Dürkopp Adler 512 User manual

Operating Instructions
512/532
DA_512-211_deen_12-2013.qxd:DA-6-pages.qxd 04.12.2013 12:38 Uhr Seite 3

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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 – 2016

Table of Contents
Operating Instructions 512/532 - 04.0 - 08/2016 1
1 About these instructions .................................................................... 5
1.1 Scope ....................................................................................................5
1.2 For whom are these instructions? .........................................................5
1.3 Representation conventions – symbols and characters........................6
1.4 Other documents...................................................................................7
1.5 Liability ..................................................................................................8
1.5.1 Transport ...............................................................................................8
1.5.2 Proper use.............................................................................................8
2 Technical Specifications .................................................................. 11
2.1 Characteristics of the 512.................................................................... 11
2.2 Characteristics of the 532.................................................................... 12
2.3 Declaration of conformity.....................................................................13
2.4 Technical data .................................................................................... 13
3 Safety Information ............................................................................. 15
3.1 Basic safety instructions...................................................................... 15
3.2 Signal words and symbols used in warnings.......................................17
4 Operation ........................................................................................... 21
4.1 Threading needle thread .....................................................................21
4.2 Setting the needle thread tension........................................................22
4.3 Setting the thread regulator.................................................................23
4.4 Winding the hook thread .....................................................................24
4.5 Replacing the hook thread bobbin....................................................... 25
4.6 Setting the hook thread tension...........................................................27
4.7 Changing needle ................................................................................. 28
4.8 Adjusting the button mount of the button clamp (Class 532)............... 30
4.9 Shank shaper (optional) ...................................................................... 32
4.10 Sewing.................................................................................................33
4.11 Customer service ................................................................................34
5 Programming ..................................................................................... 35
5.1 Control panel ....................................................................................... 35
5.2 Switching on the sewing machine .......................................................36
5.3 Referencing the machine ....................................................................37
5.4 Selecting the seam appearance..........................................................37
5.5 Scaling the axes .................................................................................. 37
5.5.1 Scaling the X axis (software version up to M2.10) ..............................37
5.5.2 Scaling the X axis (from software version M2.14) ...............................38
5.5.3 Scaling the Y axis (software version up to M2.10) ..............................38
5.5.4 Scaling the Y axis (from software version M2.14) ...............................38
5.5.5 Recalculate the button hole clearance (class 532)
(software version up to M2.08)............................................................38

Table of Contents
2 Operating Instructions 512/532 - 04.0 - 08/2016
5.5.6 Recalculate the button hole clearance (class 532)
(from software version M2.10).............................................................39
5.5.7 Recalculate the bartack dimensions (class 512)
(software version up to M2.10)............................................................39
5.5.8 Recalculate the bartack dimensions (class 512)
(from software version M2.14).............................................................40
5.6 Setting the speed ................................................................................40
5.7 Checking the seam appearance..........................................................40
5.8 Changing the seam appearance ......................................................... 41
5.9 Bobbin winding ....................................................................................41
5.10 Sewing.................................................................................................42
5.11 Counter................................................................................................42
5.12 Pausing sewing ................................................................................... 43
5.13 Disabling standard seam appearances ............................................... 43
5.14 Saving seam appearances.................................................................. 43
5.14.1 Assigning the memory buttons ............................................................44
5.14.2 Sewing with the memory buttons ........................................................ 45
5.14.3 Deleting the memory button assignments ...........................................45
5.15 Saving seam appearance sequences ................................................. 46
5.16 Sewing with a seam appearance sequence........................................47
5.17 Deleting a seam appearance sequence.............................................. 47
5.18 Finishing sewing .................................................................................. 48
5.19 Editing parameters in memory ............................................................48
5.19.1 Editing parameters at the M1 level......................................................48
5.19.2 Editing parameters at the M2 level......................................................49
5.20 Resetting parameters to factory defaults.............................................50
5.21 Externally editing seam appearances ................................................. 51
5.22 Working with a USB stick ....................................................................52
5.23 Error messages ...................................................................................55
5.24 Loading software from a USB stick ..................................................... 58
5.24.1 Loading the main program ..................................................................58
5.24.2 Loading seam appearances ................................................................59
5.24.3 Setting parameter U085 (Class 532)................................................... 59
5.24.4 Checking the software version ............................................................ 60
6 Maintenance....................................................................................... 61
6.1 Cleaning .............................................................................................. 61
6.2 Lubrication...........................................................................................63
6.2.1 Checking the oil level .......................................................................... 64
6.2.2 Lubricating with grease .......................................................................66
7 Seam appearances............................................................................ 69
7.1 Standard seam appearances for class 512......................................... 69
7.2 Standard seam images for class 532 .................................................. 73

Table of Contents
Operating Instructions 512/532 - 04.0 - 08/2016 3
8 Setup .................................................................................................. 75
8.1 Checking the scope of delivery ...........................................................75
8.2 Removing the transport securing devices ...........................................76
8.3 Assembly............................................................................................. 76
8.3.1 Checking the table plate...................................................................... 76
8.3.2 Assembling the frame..........................................................................77
8.3.3 Completing the table plate...................................................................78
8.3.4 Mounting the upper section support .................................................... 80
8.3.5 Setting the working height ................................................................... 81
8.3.6 Mounting upper machine section ........................................................82
8.3.7 Fitting the oil collection reservoir .........................................................83
8.3.8 Electrical connection ........................................................................... 84
8.3.9 Checking the mains voltage ................................................................84
8.3.10 Connecting the cables to the controller ............................................... 84
8.3.11 Mount the hood ................................................................................... 85
8.3.12 Fit the eye protection...........................................................................86
8.4 Fit the button container (class 532) .....................................................87
8.5 Sewing test..........................................................................................88
9 Disposal ............................................................................................. 89
10 Appendix ............................................................................................ 91

Table of Contents
4 Operating Instructions 512/532 - 04.0 - 08/2016

About these instructions
Operating Instructions 512/532 - 04.0 - 08/2016 5
1 About these instructions
These instructions for the special sewing machines 512 and 532
was compiled with the utmost care. It contains information and
notes in order to make long-term and reliable operation possible.
Should you notice any discrepancies or if you have improvement
requests, then we would be glad to receive your feedback to the
Customer service,
 S. 34.
Consider these instructions part of the product and keep it on hand
at all times. Be sure to read the instructions completely before
using the product for the first time. Only give the product to
someone else along with the instructions.
1.1 Scope
These Instructions describes the set-up and intended use of the
special sewing machines 512 and 532.
1.2 For whom are these instructions?
These instructions are for:
• Operators:
This group of employees has been trained in operating
the machine and can access the operating manual. Speci-
fically, Operation is intended for this group.
• Technicians:
This group of employees has the appropriate technical
training allowing them to perform maintenance on the
sewing unit or to repair faults. Specifically, Setup is
intended for technical personnel.
Service instructions are supplied separately.
With regard to minimum qualification and other requirements to
be met by the personnel, please also observe Safety instruc-
tions.

About these instructions
6 Operating Instructions 512/532 - 04.0 - 08/2016
1.3 Representation conventions – symbols and
characters
Various information in th3ese instructions is represented or high-
lighted 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 equipping)
Steps to be performed for servicing, maintenance, and
installation
Steps to be performed via the software control panel
The individual steps are numbered:
1. First step
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.
1.
2.
...
•


About these instructions
Operating Instructions 512/532 - 04.0 - 08/2016 7
Information
Additional information, e. g. on alternative operating possibilities.
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 desig-
nated. Since safety is of particular importance, hazard symbols,
levels of danger and their signal words are described separately
in 3 Safety Information.
Orientation Information on where something is positioned using the terms
“right” or “left” must always be regarded from the operator's point
of view if the figure gives no other obvious indication for determi-
ning the location.
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 ap-
plicable European and national regulations. The proper use of
these components is described in each manufacturer's manual.

About these instructions
8 Operating Instructions 512/532 - 04.0 - 08/2016
1.5 Liability
All information in these instructions were compiled with conside-
ration to the state of the art, and applicable standards and regu-
lations.
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. Re-
port any damage to the last transport manager. This applies even
if the packaging is undamaged.
Leave machines, equipment and packaging material in the con-
dition 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 512/532 is intended for sewing light to mode-
rately heavy material.
The machine is only intended for use with dry material. The
material cannot contain any hard objects.
The seam is produced using core spun threads, polyester fibers,
or cotton threads.
Class 512 thread strength of dimensions 50/3 - 130/3
Class 532 thread strength of dimensions 50/3 - 150/3
The sewing machine is intended for industrial use.

About these instructions
Operating Instructions 512/532 - 04.0 - 08/2016 9
The machine may only be set up and operated in dry conditions
on well-maintained premises. If the machine is operated on pre-
mises 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 injury due to electric shock, moving and
sharp parts!
Crushing and cutting are possibel.
Follow all instructions provided.
NOTICE
Property damage from non-observance!
Improper use can result in material damage at the machine.
Follow all instructions provided.

About these instructions
10 Operating Instructions 512/532 - 04.0 - 08/2016

Technical Specifications
Operating Instructions 512/532 - 04.0 - 08/2016 11
2 Technical Specifications
The Dürkopp Adler 512 is a CNC double lockstitch bartack sewing
machine. Die Dürkopp Adler 532 is a button sewing machine.
2.1 Characteristics of the 512
The existing programs are scalable and can be saved in this
modified form. The machine is equipped with an automatic sewing
foot lifter, thread cutter, thread wiper, a needle thread clamp below
the stitch plate for reliable sewing-on and an integrated DC direct
drive including an operating panel.
Technical features
• The sewing machine is driven by an integrated positioning
drive. A controller controls the sewing drive and also 2 stepper
motors for the X and Y motions required for generating the
seam geometry.
• The clamps are raised by a stepper motor.
• The maximum size of the sewing field is 40 mm in the X direc-
tion (lateral to the arm) and 30 mm in the Y direction (parallel
to the arm).
• The upper section is oil-free. This means that there is no dan-
ger of soiling the sewn material with oil.
• The hook is lubricated by a wick lubrication system, fed from a
reservoir visible to the operator.
• 50 pre-programmed bartacks are available. The standard pat-
terns can be temporarily modified (changes to the total length,
total width, speed). When the machine is switched off, the
modified values of the most recently used bartack are restored
when the machine is switched on again.
• 50 additional modified standard patterns can also be stored.
• A maximum of 16,000 stitches can be stored.
• 25 sequence programs with up to 30 seam appearances per
sequence can be stored.
• The coordinate entry system has an accuracy of 0.1 mm.
• The machine has a bobbin thread decrementing counter and a
daily item counter.
• The arm shaft is directly driven by a brushless DC motor.
• Speeds of up to 3000 min-1 can be set, in 100 min-1 steps.

Technical Specifications
12 Operating Instructions 512/532 - 04.0 - 08/2016
2.2 Characteristics of the 532
The existing programs are scalable and can be saved in this
modified form. The machine is equipped with an automatic sewing
foot lifter, thread cutter, thread wiper, a needle thread clamp below
the stitch plate for reliable sewing-on and an integrated DC direct
drive including an operating panel.
Technical features
• The sewing machine is driven by an integrated positioning
drive. A controller controls the sewing drive and also 2 stepper
motors for the X and Y motions required for generating the
seam geometry.
• The clamps are raised by a stepper motor.
• The maximum size of the sewing field is 40 mm in the X direc-
tion (lateral to the arm) and 30 mm in the Y direction (parallel
to the arm).
• The upper section is oil-free. This means that there is no dan-
ger of soiling the sewn material with oil.
• The hook is lubricated by a wick lubrication system, fed from a
reservoir visible to the operator.
• A maximum of 33 pre-programmed standard button patterns
are available. These standard patterns can be temporarily
modified (changes to the total length, total width, speed).
When the machine is switched off, the modified values of the
most recently used bartack are restored when the machine is
switched on again.
• A maximum of 16,000 stitches can be stored.
• 25 sequence programs with up to 30 seam appearances per
sequence can be stored.
• The coordinate entry system has an accuracy of 0.1 mm.
• The machine has a bobbin thread decrementing counter and a
daily item counter
• The arm shaft of the button sewing machine is directly driven
by a brushless DC motor.
• Speeds of up to 3000 min-1 can be set, in 100 min-1 steps.
• Up to 10 user-defined button patterns can be programmed
and stored.
• A total of 50 button patterns can be stored under the
25 favorite buttons.

Technical Specifications
Operating Instructions 512/532 - 04.0 - 08/2016 13
2.3 Declaration of conformity
The machine complies with the European regulations specified in
the declaration of conformity or in the installation declaration.
2.4 Technical data
Class 512-211-01 512-212-01 532-211-01
Stitch type 301 301 301
Hook type Oscillating hook Oscillating hook Oscillating hook
Number of needles 1 1 1
Needle system 134 | DPx5 134 | DPx5 135x17 | DPx17
Needle thicknesses 80 - 110 | 12 - 18 80 - 110 | 12 - 18 80 - 110 | 12 - 18
Stitch length [mm] Depends on seam
appearance
(0.1 - 10 mm)
Depends on
seam
appearance
(0.1 - 10 mm)
Depends on seam
appearance
(0.1 - 6,8 mm)
Empty transport > 10 possible after
thread cutting
> 10 possible
after thread
cutting
> 10 possible after
thread cutting
Max. speed [min-1]3000 3000 3000
Speed on delivery [min-1]2700 2700 2700
Sewing field size [mm] max. in X direction:
40
max. in Y direction:
30
max. in X
direction: 8,0
max. in Y
direction: 4,0
max. in X direction:
10
max. in Y direction:
10
Number of standard
patterns
50 50 33

Technical Specifications
14 Operating Instructions 512/532 - 04.0 - 08/2016
Dimensional data
Number of storable
modified patterns
50 50 50
Number of sequences 25 25 25
Number of seam
appearances per
sequence
30 30 30
Soft start Can be switched
in and out
Can be switched
in and out
Can be switched
in and out
Operating pressure [bar] -- -- --
Air consumption [NL] -- -- --
Length, width, height
(upper section incl.
packaging)
[mm] 870 /430 / 890 870 /430 / 890 870 /430 / 890
Length, width, height
(upper section only)
[mm] 660 / 230 / 430 660 / 230 / 430 660 / 230 / 430
Weight
(upper section,
excluding controller)
[kg] 69 69 69
Length, width, height
(controller incl.
packaging)
[mm] 600 / 450 / 300 600 / 450 / 300 600 / 450 / 300
Weight (controller
only)
[kg] 18 18 18
Class 512-211-01 512-212-01 532-211-01
Class 512 532
Voltage [V] 230 230
Frequency [Hz] 50 / 60 50 / 60
Power [W] 500 500

Safety Information
Operating Instructions 512/532 - 04.0 - 08/2016 15
3 Safety Information
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 only be used as described in this operating
manual.
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
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.
Setup 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.

Safety Information
16 Operating Instructions 512/532 - 04.0 - 08/2016
Obligations
of the operator
Observe the country specific safety and accident prevention re-
gulations 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
be met by the
personnel
The machine should only be set up by qualified technicians.
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 have read the operating manual
first.
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
equipment
Safety equipment should not be removed or deactivated. If this
cannot be avoided for a repair operation, the safety equipment
must be refitted and put back into service immediately afterwards.

Safety Information
Operating Instructions 512/532 - 04.0 - 08/2016 17
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 endangerment that they describe:
Symbols The following symbols indicate the type of risk to personnel:
Signal word Endangerment
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.
Symbol Type of danger
General risk
Risk of electric shock
Risk of puncturing
Risk of crushing

Safety Information
18 Operating Instructions 512/532 - 04.0 - 08/2016
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 not
complied with.
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 not
complied with.
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 not complied with.
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 material damage if not complied with.