Duerkopp Adler 512/532 User manual

512/532
Operating Manual

All Rights Reserved.
Property of Dürkopp Adler AG and subject to copyright. Any use of this content, or part of it, is
prohibited without prior written permission of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG - 2013

Table of Content
Operating manual 512/532 Version 01.0 - 03/2013 1
1 About this manual ......................................................................3
1.1 Scope of this guide.......................................................................3
1.2 Declaration of conformity..............................................................3
1.3 Applicable documents...................................................................3
1.4 Transport damage ........................................................................3
1.5 Limited liability ..............................................................................3
1.6 Intended use.................................................................................4
2 Safety instructions .....................................................................5
2.1 General Safety Precautions..........................................................5
2.2 Marking of safety instructions.......................................................6
3 Performance description ...........................................................9
3.1 Performance characteristics class 512.........................................9
3.2 Performance characteristics class 532.......................................10
3.3 Technical specifications..............................................................11
4 Operating manual.....................................................................13
4.1 Threading the needle thread.......................................................13
4.2 Adjusting the needle-thread tension...........................................14
4.3 Adjusting the thread regulator.....................................................15
4.4 Winding on the hook thread........................................................16
4.5 Changing the hook thread bobbin...............................................17
4.6 Setting the hook thread tension..................................................18
4.7 Changing the needle...................................................................19
4.8 Adjusting hook feet on the button clamp (class 532)..................20
4.9 Button shank shaper (optional)...................................................21
4.10 Sewing........................................................................................22
5 Settings via software................................................................23
5.1 Control panel ..............................................................................23
5.2 Switching on the sewing machine...............................................24
5.3 Selecting sewing patterns...........................................................24
5.4 Scaling axes ...............................................................................25
5.4.1 Changing the X-axis ...................................................................25
5.4.2 Changing the Y-axis ...................................................................25
5.4.3 Converting the buttonhole gap (class 532).................................25
5.4.4 Converting backtack dimensions (class 512) .............................26
5.5 Setting the speed........................................................................26
5.6 Checking sewing patterns...........................................................26
5.7 Changing sewing patterns..........................................................26
5.8 Winding.......................................................................................26
5.9 Sewing........................................................................................27
5.10 Counter.......................................................................................27
5.11 Interrupting sewing .....................................................................28
5.12 Editing parameters in memory....................................................28
5.12.1 Editing parameters in level M1 ...................................................28
5.12.2 Editing parameters in level M2 ...................................................28
5.13 Protecting standard sewing patterns ..........................................29
5.14 Storing sewing patterns..............................................................29
5.14.1 Mapping memory buttons...........................................................29
5.14.2 Sewing with memory buttons......................................................30

Table of Content
2Operating manual 512/532 Version 01.0 - 03/2013
5.14.3 Deleting the memory button assignments ..................................30
5.15 Storing sewing pattern sequences..............................................30
5.16 Sewing sewing pattern sequences.............................................31
5.17 Deleting sewing pattern sequences............................................31
5.18 Stopping sewing .........................................................................31
5.19 Resetting parameters to the factory settings..............................32
5.20 Editing sewing patterns externally..............................................32
5.20.1 MS Excel or text editor................................................................32
5.20.2 DA-CAD 5000.............................................................................34
5.21 Working with a USB stick............................................................34
5.22 Error messages ..........................................................................36
6 Maintenance..............................................................................39
6.1 Cleaning and inspection .............................................................39
6.2 Lubricate.....................................................................................40
7 Sewing patterns........................................................................43
7.1 Standard sewing patterns class 512...........................................43
7.2 Standard sewing patterns class 532...........................................46
8 Installation Instructions...........................................................47
8.1 Scope of delivery........................................................................47
8.2 General information and transport safety ...................................47
8.3 Installation...................................................................................48
8.3.1 Checking table tops....................................................................48
8.3.2 Assembling the frame.................................................................48
8.3.3 Completing the table top.............................................................49
8.3.4 Assembling the machine head support.......................................50
8.3.5 Adjusting the working height.......................................................51
8.3.6 Fitting the machine head ............................................................52
8.3.7 Fitting the collecting container....................................................53
8.4 Electrical connections.................................................................53
8.4.1 Checking mains voltage..............................................................54
8.4.2 Connecting the cables to the control unit....................................54
8.5 Fitting the cover..........................................................................55
8.6 Fitting the eye guard...................................................................55
8.7 Fastening the button holder (class 532) .....................................56
8.8 Sewing test.................................................................................56
9 Appendix ...................................................................................57
9.1 Drawings.....................................................................................57

About this manual
Operating manual 512/532 Version 01.0 - 03/2013 3
1 About this manual
This operating manual is intended to help the user familiarize themself
with the machine and to enable correct utilization.
The operating manual contains important information on how to operate
the machine safely, correctly and economically. Observation of the in-
structions eliminates danger, reduces costs for repair and downtime, and
increases the reliability and service life of the machine.
1.1 Scope of this guide
This manual describes the intended use and installation of the special
sewing machines 512 and 532.
1.2 Declaration of conformity
The machine conforms with the European regulations stated in the decla-
ration of conformity or incorporation.
1.3 Applicable documents
The machine contains components by other manufacturers, e.g., drive
motors. The respective manufacturers have performed risk assessment
for these supply parts and declared the conformity of their design with per-
tinent European and national regulations. The intended use of the incor-
porated components is described in the respective third-party
manufacturer's guides.
1.4 Transport damage
Dürkopp Adler is not liable for breakage and transport damage. Please
check the delivery carefully immediately on receipt. Claim against the for-
warder for damage. This also applies if the packaging is undamaged.
Leave the machine device and packaging material in the state it was in
when you ascertained the damage. This will help you assert your claim
against the forwarder.
Report all other complaints without delay after receipt of delivery to
Dürkopp Adler.
1.5 Limited liability
All information and instructions for use in this guide were compiled taking
account of the latest state of the art, and applicable standards and regula-
tions.

About this manual
4Operating manual 512/532 Version 01.0 - 03/2013
The manufacturer accepts no liability in case of damage due to:
• failure to observe this guide
• unintended use
• unauthorized modifications to the machine
• use of untrained staff
• breakage and transport damage
• use of non-approved spare parts
1.6 Intended use
The class 512 is a bartacker, the class 532 a button sewer designed for
sewing light to moderately heavy material. Such material generally con-
sists of textile fibres, but can also include leather. It is used in the clothing
industry and for domestic and motor-vehicle upholstery.
Itmayalsobepossibletoproducetechnicalseamswiththisbartacker/but-
ton sewer. In this case, however, the operator must assess the possible
riskswhichmayarise(DÜRKOPPADLERAGwouldbepleasedtoassist),
sincesuch applications are on the one hand relatively unusual and, on the
other, so varied that no single set of criteria can cover them all. The out-
come of this assessment may require appropriate safety measures to be
taken.
Asageneral rule,only drymaterialmaybesewn withthisbartacker/button
sewer. The material must not be thicker than 10 mm (512) or 9 mm (532)
when compressed by the lowered sewing feet. The material may not con-
tain any hard objects.
The seam is typically sewn with sewing threads made from textile fibres
(cotton threads, synthetic threads or core threads) of the following dimen-
sions:
Class 512 Thread thickness dimension 50/3 - 130/3
Class 532 Thread thickness dimension 50/3 - 150/3
Before using any other thread the possible dangers arising must be as-
sessed and appropriate safety measures implemented if necessary.
This automatic sewing machine may only be set up and operated in dry,
well-maintained premises. If the automatic sewing machine is used in
premises which are not dry and well-maintained, it may be necessary to
take further precautions which should be agreed in advance (see EN
60204-31:1999).

Safety instructions
Operating manual 512/532 Version 01.0 - 03/2013 5
2 Safety instructions
This chapter contains basic instructions for your safety.
Read these instructions carefully before you install, program, maintain or
operate the machine.
Always follow the provisions in the safety instructions. Failure to observe
can lead to severe injury and damage to property.
2.1 General Safety Precautions
Only authorised persons must work on or with the machine. Every person
working on or with the machine must read the Operating Guide before do-
ing so.
The machine must only be used as described in this guide.
The Operating Guide must be kept at the machine's place of use.
Pleaseobserveallgeneralsafetyandaccidentpreventionregulationsand
the legal requirements on occupational safety and environmental protec-
tion.
Observe the safety instructions and the operating manual provided by the
motor manufacturer for the drive.
All warning signs on the machine must always be kept in legible state and
must not be removed. Missing or damaged signs must be replaced imme-
diately.
In the following situations, always de-energise the machine at the main
switch or by unplugging the mains plug:
• Threading
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing maintenance work and repairs
Check the machine during use for signs of visible damage. Stop working
if you notice any changes to the machine's behaviour. Report all changes
to the appropriate supervisor. You must not continue using a damaged
machine.
Machines or machine parts that have reached the end of their service life
must not be operated. Dispose of these machines in line with environmen-
tal legislation.
Only qualified and trained staff are allowed to install the machine.
Only qualified and trained staff are allowed to perform servicing, mainte-
nance and repairs.

Safety instructions
6Operating manual 512/532 Version 01.0 - 03/2013
Safety devices must not be removed or disabled. If this is unavoidable for
repairs, the safety devices must be refitted and re-enabled immediately af-
ter completing the repairs.
Work on the machine's electrical equipment must be performed by a qual-
ified electrician.
The connecting cable must have a plug with country-specific approval.
Only a qualified electrician is permitted to connect the plug to the power
cable.
Work on live parts and assemblies is prohibited. Exceptions are regulated
in DIN VDE 0105.
Onlyuseoriginalsparepartsbythemanufacturer.Incorrectorfaultyspare
parts can impair safety and damage the machine.
2.2 Marking of safety instructions
Coloured bars highlight the safety instructions in the text.
Signal words indicate the severity of the risk:
•Danger: Certainty of serious or fatal injury.
•Warning: Risk of serious or fatal injury.
•Caution: Risk of moderate or minor injury.
•Attention: Risk of damage.
Symbols in the text In case of dangers for persons, these symbols indicate the type of danger:
Examples Examples for marking of safety instructions in the text:
General danger
Danger due to pointed objects
Danger due to electric shock
Danger due to crushing
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Warningnoticewherefailuretoobservewillleadto
fatal or serious injury.
DANGER

Safety instructions
Operating manual 512/532 Version 01.0 - 03/2013 7
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Warning notice where failure to observe can lead
to fatal or serious injury.
WARNING
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Warning notice where failure to observe can lead
to moderate or minor injury.
CAUTION
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
This is what environmental protection instructions
for compliant disposal look like. Failure to observe
can lead to environmental damage.
CAUTION
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to damage to prop-
erty.
ATTENTION

Safety instructions
8Operating manual 512/532 Version 01.0 - 03/2013

Performance description
Operating manual 512/532 Version 01.0 - 03/2013 9
3 Performance description
3.1 Performance characteristics class 512
The Dürkopp Adler 512 is a CNC double lockstitching backtacker. The ex-
isting standard backtacking patterns are scalable and can be memorized
in this modified form. The machine is equipped with automatic sewing foot
raising, a thread cutter, a thread wiper, a needle thread clamp below the
sewing plate for a safe sewing start, and integrated DC direct drive includ-
ing a control panel.
Technical specifications
• The sewing unit is driven by a integrated positioning drive. Besides con-
trolling the sewing drive, a control unit also controls 2 step motors
required for the X and Y motions of the seam geometry.
• Clamp lifting is effected by a step motor.
• The maximum size of the sewing field is 40 mm in X direction (trans-
verse direction of arm) and 30 mm in Y direction (longitudinal direction
of arm).
• The machine head is oil-free. This removes the risk of oil soiling the
material to be sewed.
• The hook is lubricated by a wick lubricator from an oil tank in the opera-
tor's field of view.
• 50 pre-programmed backtacks are available. These standard patterns
can be temporarily modified (changes to overall length, overall width,
speed). When the machine is switched off, the modified values for the
last backtack to be used are kept until the machine is powered back on.
• 50 modified standard patterns can also be memorized.
• A maximum of 16,000 stitches can be memorized.
• 25 sequence programs, each with up to 30 sewing patterns per
sequence can be memorized.
• The accuracy of the coordinate input 0.1 mm.
• The machine has a bobbin thread counter and daily item counter.
• The arm shaft is directly driven by a brushless DC motor.
• Speeds of up to 3000 rpm can be set in 100 rpm steps.

Performance description
10 Operating manual 512/532 Version 01.0 - 03/2013
3.2 Performance characteristics class 532
The Dürkopp Adler 532 is a CNC double lockstitching button sewer. The
existing programs are scalable and can be memorized in this modified
form. The machine is equipped with automatic sewing foot raising, a
thread cutter, a thread wiper, a needle thread clamp below the sewing
plate for a safe sewing start, and integrated DC direct drive including a
control panel.
Technical specifications
• The sewing unit is driven by a integrated positioning drive. Besides con-
trolling the sewing drive, a control unit also controls 2 step motors
required for the X and Y motions of the seam geometry.
• Clamp lifting is effected by a step motor.
• The maximum size of the sewing field is 40 mm in X direction (trans-
verse direction of arm) and 30 mm in Y direction (longitudinal direction
of arm).
• The machine head is oil-free. This removes the risk of oil soiling the
material to be sewed.
• The hook is lubricated by a wick lubricator from an oil tank in the opera-
tor's field of view.
• A maximum of 33 standard button patterns is available. These standard
patterns can be temporarily modified (changes to overall length, overall
width, speed). When the machine is switched off, the modified values
for the last backtack to be used are kept until the machine is powered
back on.
• A maximum of 16,000 stitches can be memorized.
• 25 sequence programs, each with up to 30 sewing patterns per
sequence can be memorized.
• The accuracy of the coordinate input 0.1 mm.
• The machine has a bobbin thread counter and daily item counter.
• The arm shaft on the button sewer is directly driven by a brush-less DC
motor.
• Speeds of up to 3000 rpm can be set in 100 rpm steps.
• Up to 10 user-defined button patterns can be programmed and memo-
rized.
• A total of 50 button patterns can be memorized on the 25 shortcut keys.

Performance description
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3.3 Technical specifications
Ratings
Class 512 532
Type of stitch 301 301
Hook type oscillating hook oscillating hook
number of needles 1 1
Needle system 134 | DPx5 135x17 | DPx17
Needle size 80 - 130 | 12 - 20 80 - 110 | 12 - 18
Stitch length [mm] Depending on the seam pattern
(0.1 – 10 mm) Depending on the seam pattern (0.1 – 10 mm)
Max. speed rpm 3000 3000
Factory set speed rpm 2700 2700
Sewing field size [mm] max. in X direction: 40
max. in Y direction: 30 max. in X direction: 40 max. in Y direction: 30
Number of standard patterns 50 33
Number of storable modified patterns 50 50
Number of sequences 25 25
Number of sewing patterns per
sequence 30 30
Soft start can be enabled/disabled can be enabled/disabled
Operating pressure [bar] -- --
Air consumption [NL] -- --
Length, width, height
(machine head incl. packaging) [mm] 870 /430 / 890 870 /430 / 890
Length, width, height (machine head
only) [mm] 660 / 230 / 430 660 / 230 / 430
Weight (machine head, without con-
trol unit) [kg] 69 69
Length, width, height (control unit
incl. packaging) [mm] 600 / 450 / 300 600 / 450 / 300
Weight (control unit only) [kg] 18 18
Class 512 532
Voltage [V] 230 230
Frequency [Hz] 50 / 60 50 / 60
Output [W] 500 500

Performance description
12 Operating manual 512/532 Version 01.0 - 03/2013

Operating manual
Operating manual 512/532 Version 01.0 - 03/2013 13
4 Operating manual
4.1 Threading the needle thread
1. Putthethread reelon thethreadstandandguidetheneedle threadand
the hook thread through the unwinder arm.
• The unwinder arm must be in a horizontal position above the thread
reels.
2. Thread the needle thread as illustrated in the following figure.
Fig. 1: Threading the needle thread
3. After threading, pull about 4 cm of the needle thread out through the
needle.
This guarantees a safe start to sewing.
4. If you are using silicone oil, additionally thread the needle thread in
through the silicone oiler (1).
Risk of injury due to the needle tip and moving
parts
Only thread the needle thread while the automatic
sewing machine is switched off.
CAUTION
1
2
(1) - Silicone oiler (optional) (2) - Guide

Operating manual
14 Operating manual 512/532 Version 01.0 - 03/2013
4.2 Adjusting the needle-thread tension
Fig. 2: Adjusting the needle-thread tension
Pre-tension
When the main tensioner (2) is open, the needle thread must be under
slight residual tension. This residual tension is produced by the pre-ten-
sioner (1).
The pretension also affects the length of the end of the cut-off needle
thread (the starting thread for the next seam).
1. For a shorter starting thread turn the knurled nut (1) clockwise (in the
direction of -).
2. Fora longerstarting threadturn theknurled nut(1)anticlockwise(inthe
direction of +).
Main tension
1. Set the main tensioner (2) as low as possible.
Thecross-overpointofthethreadshouldbeinthecentreofthematerial.
Whenusingthinmaterial,excessivethreadtensioncancauseunwanted
gathering and thread breakage.
Opening the thread tension
Main tensioner (2) opens automatically when cutting the thread and lifting
the material clamp feet.
1
2
(1) - Knurled nut pretension (2) - Main tensioner

Operating manual
Operating manual 512/532 Version 01.0 - 03/2013 15
4.3 Adjusting the thread regulator
Fig. 3: Adjusting the thread regulator
The thread regulator (3) controls the quantity of needle thread required for
stitch formation. The thread regulator must be precisely adjusted for an
optimum result.
With correct setting the needle-thread loop must slide with low tension
over the thickest point of the hook.
1. Release the screw (1).
2. Adjusting the position of the thread regulator (3).
Thread regulator to the left = more needle thread
Thread regulator to the right = less needle thread
3. Tighten screw (1).
Adjustment information:
If the maximum amount of thread is required, the thread tension spring (2)
must be pulled downwards approximately 0.5 mm from its upper end po-
sition.This isthecase ifthe needle threadloop passesthemaximum hook
diameter.
Risk of injury due to the needle tip and moving
parts
Only thread the needle thread while the automatic
sewing machine is switched off.
CAUTION
32
1
(1) - Screw
(2) - Thread tensioning spring (3) Thread regulator

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16 Operating manual 512/532 Version 01.0 - 03/2013
4.4 Winding on the hook thread
Fig. 4: Winding on the hook thread
1. Place the bobbin (5) on the winder shaft (4).
2. Pull the thread through the guide (2) and around the tensioner (1).
3. Wind the thread approx. 5 x anticlockwise around the bobbin core (5).
4. Press the bobbin-winder lever (3) into the bobbin.
5. Start sewing.
• After reaching the set bobbin fill quantity (see Service Manual) the
bobbin winder switches off automatically.
6. After winding, tear off the thread at thread clamp (6).
Tip
If you want to wind on the thread without sewing, you can set thread wind-
ing mode on the control unit.
43
6
2
1
(1) - Tension
(2) - Guide
(3) - Bobbin-winder lever
(4) - Winder shaft.
(5) - Bobbin
(6) - Thread clamp
5

Operating manual
Operating manual 512/532 Version 01.0 - 03/2013 17
4.5 Changing the hook thread bobbin
Fig. 5: Changing the hook thread bobbin
Remove the empty bobbin.
1. Slide the hook cover (3) downwards.
2. Lift the bobbin case flap (1).
3. Remove the bobbin case (2) with bobbin (6).
4. Remove the empty bobbin from the upper part of the bobbin case (2).
Insert a full bobbin.
1. Insert a full bobbin (2) into the upper part of the bobbin case.
2. Pull the hook thread through the bobbin case slot (5) below the tension
spring (7) and into the hole (4).
3. Pull approx. 2.5 cm of hook thread from the bobbin case (2).
• When pulling the hook thread, the bobbin must rotate in the direction
indicated by the arrow.
4. Insert the bobbin case (2).
5. Close the hook cover (3).
Risk of injury due to the needle tip and moving
parts
Onlyfitthehookthreadbobbin while the automatic
sewing machine is switched off.
CAUTION
3
1
62
7
4
25
(1) Bobbin case flap
(2) - Upper part of bobbin case.
(3) - Hook cover
(4) - Hole
(5) - Slot in bobbin case
(6) - Bobbin
(7) - Tension spring

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18 Operating manual 512/532 Version 01.0 - 03/2013
4.6 Setting the hook thread tension
Fig. 6: Setting the hook thread tension
The necessary hook thread tension should be generated by the thread
tension spring (1). The upper part of the bobbin case (3) slowly drops
thanks to its own deadweight if held by the threaded hook thread.
Setting the tension spring
1. Remove the upper part of the bobbin case (3) with the bobbin.
2. Set the tension spring (1) by turning the adjustment screw (2) until the
needed tension value is reached.
3. Insert the upper part of the bobbin case.
Risk of injury due to the needle tip and moving
parts
Thehookthreadtensionmayonlybeadjustedwith
the sewing unit switched off.
CAUTION
3
2
1
(1) - Tension spring
(2) - Adjusting screw (3) - Upper part of bobbin case.