. Important If the empty bobbin is not replaced with a full one, the control panel will display the error message again during the next seam. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 49 1. Switch off the machine. 2. Clean sensors (2) using compressed air. 3. Clean the surface on the hook (1) and the sensors (2) with a cloth.  The machine can be switched back on. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 50: Quick Stroke Adjustment
The sewing foot stroke remains active for as long as you hold down the knee button (hold-to-run mode) / until the next time you press the knee button (push-to-run mode). 1. Press the button (2). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 51: Switching On And Off The Sewing Light
You can assign functions to the buttons via software at the control panel (Burger menu - Settings - User Configuration - Smart keys configuration). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 52: Additional Equipment
The end label MUST be scanned and sewn into a free seam section at the end of a sewing process. Otherwise, the finished sewing material will be faulty and not suitable for use. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 53: Barcode Scanner For Needle And Hook Thread
/ a bobbin is wound. Information The barcodes under the needle and hook thread reels must be aligned so that they can be captured completely by the barcode scanners. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 54: Bobbin Identification
This ensures that the hook thread matches the seam record set. If a dif- ferent hook thread has been defined in the seam record set, the machine will lock the sewing process and report an error. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 55: Needle Cooling From Above
Fig. 42: Operation lock (2) If shown an error message, close the needle area cover and the throat plate slide. Acknowledge the error message. Afterwards, start the sewing process again. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 56: Sewing
• Sewing in a second label if necessary To start the sewing process: 1. Log in ( p. 75). 2. Press the Sew button on the main screen.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 57 4. Scan 2 multiple barcodes. You can predefine up to 9 multiple barcodes. In this seam record set, 2 multiple barcodes will be requested at the beginning. 5. Sew seam sections.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 58: Pressing The Pedal
If an error occurs, especially during a monitored seam section, an error message will be displayed ( p. 233). 4.14.1 Pressing the pedal WARNING Risk of injury from moving parts! Crushing possible. Do NOT put your hands under the lifted sewing foot. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 59  The machine sews. The speed increases the further forward the pedal (5) is pressed. During sewing To interrupt the seam: 1. Press the pedal (5) to position 0 (3).  The machine stops. Needle and sewing foot are up / down. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 60: Sewing In The End Label
The end label printer will then automatically print the end label at the end of the documented seam section. A scan of the end label barcode is used to check if the correct end label is sewn in. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 61 Users with security level 0 will only be able to cancel the sewing process from here on. The sewing material in this case is faulty and not suitable for use. 3. Log in with security level 1 or 2.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 62  A tap on the No button will end the sewing process. The sewing material is faulty and not suitable for use. A tap on the YES button will cause the display to switch to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 63: Disruption Of The Power Supply
An acoustic warning will sound, and a message will be displayed on the control panel, indicating how long the battery capacity will last until the machine will be switched off automatically. Fig. 51: Disruption of the power supply Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 64: Switching Off The Machine
 If a user with security level 0 or 1 is logged in, the display will switch Fig. 53: Switching off the machine (2)  If a user with security level 2 is logged in, the display will switch to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 65  The machine (including the control panel) is now switched off.  The UPS will switch off automatically after a preset period of time (time can be set in the software: Check > Setup). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 66 Operation Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 67: Programming
Full access to the following work steps at the machine Access Highly restricted access Sewing Access Moderately restricted Sewing access Seam record sets Database Access Unrestricted access Sewing Seam record sets Database Check Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 68 Cancel within a tearing seam Continue tearing seam To adjust the security levels: 1. Log in with security level 2 ( p. 75). 2. Open the Setup display ( p. 132).  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 69  The factory setting does not allow for the option to assign every security level to every user. For instance, it is not possible to allow a user with security level 0 to access the Check display, which provides access to all essential settings. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 70: Start Screen - Preparing The Machine For Operation
To use the displays on the start screen if the machine is neither equipped with barcode scanners for the needle and hook thread nor with a bobbin barcode scanner: 1. Use the hand scanner to scan the needle thread barcode below the needle thread cone. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 71 6. If necessary, turn the bobbin such that you can read the bobbin number. 7. Enter the bobbin number. 8. Confirm with  You are now ready to log in ( p. 75). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 72 2. If necessary, align the bobbin such that the bobbin barcode can be scanned in full.  Once the bobbin barcode has been scanned successfully, the display Hand scanner will disappear. You are now ready to log in ( p. 75). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 73: Main Screen
Fig. 62: Main screen (1) The main screen for a user with security level 1 looks like this: Fig. 63: Main screen (2) The main screen for a user with security level 2 looks like this: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 74 0, 1 and 2 Reset Delete bobbin Delete the bobbin in the system  p. 174 0, 1 and 2 Exit program  p. 187 Exit Shut down PC 0, 1 and 2 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 75: Register Screen
This is the register screen for a user with security level 2: Fig. 66: Register screen (2) To open the register screen: 1. Press the Access button on the main screen.  The display switches to the register screen. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 76: Recurring Elements
A press of these white input fields will open an input window. Once entered, the new value appears in the white input field. The arrow in the first column of a list indicates which row / file has been selected. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 77: Input Window
All functions that are not available to the logged-in user on account of their access rights are displayed semi-transparent. These functions cannot be selected. All functions that are available to the logged-in user on account of their access rights are displayed in full color. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 78: Logging In With The Hand Scanner
Fig. 68: Logging in with the hand scanner (1) ① (1) - Hand scanner Fig. 69: Main screen (3) To log in using the hand scanner: 1. Click and hold the Access button with the mouse.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 79: Logging In With A Password
2. Use the hand scanner (1) to scan the user's access barcode.  The user has been logged in. 5.2.2 Logging in with a password Fig. 71: Logging in with a password (1) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 80 2. Press the Log in button.  The display switches to: Fig. 73: Logging in with a password (3) 3. Press the User input field.  An input window appears. 4. Enter the desired name. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 81 Programming 5. Confirm with OK. 6. Press the Password input field.  An input window appears. 7. Enter the desired password. 8. Confirm with OK.  You have been logged in. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 82: Logging In Using The Fingerprint Scanner
 The control panel shows a notice indicating that the fingerprint scanner (2) is active. Information If pressing the Access button too long, you will start the login procedure for the hand scanner rather than the fingerprint scanner. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 83 If the fingerprint is not recognized because it is unknown or was captured only partially, a corresponding error message will be displayed. If a user is logged in, they will be logged out automatically. Repeat the login procedure. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 84: Managing Users
1. Log in with security level 2 ( p. 75). 2. Open the user database ( p. 82). 3. Select the user whose access barcode you wish to print. 4. Press the Print BC button.  The access barcode is printed again. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 85: Opening The Fingerprint Database
To store an image for a created user: 1. Log in with security level 2 ( p. 75). 2. Open the register screen ( p. 73). 3. Press the Show users button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 86 6. Press the Open button.  The user image is loaded. From now on, the user image will appear on the main screen and on the register screen as well as during sewing. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 87: Creating A New User
1. Log in with security level 2 ( p. 75). 2. Open the register screen ( p. 73). 3. Press the New button.  The display switches to: Fig. 80: Creating a new user (1) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 88 To create a new user using fingerprint detection: 1. Log in with security level 2. 2. Open the register screen ( p. 73). 3. Press the New button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 89 The fingerprint must be immediately linked to a user profile as it cannot be added later once the user has been set up. 7. Press the FingerPrnt button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 90 9. BRIEFLY click the Access (1) button with the mouse. Information A LONG press on the Access button with the mouse will start the login procedure using the hand scanner.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 91 (2) - Fingerprint sensor (3) - Fingerprint scanner 11. Place your finger tip on the fingerprint sensor (2) for approximately 3 seconds.  The display switches to: Fig. 86: Creating a new user (7) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 92  After 3 successful scans, the display will switch to: Fig. 88: Creating a new user (9) 16. Confirm with OK.  An Identity number will appear automatically in the input field of the same name. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 93: Deleting Users
Only users with security level 2 can delete users. To delete a user: 1. Log in with security level 2 ( p. 75). 2. Open the register screen ( p. 73). 3. Press the Delete button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 94  The arrow in the first column on the left indicates which user is currently selected. 5. Press the Delete user button.  The display switches to: Fig. 91: Deleting users (2) 6. Confirm with OK.  The user has been deleted. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 95: Deleting The Fingerprint Database
Fig. 92: Deleting the fingerprint database (1) 4. Press the FP Init. button.  The display switches to: Fig. 93: Deleting the fingerprint database (2) 5. Confirm with OK.  The fingerprint database has been deleted. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 96: Seam Record Sets
1. Log in with security level 1 or 2 ( p. 75). Fig. 94: Opening the Seam record sets display (1) 2. Press the Seam record sets button on the main screen.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 97: Creating A New Seam Record Set
2. Open the Seam record sets display ( p. 94).  The display switches to: Fig. 96: Creating a new seam record set (1) 3. Press the New seam record set button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 98 Fig. 98: Creating a new seam record set (3) 10. Enter a seam section: press +. 11. Delete a seam section: press - 12. Confirm with OK.  The display switches to ( p. 97): Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 99: Editing A Seam Record Set (Edit Seam Parameter Record)
Seam section switch via notch detection, stitch counting or manual operation (pedal set to position -2)  p. 104 Thread.Tens.Teach-In Selection of a teach-in file (for ETT only)  p. 107 LabelScript Selection of a label script file  p. 107 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 100 The bars of the documented seam sections are set apart from the non- documented seam sections by a different color ( p. 100). The tallest bar in the row represents the present seam section in which settings are currently being edited. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 101 5. Enter the ID of the desired seam record set. 6. Confirm with OK.  The input window disappears, and the desired seam record set ID is displayed in the input field. 7. Confirm with OK.  The following display appears: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 102 To define a free seam section: 1. Open the Seam record set display ( p. 99). 2. Select the documented seam section you wish to convert into a free seam section ( p. 100). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 103 To set the desired stitch length: 1. Open the Seam record set display ( p. 99). 2. Press the Stitch length input field.  An input window appears. 3. Enter the desired stitch length (mm/10). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 104 3. Enter the desired lowest thread tension (cN). 4. Confirm with 5. Press the Thread tension max. input field.  An input window appears. 6. Enter the desired highest thread tension (cN). 7. Confirm with Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 105 To set the desired stroke: 1. Open the Seam record set display ( p. 99). 2. Press the Stroke input field.  An input window appears. 3. Enter the desired stroke. 4. Confirm with Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 106 1. Open the Seam record set display ( p. 99). 2. Press the Notch button.  The checkmark confirms the selection. 3. Press the Notch input field. 4. Enter the desired number of stitches for which notch detection will be deactivated. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 107 To set the length of the documented seam section: 1. Open the Seam record set display ( p. 99). 2. Press the Total length input field.  An input window appears. 3. Enter the desired length (mm). 4. Confirm with Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 108 This label is only available in a documented seam section. Another option is to link a label script file to the seam record set that contains all informa- tion about the end label ( p. 189). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 109 5. To bring up and view the settings, press the Edit button. Information If a label script file is linked to a seam record set, all other settings regard- ing the end label will be overwritten by the information stored in the file. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 110 To set a single start/end bartack: 1. Open the Seam record set display ( p. 99). 2. Press the single button below the heading Start/end tack. 3. Enter the desired number of stitches. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 111 1. Open the Seam record set display ( p. 99). 2. Select Sew label on.  If the checkmark is set, the function Sew label on is enabled.  If the checkmark is not set, the function Sew label on is disabled. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 112  If the checkmark is set, the sewing foot will be lifted at a sewing stop.  If the checkmark is not set, the sewing foot will not be lifted at a sew- ing stop. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 113 1. Open the Seam record set display ( p. 99). 2. Select the seam section you wish to delete. 3. Press the Delete button.  The display switches to a confirmation prompt. 4. Confirm with OK. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 114 Autom. Lift Seam end sewing foot is lifted automatically at the end of the seam Sewing backwards Needle cooling Seam Center Guide Puller Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 115: Copying A Seam Record Set
 An input window appears. 5. Enter the ID of the seam record set you wish to copy. 6. Confirm with OK.  The display switches to Enter ID and name of new seam record set: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 116: Deleting A Seam Record Set
To delete a seam record set: 1. Log in with security level 1 or 2 ( p. 75). 2. Open the Seam record sets display ( p. 94).  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 117 5. Enter the ID of the seam record set you wish to delete. 6. Confirm with  The display switches to a 2 confirmation prompt. 7. Confirm with OK.  The seam record set has been deleted successfully. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 118: Changing The Thread (Change Thread In Seam Records)116
3. Press the Change thread in seam records button.  The display switches to: Fig. 113: Changing the thread (Change thread in seam records) (2) 4. Scan the needle thread barcode on the needle thread reel. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 119: Exporting A Seam Record Set
5.4.7 Exporting a seam record set Seam record sets can be exported individually from a class 550-D800 and imported to another class 550-D800 machine. An import from a class 550-867 to a class 550-D800 can be performed as well. To export individual seam records: 1.
Page 120: Database
5.5.1 Opening the Database display To open the Database display: 1. Log in with security level 1 or 2 ( p. 75). 2. Press the Database button on the main screen.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 121: Opening The Protocol Database
3. Press the File button.  The display switches to: Fig. 117: Opening the protocol database (1) 4. Select the desired protocol database. 5. Confirm with Open.  The selected protocol database is displayed. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 122: Printing A Protocol File
It is, therefore, essential to regularly copy / store external backups of the entire protocol database. Dürkopp Adler is NOT responsible for saving, backing up or managing the data. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 123: Error Codes (Help)
2. Open the Database display ( p. 118). 3. Select the desired protocol file. 4. Press the Lab. Copy button.  The display switches to: Fig. 119: Printing a copy of an end label (Lab. Copy) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 124: Thread Tension (Thr. Tens.)
1. Log in with security level 1 or 2 ( p. 75). 2. Open the Database display ( p. 118). 3. Select the desired protocol file. 4. Press the Thr. tens. button.  The display switches to: Fig. 120: Thread tension (Thr. Tens.) (2) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 125: Check
 p. 133 Define delimiters  p. 133 Set components Set batch mode  p. 135  p. 162 Scan multi barcodes  p. 135 Set values Change security levels  p. 66 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 126 Check scanner  p. 147 Check the sewing motor Check thread tension  p. 148 Create teach-in file  p. 181 Check software version  p. 149 Uninterrupted power supply (UPS)  p. 151 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 127: Opening Thechecks Display
Backup & Recovery ®; see http://www.acronis.de. Important As the SAB software only monitors and saves the data of the tearing seams, you need to create a backup of the entire system on a regular basis. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 128 5. Select the storage location. 6. Confirm with OK.  The system backup is saved to the desired storage location. Information This function is useful if you want to set up multiple machines with the same settings. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 129: Restoring Data (Restore System)
1. Log in with security level 2 ( p. 75). 2. Open the Checks display ( p. 125). 3. Press the Restore system button.  The display switches to: Fig. 125: Restoring data (Restore system) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 130: Creating A Backup Of The Protocol Database (Backup Protoc. Db)
Information The name of the machine can be changed on the Setup display ( p. 133). You can change the storage location as needed ( p. 175). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 131: Printing A Barcode Label (Print Bc Label)
5.6.8 Copying dump files This function is used to copy all dump files. To copy dump files: 1. To copy dump files, proceed as explained for the creation of a system backup ( p. 125). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 132: Reducing The Volume Of The Protocol Database (Reduce Protoc. Db)
Programming of the service instructions for class D867 machines. 5.6.11 Setup Stored on the Setup display are the basic settings of the machine. These settings have been grouped into three categories: • General settings • Components • Values Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 133 Stored under the buttons Barcodes, Label and Path+netw. are additional setting options for the barcodes, the end label and the storage paths of the control panel. Only users with security level 2 can open the Setup display and change settings. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 134 1. Log in with security level 2 ( p. 75). 2. Open the Checks display ( p. 125). 3. Press the Setup button.  The display switches to: Fig. 128: Opening the Setup display Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 135 (6 mm or 9 mm). Fig. 129: General settings (General settings) The general settings allow to you set the following: Setting Meaning General settings Set the system language Language Assign a name for the manufacturer Manufacturer Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 136 (approx. 1.0-1.5 mm; the airier the material, the longer the short cutter stitch needs to be) If an end label is sewn in later, the seam will be sewn with the Stitch count number of stitches set here. label sewing Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 137 Allows for repeated sewing after a single scan.  p. 162 With batch mode Scanner needle thread Reading the needle thread barcode using the stationary scanner (optional) Scanner bobbin thread Reading the hook thread barcode using the stationary scanner (optional) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 138 Additional equipment used to detect/monitor the distance Edge measuring of the needle to the material edge Allows for setting different tack stitches for start and end Tack stitches for bartack in the respective seam sections each seam section Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 139 When deactivated, the fingerprint scanner cannot be used fingerprint scanner by any user for logging in. (Finger Print Sensor) Users with fingerprint detection will then only be able to log in via software.  p. 77 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 140  If the checkmark is set, the function is activated.  If the checkmark is not set, the function is deactivated. Values Fig. 131: Values Press the arrows on the right next to the buttons to open a selection menu. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 141 • Protocol database • System database • Automatic copy of protocol database You can also use the display to set the interval at which the protocol database will be backed up automatically ( p. 177). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 142: Opening The Thread Database (Threads)
1. Log in with security level 2 ( p. 75). 2. Open the Checks display ( p. 125). 3. Press the DB print button.  The protocol database is printed. Information The protocol database is always printed out in full. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 143: Opening The Seam Database (Show Db)
The bobbin database contains the information about all bobbins that are registered and can be used with the machine. Information The bobbins can be deleted here and on the main screen ( p. 174). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 144: Needle Database (Needle Db)
This check and any necessary change will be documented in the needle database. Information If the function Needle control is deactivated on the Setup display, the Needle DB button will be displayed semi-transparent. It will then not be possible to open the needle database. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 145 1. Open the needle database ( p. 142). 2. Press the Checked button.  The display switches to: Fig. 136: Scheduling a needle check 3. Check the needle. 4. Enter the date of the next check. 5. Confirm with OK. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 146: Calibrating The Stepper Motor (Sm-Cali)
To open the stepper motor calibration database: 1. Log in with security level 2 ( p. 75). 2. Open the Checks display ( p. 125). 3. Press the SM-Cali button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 147: Opening The Calibration Database (T.tens.-Cali)
To open the calibration database of the thread tension sensor: 1. Log in with security level 2 ( p. 75). 2. Open the Checks display ( p. 125). 3. Press the T.Tens.-Cali button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 148 Programming Fig. 139: Opening the calibration database (T.Tens.-Cali) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 149: Checking The Scanners (Scanner)
Fig. 140: Checking the scanners (Scanner) 4. Press the read button below the scanner you wish to check. Information The Check Scanner display can also be opened using the Check scan- ner button on the main screen. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 150: Thread Tension (Thread Tens.)
Manual thread tension requires that you enter the minimum and maximum values and the stitch length manually: To load a Teach-In for Thread Tension file: 1. Log in with security level 2 ( p. 75). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 151 To check which software version is currently installed on the thread tension circuit board: 1. Log in with security level 2. 2. Open the display Checking thread tension monitor ( p. 148). 3. Press the Settings button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 152 Programming Fig. 143: Checking the software version Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 153: Uninterrupted Power Supply(Ups)
You will then have no more than 5 minutes to complete the current sewing process and switch off the machine. Information The power consumption in standby mode is lower than during sewing. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 154: Protocol Printer
5.8 Uninstalling the barcode printer drivers By default, the Windows printer screen shows one protocol printer driver (Zebra ZD420). Important The protocol printer driver may only be uninstalled using the included Uninstall program. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 155 Run as admin.  The display switches to: Fig. 146: Uninstalling the barcode printer drivers (2) 5. Press the Next button.  The display switches to: Fig. 147: Uninstalling the barcode printer drivers (3) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 156: Calibrating The End Label Printer
Barcodes can be read up to the 30 digit. If a barcode is longer, the code can still be scanned, but the information can no longer be read starting with the 31 digit. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 157: Barcodes At A Glance
Barcode of the hook Barcode on the hook thread reel (optional). thread reel Barcode on printed Barcode on the end label by means of which the production label data can be traced back at any time Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 158: Opening The Barcodes Display
0 = the digit of the barcode will not be read 1 = the digit of the barcode will be read All information must be stored in places that are defined as 1. Fig. 150: Opening the Barcodes display (2) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 159 Code A Setpoint If you wish to exclusively process pieces with a specific ID number, enter that ID number here. If you wish to sew pieces with different ID numbers, you must not enter anything here. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 160: Changing The Barcode Type
2. Open the Setup display ( p. 132). 3. Open the Barcodes display ( p. 156). 4. Press the Primary barcode type input field.  A drop-down menu opens. 5. Select the desired barcode type. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 161: Defining A Barcode
2-4 digits) Left seat cover (piece 1 and piece 2 Mask left/ must have the same left/right code) right Scan two multi barcodes at the Qty Multiple beginning of the sewing process barcodes Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 162: Saving A Barcode Profile
5. Select the desired barcode profile name. 6. Press Save to confirm.  The barcode profile is stored on the hard drive of the control panel and can be loaded at any time ( p. 171). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 163: Loading A Barcode Profile
 The display switches to: Fig. 153: Loading barcode 5. Select the desired barcode profile name. 6. Confirm with Open.  The settings stored in the barcode profile are now the current settings. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 164: Setting Batch Mode
To set multi barcodes: 1. Log in with security level 2 ( p. 75). 2. Open the Setup display ( p. 132). 3. Open the Barcodes display ( p. 156).  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 165: Preparing The End Label (Label)
You can use the button Define extended label printing to add additional information to the end label. You can use the software or the additional program Label Creator to create the end label ( p. 189). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 166: Opening The End Label Display
• Barcode label text 2 • Barcode label text 3 • Barcode label text left • Barcode label text right  An input window appears. 4. Enter the desired text. 5. Confirm with Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 167: Positioning The Text On The End Label
6. Press the Pos. text1 Y input field.  An input window opens. 7. Enter the desired value. 8. Confirm with 9. To position the texts 2, 3 and left/right, repeat steps 4-9. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 168: Defining The Format Of The End Label
2. Open the End label display ( p. 164). 3. Press the Label direction input field.  An input window opens. 4. Enter the desired value: • Landscape: 0 or 2 • Portrait: 1 or 3 5. Confirm with Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 169: Positioning The End Label Barcode
2. Open the End label display ( p. 164). 3. Press the Txt1 font, Txt2 font or L/R font input field.  An input window opens. 4. Enter the desired value (1-5). 5. Confirm with Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 170: Defining The End Label Barcode Type
Fig. 159: Defining the format of the end label barcode 3. Press the Information within printed barcode input field.  An input window opens. 4. Enter the acronyms of the desired information in the desired order. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 171 The number of digits and the coding are defined using the mask given under Prim. barcode mask printed label. The number of digits and the coding are defined using the mask given under Barcode mask needle thread lab. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 172: Saving An End Label
1. Log in with security level 2 ( p. 75). 2. Open the End label display ( p. 164). 3. Press the Save button.  The display switches to the storage path: Fig. 160: Saving an end label Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 173: Loading An End Label
Fig. 161: 4. Select the desired end label profile. 5. Confirm with Open.  The settings currently shown on the Label display now correspond to those included in the desired end label profile. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 174: Defining Extended Label Printing
Fig. 162: Defining extended label printing 5. Select the desired acronyms. 6. Press Save to confirm. Code Code Information MB1-MB9 Multi barcodes 1-9 Section of the multi barcode cut out with the end label multi barcode mask Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 175 Section of the barcode parts primary 1 defined for the end label using the mask provided on the Barcode display p. 159 Barcode on printed label End label barcode which was generated with SecondBC.txt Current material barcode Daily incrementing code of the produced piece Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 176: Deleting A Bobbin
1. Press the Delete bobbin button on the main screen.  An input window appears: Fig. 164: Deleting a bobbin (2) 2. Enter the 3-digit bobbin number (001-999). 3. Confirm with  The display switches to: Fig. 165: Deleting a bobbin (3) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 177: Storage Locations And Automatic Backups (Path+Netw.)
 p. 120 To change a storage location: 1. Log in with security level 2. 2. Open the Setup display ( p. 132). 3. Press the Path+netw. button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 178 Fig. 167: Path + network (1) 4. Press the desired Change path button.  The display switches to, for instance: Fig. 168: Path + network (2) 5. Select the desired path/new storage location. 6. Confirm with OK. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 179: Setting An Automatic Backup Of The Protocol Database
 An input window opens. 6. Enter the desired number of minutes.  In the example given, an automatic backup of the protocol database will be generated every 60 minutes. 7. Confirm with OK. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 180: Thread Database
If the threads match the seam record set, the sewing process can be started. If not, an error message will be displayed, and the sewing process cannot be started. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 181  If the checkmark in front of it disappears, the corresponding thread has not been selected for use. 13. Confirm with OK.  The display returns to Thread database. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 182: Changing A Thread
2. Open the Thread database ( p. 178). 3. Select the desired thread in the thread database.  The small arrow in the left column marks the currently selected thread. 4. Press the Delete thread button. 5. Confirm with OK. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 183: Creating A Teach-In File
1. Log in with security level 2 ( p. 75). 2. Open the Checks display ( p. 125). 3. Press the Thread tens. button. 4. Press the Teach-In button.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 184 • Stitch length in mm/10 • Stroke • Sewing foot pressure 8. Press the T.Tens.Target Point button.  The value of the needle thread tension is adopted, and the stepper motor moves to the corresponding position. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 185 The percentage must not be smaller than 5 percent relative to the operat- ing point. If a difference of 5 percent is not enough to reach the setpoint, the setpoint must be adjusted based on the measured value. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 186  Step 1 and step 2 are now highlighted in green and yellow, respectively. 27. Press the Start Sewing button.  If the test seam was completed successfully, the display switches to: Fig. 176: Creating a teach-in file (4) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 187 Fig. 178: Creating a teach-in file (6)  The currently measured values are listed under steps 2-5. Important Step 5 requires that AT LEAST 6 seams; the total number of possible seams is 15. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 188: Restarting The Program (Reset)
To restart the program: 1. Press the Reset button on the main screen.  The program is closed and restarted automatically. Once the program has restarted, the user can log back in and continue working. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 189: Exiting The Program
Fig. 181: Exiting the program (2) 2. Press the YES button.  The program is closed, and the Windows user interface appears.  You can restart the program or shut down the PC. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 190: Logging Out Of The System
 The display switches to: Fig. 184: Logging out of the system (3)  The user has been logged out. Information Users with security level 0 are logged out automatically after 2 minutes of inaction. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 191: Additional Program Label Creator
The following description refers to the factory settings. This description cannot include any individual changes such as modified storage location. Label script files may only be created and linked to seam record sets by qualified specialists with security level 2. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 192: Preparing The End Label (Example)
( p. 187). 3. Open Windows Explorer. 4. Go to the c:SabSoft_SystemDB and open the additional program named DALabelCreator.  The display switches to: Fig. 185: Preparing the end label (example) (1) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 193 9. Create and insert standard text ( p. 200). 10. Create and insert variable text ( p. 201). 11. Insert a graphic; e.g. the company logo ( p. 202). 12. Save the new label script file ( p. 203). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 194: Default Settings
5.21.3 Adjusting the end label size Fig. 187: Opening the toolbox (2) To adjust the size of a new end label: 1. Click on the Edit menu item. 2. Click on Label dimensions.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 195 Option Cutter. The included end label printer does not come with a cutting device. 7. To set the resolution of the end label printer, enter the corresponding DPI number in the Printer Resolution DPI input field. 8. Press OK to save. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 196: Opening The Toolbox
2. Select Show Toolbox.  The Toolbox is displayed on the main interface. Fig. 191: Opening the toolbox (3) 3. Move the Toolbox to the position of your choice on the main interface. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 197: Inserting Contents
The marking always refers to the corner at the top left.  The display switches to the setting options available for the corresponding content. 3. Adjust the content. 4. Press OK to save. Important Every end label MUST have an end label barcode. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 198: Moving Contents
3. To move content, click on the blue arrow buttons. Fig. 193: Moving contents (2) 4. Once the content has been positioned correctly, click on the green checkmark.  The display Move component disappears. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 199: Creating A Barcode
Barcode Type field. Important Select the same barcode type here that has been set as the hand scanner barcode on the Setup display ( p. 138). Fig. 196: Creating an end label barcode (3) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 200 10. To adjust the height of the barcode, modify its value in the Barcode height input field. 11. If the barcode is the end label barcode, set a checkmark at Barcode for database part identification. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 201: Adding An Additional Barcode
You must define 1 barcode on the end label as the end label barcode. An error message will be displayed if • no barcode has been defined as the end label barcode. • more than 1 barcode has been defined as the end label barcode. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 202: Creating Standard Text
If you wish to place an additional character such as an * at the beginning and the end of the text information, enter the asterisk as static text. 4. Adjust the desired default settings ( p. 192). 5. Press OK to save. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 203: Creating Variable Text
4. Select the desired option from the drop-down menu in the Information input field. This is the information that will be printed on the end label as variable text. 5. Adjust the desired default settings ( p. 192). 6. Press OK to save. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 204: Inserting A Graphic
 The display switches to: Fig. 200: Inserting a graphic (2) 4. Select the desired bmp file. 5. Confirm with Open. 6. Adjust the desired default settings ( p. 192). 7. Press OK to save. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 205: Saving A Label Script File
You must define 1 barcode on the end label as the end label barcode. An error message will be displayed if • no barcode has been defined as the end label barcode. • more than 1 barcode has been defined as the end label barcode. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 206: Printing A Test End Label
• Bobbin number (Bobbin number) • Username (User name) • Name of seam record (Name of the protocol file) • Machine code (Machine designation) • Manufacturer code (Manufacturer name) • Errorcode (Error code) • Multi barcodes Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 207: Performing A Search (Example)
4. Access the directory c:SabSoft and open the program SABSearch.  The display switches to: Fig. 203: Performing a search (example) (1) 5. Enter the password ( p. 204).  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 208 If you do not select a specific protocol database, the program will scan all protocol databases stored in the storage location. 9. Confirm with OK.  The display switches to: Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 209 12. Enter plain text (text below the end label barcode). Information This text must be entered manually. You cannot scan the barcode here. 13. Confirm with OK.  The display switches to, for instance: Fig. 208: Performing a search (example) (6) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 210 14. Confirm with OK.  The display switches to: Fig. 209: Performing a search (example) (7)  This search produced 11 protocol files that document the sewing of the sewing material by a specific user. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 211: Exiting Sabsearch
5.22.2 Exiting SABSearch Fig. 210: Exiting SABSearch (1) To exit the additional program SABSearch: 1. Click on the Quit button.  The display switches to: Fig. 211: Exiting SABSearch (2) 2. Confirm with Yes. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 212 Programming Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 213: Maintenance
Removing sewing dust and thread residues  Lubricating Lubricating the machine head  Lubricating the hook  Servicing the pneumatic system Adjusting the operating pressure  Draining the water condensation  Cleaning the filter element  Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 214: Cleaning
Use only solvent-free substances for cleaning. Fig. 212: Cleaning ④ ① ③ ② (1) - Area around the needle (3) - Area under the throat plate (2) - Hook (4) - Knife on the winder Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 215: Lubricating
If oil has come into contact with your skin, wash the affected areas thoroughly. NOTICE Property damage from incorrect oil! Incorrect oil types can result in damage to the machine. Only use oil that complies with the data in the instructions. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 216: Lubricating The Machine Head
9047 000012 9047 000013 9047 000014 6.2.1 Lubricating the machine head Fig. 213: Lubricating the machine head ① ② ③ (1) - Refill opening (3) - Minimum level marking (2) - Maximum level marking Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 217: Lubricating The Hook
10 seconds with the sewing feet lifted and at a speed of 3000.  The blotting paper will show a thin strip of oil when sewing is complete. Fig. 214: Lubricating the hook ① (1) - Screw Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 218: Servicing The Pneumatic System
The operating pressure cannot deviate by more than ± 0.5 bar. Check the operating pressure on a daily basis. Fig. 215: Adjusting the operating pressure ① ② (1) - Pressure regulator (2) - Pressure gage Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 219: Draining The Water-Oil Mixture
1. Disconnect the machine from the compressed air supply. 2. Place the vessel under the drain screw (3). 3. Loosen the drain screw (3) completely. 4. Allow the water-oil mixture to drain into the vessel. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 220: Cleaning The Filter Element
6. Wash out the filter tray using benzine. 7. Tighten the filter element (1). 8. Tighten the collection tray (2). 9. Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 221: Parts List
Maintenance 6.4 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 222 Maintenance Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 223: Setup
Restore the working height as soon as the machine is set up at its destination. 7.3 Removing the transport locks Remove all transport locks before setting up the machine: • at the machine head • at the table • at the stand Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 224: Adjusting The Working Height
(1) - Pedal (3) - Screw (2) - Cross strut The pedal (1) must be tilted to a degree that allows the user to move the pedal forward and backward without a problem. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 225: Electrical Connection
Unprotected contact with electricity can result in serious injuries or death. Only qualified specialists may perform work on electrical equipment. Important The voltage on the type plate of the sewing motor must correspond to the mains voltage. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 226: Pneumatic Connection
Ensure that the machine is only used when the operating pressure is set correctly. Proper setting Refer to the Technical Data ( p. 259) chapter for the permissible operating pressure. The operating pressure cannot deviate by more than ± 0.5 bar. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 227: Checking The Lubrication
All wicks and felt bits of the machine head are soaked in oil at the factory. This oil is conveyed to the reservoir during use. This is why you should avoid filling too much oil during initial filling. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 228 (1). 3. If the oil level is below the minimum level marking (3): Top off oil through the refill opening ( p. 214). Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 229: Putting The Machine Into Operation
When setup is complete, perform a test run to check the functionality of the machine. For this purpose, perform a thread tension check  p. 148. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 230 Setup Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 231: Decommissioning
5. Cover the control panel to protect it from soiling. 6. Cover the control to protect it from soiling. 7. Cover the entire machine if possible to protect it from contamination and damage. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 232 Decommissioning Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 233: Disposal
When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 234 Disposal Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 235: Troubleshooting
Piece has been The barcodes of a piece to be Sew the piece. released sewn has been scanned and released Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 236: Error Messages
Error wrong thread tension values for stitch counting sewing motor EC23000 Error thread breaking in documented seam section EC23010 Error thread breaking (left) in documented seam section EC23100 Error skip stitch in documented seam section Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 237 Error thread breaking in free seam section (sensor) EC25910 Error thread breaking (left) in free seam section (sensor) EC26000 External barcode label (additional barcode) not read EC27000 Hardware error, sewing motor not responding Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 238 EC34000 Protocol data cannot be stored EC35000 Door of thread cabinet not closed EC35100 Sensor needle thread cone not closed EC35200 Sensor bobbin thread cone not closed EC35300 Sensor slide plate not closed Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 239 • Perform reset • Check class (t 51 04) 1007 Error Error in the reference run • Replace encoder • Check for stiff movement 1008 Error Sewing motor encoder error • Replace encoder Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 240 Position not reached (during • Check the controller thread cutting, reversal, etc.) settings and change them if necessary (e.g. thread trimmer setting, belt tension, etc.) • Check position thread lever at top dead center Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 241 2176 Error Stepper motor card X30 not • Replace control Enabled (Stitch length) 2177 Error Stepper motor card X30 • Check for stiff movement Overload (Stitch length) • Replace encoder • Replace motor Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 242 • Connect encoder cable to encoder plug (Sub-D, 9-pin) the control, use the not connected correct interface 2222 Error Stepper motor card X40 rotor • Check stepper motor 1 for position not found stiff movement Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 243 Stepper motor card X40 • Check for stiff movement Reference run failure • Replace encoder (Sewing foot lift) • Replace motor 2283 Error Stepper motor card X40 • Replace control overcurrent (Sewing foot lift) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 244 • Replace control Sewing motor encoder not connected (Sewing foot stroke) 2374 Error Stepper motor card X50 • Perform software update Sewing motor encoder not • Check selection of class init (Sewing foot stroke) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 245 • Check selection of class (Sewing foot stroke) 2388 Error Stepper motor card X50 • Check for stiff movement Reference run failure • Replace encoder (Sewing foot stroke) • Replace motor Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 246 Stepper motor card X60 • Check for stiff movement Overload (motorized edge • Replace encoder guide) • Replace motor 2478 Error Stepper motor card X60 • Replace encoder Encoder failure (motorized edge guide) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 247 • Connect encoder cable to encoder plug (Sub-D, 9-pin) the control, use the not connected correct interface 2522 Error Stepper motor card X70 rotor • Check stepper motor 1 for position not found stiff movement Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 248 Error Stepper motor card X70 • Check for stiff movement Reference run failure • Replace encoder (upper Puller) • Replace motor 2583 Error Stepper motor card X70 • Replace control overcurrent (upper Puller) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 249 / overvoltage / • Replace control overcurrent (bottom puller) • Replace encoder • Replace stepper motor 2673 Error Stepper motor card X80 • Replace control Sewing motor encoder not connected (bottom puller) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 250 Stepper motor card X80 • Check for stiff movement Reference run failure • Replace encoder (bottom puller) • Replace motor 2901 Error General Reference Timeout • Check the reference of the stepper motors sensors Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 251 Right thread tension magnet • Check the connection of is not connected right thread tension magnet 3111 Information Left thread tension magnet is • Check the connection of not connected left thread tension magnet Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 252 • Reset or machine class change necessary 4908 Information • Reset necessary 4911 Information • Reset necessary 4918 Warning Invalid update file • Contact DA Service 4919 Warning Reset failed • Contact DA Service Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 253 • Switch off the control, wait internal data structures are until the LEDs have gone not compatible with the out, and then switch on external data storage device) the control again • Software update Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 254 Lower machine head pcb is • Check cable not connected • Perform software update • Replace PCB 9352 Error Left thread tension pcb is not • Check cable connected • Perform software update • Replace PCB Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 255 • Check 24V • Replace control 9923 Warning Update required • Press OK for Restart or ESC for cancel 9924 Warning Security key generated • Creation of a security key on a USB key Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 256 Right hook cover open • Close the hook cover 9936 Warning Left hook cover open • Close the hook cover 9937 Warning Needle area cover open • Close needle area cover 9938 Warning ENG ON 4 Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 257: Editing Error Messages
Users with security level 1 or 2 will be able to release or cancel the sewing process. To edit an error message: 1. Log in with security level 1 or 2.  The display switches to: Fig. 224: Editing error messages (2) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 258 If an error has occurred, the programmed batch mode, if applicable, will be canceled accordingly. If you wish to start a new sewing process, you need to call the function Sew on the main screen after the sewing process was interrupted. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 259: Errors In Sewing Process
Check the assembly of the reel stand assembled incorrectly Thread tensions are too Check thread tensions  p. 36 tight Throat plate, hook or Have parts reworked by qualified spread have been specialists damaged by the needle Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 260 Check threading path  p. 24, thread have not been  p. 26,  p. 34 threaded correctly Needle breakage Needle thickness is Use recommended needle thickness unsuitable for the sewing  p. 259 material or the thread Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 261: Technical Data
Lifting height [mm] Mains voltage Mains frequency [Hz] 50/60 Operating pressure [bar] Length [mm] Width [mm] Height [mm] 11.2 Requirements for fault-free operation Compressed air quality must conform to ISO 8573-1: 2010 [7:4:4]. Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 262 Technical data Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 263 Appendix 12 Appendix Fig. 226: Wiring diagram (1) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 264 Appendix Fig. 227: Wiring diagram (2) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 265 Appendix Fig. 228: Wiring diagram (3) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 266 Appendix Fig. 229: Wiring diagram (4) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 267 Appendix Fig. 230: Wiring diagram (5) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 268 Appendix Fig. 231: Wiring diagram (6) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 269 Appendix Fig. 232: Wiring diagram (7) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 270 Appendix Fig. 233: Wiring diagram (8) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 271 Appendix Fig. 234: Wiring diagram (9) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 272 Appendix Fig. 235: Wiring diagram (10) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 273 Appendix Fig. 236: Wiring diagram (11) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 274 Appendix Fig. 237: Wiring diagram (12) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 275 Appendix Fig. 238: Wiring diagram (13) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 276 Appendix Fig. 239: Wiring diagram (14) " Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 277 Appendix Fig. 240: Wiring diagram (15) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 278 Appendix Fig. 241: Wiring diagram (16) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 279 Appendix Fig. 242: Wiring diagram (17) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 280 Appendix Fig. 243: Wiring diagram (18) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 281 Appendix Fig. 244: Wiring diagram (19) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 282 Appendix Fig. 245: Wiring diagram (20) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 283 Appendix Fig. 246: Wiring diagram (21) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 284 Appendix Fig. 247: Wiring diagram (22) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 285 Appendix Fig. 248: Wiring diagram (23) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 286 Appendix Fig. 249: Wiring diagram (24) Operating Instructions 550-D800 - 01.0 - 05/2023...
Page 288 DÜRKOPP ADLER GmbH Potsdamer Str. 190 33719 Bielefeld Germany Phone: +49 (0) 521 925 00 Email: service@duerkopp-adler.com www.duerkopp-adler.com...

Dürkopp Adler 550-D800 Operating Instructions Manual

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