Duerkopp Adler 511 User manual

511
CNC-Automat für Riegel- und Kurznähte
CNC automat for bartacking seams
and short seams
Bedienanleitung / Operating Instructions
Aufstellanleitung / Installation Instructions
Serviceanleitung / Service Instructions
Postfach 17 03 51, D-33703 Bielefeld Potsdamer Straße 190, D-33719 Bielefeld
Telefon [phone] Telefax+49(0)521/9252435www.duerkopp-adler.com
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Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
08/2009 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 511001

Alle Rechte vorbehalten.
Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise
Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG
verboten.
All rights reserved.
Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner,
even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.
Copyright © Dürkopp Adler AG - 2009

Foreword
This instruction manual is intended to help the user to become familiar
with the machine and take advantage of its application possibilities in
accordance with the recommendations.
The instruction manual contains important information on how to
operate the machine securely, properly and economically. Observation
of the instructions eliminates danger, reduces costs for repair and
down-times, and increases the reliability and life of the machine.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the machine/sewing
unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
–Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
–Service (maintenance, inspection, repair) and/or
–Transport.
The user also has to assure that only authorized personnel work on the
machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

General safety instructions
The non-observance of the following safety instructions can cause
bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the
instruction book and operated by persons with appropriate training.
2. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot, needle
plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as
the entire sewing unit is found to comply with EC directives.
13. The line cord should be equipped with a country-specific mains
plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).
It is absolutely necessary to respect the safety
instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.

Contents Page:
Preface and General Safety Instructions
Part 1: Operating Instructions for Class 511
(Edition 08/2009)
1. Product Description ........................................... 3
2. Proper and Intended Use ........................................ 4
3. Sub-classes ................................................. 5
4. Additional Equipment .......................................... 5
5. Frame ..................................................... 6
6. Technical Specifications......................................... 6
6.1 Sub-class-specifictechnicalparameters................................ 7
7. Operations
7.1 Threading the needle thread ....................................... 8
7.2 Adjusting the needle thread tension ................................... 9
7.3 Opening the needle thread tension ................................... 9
7.4 Adjusting the thread regulator ...................................... 10
7.5 Winding the bobbin thread ........................................ 11
7.6 Replacing the shuttle bobbin ....................................... 12
7.7 Adjusting the bobbin thread tension ................................... 13
7.8 Replacing the needle............................................ 14
8. Operating the 511 Controller
8.1 The control panel .............................................. 15
8.1.1 Thekeys................................................... 15
8.2 Userinterface................................................ 17
8.2.1 Structureofmenu.............................................. 17
8.3 Alternumericalvalues,parametervalues,selectionofalternatives................ 18
8.3.1 Alternumericalvalues........................................... 18
8.3.2 Selectionofaparameter.......................................... 19
8.3.3 Selectionofalternatives.......................................... 19
8.4 Seampattern ................................................ 20
8.5 Powersavingmode............................................. 20
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Contents Page:
8.6 Mainmenu.................................................. 21
8.6.1 Seam pattern operation .......................................... 21
8.6.2 Programmingmode............................................. 26
8.6.3 Seam pattern sequences ......................................... 30
8.6.3.1 Switching the sequence programming mode on or off ........................ 30
8.6.3.2 Programming a sequence ......................................... 33
8.6.4 Technicianmode .............................................. 34
8.7 DistributorPCB............................................... 78
8.8 Error messages ............................................... 80
8.8.1 Error categories ............................................... 80
8.8.2 Application messages ........................................... 81
8.8.3 Machine faults (DACIII) .......................................... 83
9. Sewing .................................................... 87
10. Maintenance
10.1 Cleaning and checking ........................................... 88
10.2 Oillubrication................................................ 89
11. Standard Seam Patterns ......................................... 90
12. Clamping Feet ............................................... 97

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1. Product Description
The Dürkopp Adler 511 is a CNC machine for bartacking seams and
short seams. The available standard bartacks are size-adjustable and
can additionally be saved in this modified shape.
Free seam contours can be programmed directly at the control panel
without any further devices.
Technical features
–DAC control unit with control panel.
The following functions are available:
–50 standard bartacks.
These bartacks can temporarily be modified in respect to
length, width and speed. When switching off the machine, the
modified values of the bartack last sewn are maintained.
–40 modified bartacks can also be saved.
–9 free seam contours with a total of 5000 available stitches
canalsobesaved.
So it is possible to attach small appliqués.
The coordinates are entered at the control panel. No further
devices are required.
–25 seam pattern sequence programs with up to 20 seam
patterns per seam pattern sequence program can be created
and saved.
–The coordinates are entered with a precision of 0.1 mm.
–If there is a rectangular contour of the fabric clamping feet, the
modification of bartacks is automatically checked in order to
avoid a collision of needle and fabric clamping feet.
–Counters are available for capacity and daily number of
pieces.
–Bartacks and seam pattern sequence programs and the
modification of special bartacks can be blocked.
–The speed can be changed from 0 rpm (manual operation with
full operability of the x-y drive) up to 2700 rpm in steps of 100
rpm.
–Fabric drive via two step motors.
–Drive of the automatic bartacker directly at the arm shaft via
brushless direct current motor.
–Maximum sewing field size 40 x 20 mm.
–Oil wick lubrication of arm shaft and driving shaft with two oil
reservoirs.
–Service and maintenance work is supported by a comprehensive
test programs.
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2. Proper and Intended Use
The class 511 machine is a bartacking machine designed for sewing
light to medium-heavy material. Such material is generally made of
textile fibres, but it may also be leather. Such fabrics are used in the
clothing industry and for domestic and motor-vehicle upholstery.
Furthermore, this automatic bartacker can also sew “technical” seams.
In such a case, the operator must assess the possible dangers which
may arise (preferably in conjunction with DÜRKOPP ADLER AG). Such
applications are relatively unusual and also so varied that no single set
of criteria can cover them all. You may need to take appropriate safety
measures based on the outcome of this assessment.
Generally, only dry fabrics can be processed on this automatic
bartacker. The material may be no thicker than 10 mm when
compressed by the lowered sewing feet. The material should not
contain any hard objects. If hard objects are present, the machine must
be operated with protective eye wear. We currently do not provide such
eye protection.
In general the seam is produced with sewing threads made of textile
fibres (cotton threads, synthetic threads or core threads) with the
following dimensions:
Class 511-211/212 threads of the dimension 50/3 - 120/3
Class 511-213/214 threads of the dimension 30/3 - 120/3
If other threads are to be used, it is important to consider the possible
risks and to take corresponding safety measures.
This automatic bartacker must only be installed and operated in dry
and well-kept rooms. If it is operated in other spaces which are not dry
and well-kept, further measures may need to be agreed upon (see
EN 60204-31: 1999).
As manufacturers of industrial sewing machines, we proceed on the
assumption that personnel who work on our products will have
received training at least sufficient to acquaint them with all normal
operations and with any hazards which these may involve.
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3. Sub-classes
Class 511-211 Automatic single-needle lockstitch bartacker with thread trimmer and
thread wiper.
Equipped with special sewing equipment for general bartacking
operations in outer garments.
With electro-magnetic sewing foot lift.
Class 511-212 Automatic single-needle lockstitch bartacker with thread trimmer and
thread wiper.
Equipped with a contraction clamp specially for bartacking
double-chainstitch buttonholes.
With electro-magnetic sewing foot lift.
Class 511-213 Automatic single-needle lockstitch bartacker with thread trimmer and
thread wiper.
Equipped with special sewing equipment for particularly thick fabrics.
Field of application:
General bartacking operations, e.g. bartacking of loops, pockets or fly
pieces in jeans or working clothes.
With electro-magnetic sewing foot lift.
Class 511-213 Automatic single-needle lockstitch bartacker with thread trimmer and
thread wiper.
Equipped with a special sewing equipment for particularly thick fabrics.
Field of application:
General bartacking operations, e.g. bartacking of loops, pockets or fly
pieces in jeans or working clothes.
With electro-magnetic sewing foot lift.
4. Additional Equipment
The following optional equipment is available for the automatic
bartacker 510:
Order no. Optional equipment
Refer to Parts List Special clamping foot set (optional/special manufacture, APC)
0510 59 015 4 Electric thread wiper (511-211, -213, -214)
0510 59 006 4 Pneumatic sewing foot lifting (511-211, -213, -214)
0510 59 012 4 Separate pneumatic sewing foot lift (pneum. control unit)
and sewing foot lift arm are on right and left (511-211, -212, -213, -214).
9780 00 010 8 Maintenance unit
0510 59 009 4 Conversion set for -211 to -213
0510 15 001 4 Large capacity hook; conversion kit for classes (511-211, -212, -213)
0510 59 004 4 Laser marking light (3 lights)
0510 59 003 4 Additional laser light
0510 59 005 4 Hand switch
9822 51 002 6 Sewing light
9822 51 002 7 Table clamp
9870 00 102 1 Cable assembly K (add-on kit socket for sewing light)
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5. Frame
The following stand is available for the automatic bartacker 511:
MG55 40 029 4 Stand package
Table top size 600 x 1060 mm
Stand height 1160 to 1305 mm
MG53 40 148 4 Stand package (China)
Table top size 600 x 1060 mm
Stand height 1160 to 1305 mm
6. Technical Specifications
Noise level: Lc = 78dB (A)
Workplace-related emission value according to
DIN 45635-48-A-1-KL-2:
Bartack length: 15 mm
Stitch/bartack: 28
Throw width: 2.5 mm
Speed: 2700 min-1
Fabric: G1 DIN 23328 two-ply
Sewing cycle: 1.3 sec on and 1.0 sec off

6.1 Sub-class-specific technical parameters
Sub-class: -211 -212 -213 -214
Stitch type: 301 301 301 301
Hook type: oscillating hook
Needle system: DPx5 (134) DPx17 (135x17)
Needle size: [Nm] 90 90 120 120
Needle size [Nm]
standard production:
Thread size: 50/3 - 120/3 50/3 - 120/3 30/3 - 120/3
Stitch length: [mm] dependent on seam pattern
Max. speed [min-1] 2700
Clamp stroke [mm]
Delivery 13
maximum 17
Sewing field size [mm]
Max. in X-direction: 40
Max. in Y-direction: 20
Number of standard bartacks 50
Number of storable
modifiable bartacks 40
Number of seam-pattern
sequence programs 25
Number of seam patterns per
seam-pattern sequence program 20
Soft start: connectable / dis-connectable
Operating pressure: [bar] 6
Air consumption: [NL] 3
Sewing drive: DC motor
Rated voltage: [V] 1 ~ 230V/ 50/60 Hz
Rated load: [kW] 0.45
Length, width, height [mm] 730 / 1060/ 1160 - 1305
Weight [kg] 125
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7. Operations
7.1 Threading the needle thread
Caution – Risk of Injury !
Turnthemainswitchoff!
Insert the needle thread only when the automatic bartacker
is switched off.
–Put thread reels on the thread reel holder and insert needle thread
and bobbin thread through the unwinding arm.
The unwind holder must be perpendicular to the reel.
–Thread the needle thread as shown on the following illustration.
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7.2 Adjusting the needle thread tension
Pretension 3
With the main tension 2 open, a minor residual stress of the needle
thread is required. This residual tension is created by the
pre-tensioner 3.
The pre-tensioner 3 influences both the length of the cut needle thread
and the starter thread for the next seam.
–Shorter starter thread:
Turn knurled nut 1 in clockwise direction.
–Longer starter thread:
Turn knurled nut 1 counter-clockwise.
Main tension 2
The control unit is used to adjust the main tension 2.
A maximum of five thread tension ranges can exist for one seam
pattern. (Refer to the chapter on “Controller Operations”.)
7.3 Opening the needle thread tension
Automatic
The needle thread tension is automatically opened when trimming the
thread and when lifting the fabric clamping feet.
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7.4 Adjusting the thread regulator
Caution – Risk of Injury !
Turnthemainswitchoff.
Adjust thread regulator only when the automatic bartacker is switched
off.
The thread regulator 3 is used to control the quantity of needle thread
required by the stitch formation.
The best sewing results can only be ensured when using a precisely
adjusted thread regulator.
At the properly adjusted setting, the needle thread loop must be able to
slide over the thickest section of the hook.
–Loosen screw 1.
–Change the position of the thread regulator 3.
Thread regulator to the left = more thread.
Thread regulator to the right = less thread.
–Tighten screw 1.
Settings note:
If the largest thread quantity is required, the thread controller spring 2
must be pulled down by approx. 0.5 mm from its upper end position.
This occurs when the needle thread loop passes the section of the
hook with the widest diameter.
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7.5 Winding the bobbin thread
–Put bobbin on bobbin winder 4.
–Pull thread through guide 2 and around tension 1.
–Wind thread counter-clockwise around the core of the bobbin
(approx. 5 times).
–Press the bobbin-winder lever 3 in the bobbin.
–Sew.
The winder lever stops as soon as the bobbin is full.
–Tear off thread at thread clamp 5 after winding up is finished.
Note!
If the thread is to be wound on without sewing, the thread winding
mode can be altered in sub-menu “Special functions”.
If the thread winding mode is active, the sewing motor can be started
via pedal or push button independent of the sewing field drive
(unthread at the thread lever).
For adjustment, see chapter 8.5.1 “Thread winding mode”.
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: Off
:On
: ...
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7.6 Replacing the shuttle bobbin
Caution – Risk of Injury !
Turnthemainswitchoff.
Change hook thread bobbin only when automatic bartacker
is switched off.
Taking off the empty bobbin
–Pull down hook cover 3.
–Raise up the bobbin enclosure hood 1.
–Take out the upper part of the bobbin enclosure 2 with the bobbin 6.
–Remove the empty bobbin from the upper part of the bobbin
enclosure 2.
Inserting a full bobbin
–Place full bobbin in the top of bobbin case 2.
–Thread bobbin thread through slot 5 below tension spring 7 in the
drill-hole 4.
–Pull out the tension spring from the bobbin enclosure 2 about
2.5 cm.
When the thread is being pulled out, the bobbin must rotate in the
direction shown by the arrow.
–Replace bobbin housing 2.
–Close bobbin enclosure hood 3.
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7.7 Adjusting the bobbin thread tension
Caution – Risk of Injury !
Turnthemainswitchoff.
Adjust the bobbin thread tension only when the automatic bartacker is
switched off.
The required bobbin thread tension should be generated by tension
spring 1. The top of bobbin case 3 should drop slowly due to its own
weight when being held at the threaded-in bobbin thread.
Setting the tension spring
–Take off top of bobbin case 3 with the bobbin.
–Adjust tension spring 1 at the regulating screw 2 until the required
tension value is reached.
–Reinsert top of the bobbin case.
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7.8 Replacing the needle
Caution – Risk of Injury !
Turnthemainswitchoff.
Change the needle only when the automatic bartacker is switched off.
–Loosen screw 1.
–Push in the new needle until it reaches the limit stop in the hole for
the needle bar 2.
CAUTION !
The hollow groove 3 of the needle must point to the hook.
–Tighten screw 1.
CAUTION !
After the changeover to another needle size, the distance between
hook and needle has to be corrected (see service instructions).
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8. Operating the 511 Controller
8.1 The control panel
A control panel with an LCD display and function keys is used for input
and output of data.
8.1.1 The keys
Function key Function
Cursor keys
If no text field is activated:
Press the “ï” key to return from a sub-menu to the parent menu.
If a text field is activated:
Change between the points (this does not refer to the selection of
seam patterns or sequences).
In the sewing mode during sequence operation:
Change to the next or to the preceding seam pattern.
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Function key Function
If no text field is activated:
Change between the lines of the menus.
The selected line is displayed white on black.
If a text field is activated:
Increase or reduce the value of the respective point by one, or change
between the parameters in the event that there are functions with
several choices.
OK key If no text field is activated:
Activate the text field.
The value can be altered with the “ñ” and “ò”keys.
If a text field is activated:
The set value is applied.
If the clamping foot has been lowered using the keys OK + F:
The test procedure will be started.
ESC key If test functions are activated (Multitest / 180° disc):
You return to the selection menu.
If a text field is activated:
An input will be aborted.
The preceding value is maintained.
In the technician and programming level
The control changes over to the sewing mode.
In the sewing mode:
Lift clamping foot and stop sewing operation.
P key The control unit changes over from the sewing mode to the
programming mode.
In this mode, altered stitch patterns can be saved under a new
program number.
S key The control unit changes over from the sewing mode or seam pattern
programming mode to the sequence programming mode.
In this mode it is possible to create new sequences or to alter existing
ones.
F key The control changes over from the sewing mode to the technician
mode.
This mode can only be activated after a code has been entered.
In this operating status it is possible to set basic machine parameters
and to retrieve diagnostic and adjustment programs.
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