DURKOPP 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 – 2013

Contents
Operating Manual 512/532 Version 00.0 - 12/2013 1
1 About this operating manual..............................................................5
1.1 Scope .................................................................................................... 5
1.2 For whom is this operating manual? .....................................................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)...............29
4.9 Shank shaper (optional) ...................................................................... 31
4.10 Sewing.................................................................................................32
4.11 Customer service ................................................................................ 33
5 Settings via the software..................................................................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................................................................................37
5.5.2 Scaling the Y axis................................................................................38
5.5.3 Recalculate the button hole clearance (class 532)..............................38
5.5.4 Recalculate the bartack dimensions (class 512) .................................39
5.6 Setting the speed ................................................................................39
5.7 Checking the seam appearance..........................................................39

Contents
Operating Manual 512/532 Version 00.0 - 12/20132
5.8 Changing the seam appearance ......................................................... 40
5.9 Bobbin winding .................................................................................... 40
5.10 Sewing.................................................................................................41
5.11 Counter................................................................................................41
5.12 Pausing sewing ...................................................................................42
5.13 Disabling standard seam appearances ............................................... 42
5.14 Saving seam appearances.................................................................. 42
5.14.1 Assigning the memory buttons ............................................................43
5.14.2 Sewing with the memory buttons ........................................................44
5.14.3 Deleting the memory button assignments ........................................... 44
5.15 Saving seam appearance sequences ................................................. 44
5.16 Sewing with a seam appearance sequence........................................ 45
5.17 Deleting a seam appearance sequence.............................................. 45
5.18 Finishing sewing..................................................................................46
5.19 Editing parameters in memory ............................................................46
5.19.1 Editing parameters at the M1 level...................................................... 46
5.19.2 Editing parameters at the M2 level...................................................... 47
5.20 Resetting parameters to factory defaults.............................................48
5.21 Externally editing seam appearances ................................................. 49
5.22 Working with a USB stick ....................................................................51
5.23 Error messages ...................................................................................53
5.24 Loading software from a USB stick ..................................................... 56
5.24.1 Loading the main program ..................................................................57
5.24.2 Loading seam appearances ................................................................57
5.24.3 Setting parameter U085 (Class 532)................................................... 58
5.24.4 Checking the software version ............................................................ 58
6 Maintenance.......................................................................................59
6.1 Cleaning and checking ........................................................................ 59
6.2 Lubrication........................................................................................... 61
7 Seam appearances............................................................................65
7.1 Standard seam appearances for class 512......................................... 65
7.2 Standard seam images for class 532 .................................................. 69
8 Setup ..................................................................................................71
8.1 Checking the scope of delivery ...........................................................71
8.2 Removing the transport securing devices ........................................... 71
8.3 Assembly............................................................................................. 72
8.3.1 Checking the table plate......................................................................72
8.3.2 Assembling the frame..........................................................................72
8.3.3 Completing the table plate...................................................................73
8.3.4 Mounting the upper section support .................................................... 74
8.3.5 Setting the working height ...................................................................75
8.3.6 Mounting upper machine section ........................................................76

Contents
Operating Manual 512/532 Version 00.0 - 12/2013 3
8.3.7 Fitting the oil collection reservoir ......................................................... 77
8.3.8 Electrical connection ........................................................................... 78
8.3.9 Checking the mains voltage ................................................................78
8.3.10 Connecting the cables to the controller ............................................... 78
8.3.11 Mount the hood ...................................................................................79
8.3.12 Fit the eye protection...........................................................................79
8.4 Fit the button container (class 532) ..................................................... 80
8.5 Sewing test..........................................................................................81
9 Disposal .............................................................................................83
10 Appendix............................................................................................85

Contents
Operating Manual 512/532 Version 00.0 - 12/20134

About this operating manual
Operating Manual 512/532 Version 00.0 - 12/2013 5
1 About this operating manual
This operating manual 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, 4.11
Customer service.
Consider this operating manual part of the product and keep it on
hand at all times. Be sure to read the manual completely before
using the product for the first time. Only give the product to
someone else along with the operating manual.
1.1 Scope
This operating manual describes the set-up and intended use of
the special sewing machines 512 and 532.
1.2 For whom is this operating manual?
This operating manual is for:
• Operators:
This group of employees has been trained in operating the
machine and can access the operating manual.
Specifically,  4 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,  8 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  3 Safety
instructions.

About this operating manual
Operating Manual 512/532 Version 00.0 - 12/20136
1.3 Representation conventions – symbols and
characters
Various information in this operating manual is represented or
highlighted by the following characters in order to facilitate easy
and quick understanding:
Correct setting
Indicates proper setting.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Steps to be performed when operating the machine
(sewing and 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 this operating manual
Operating Manual 512/532 Version 00.0 - 12/2013 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
designated. 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
determining 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
applicable European and national regulations. The proper use of
these components is described in each manufacturer's manual.

About this operating manual
Operating Manual 512/532 Version 00.0 - 12/20138
1.5 Liability
All information in this operating manual was compiled with
consideration to the state of the art, and applicable standards and
regulations.
The manufacturer cannot be held liable for damages resulting
from:
• Breakage and transport damages
• Failure to observe operating manual
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
1.5.1 Transport
Dürkopp Adler cannot be held liable for breakage and transport
damages. Inspect the delivery immediately upon receiving it.
Report any damage to the last transport manager. This applies
even if the packaging is undamaged.
Leave machines, equipment and packaging material in the
condition in which they were found when the damage was
discovered. This will ensure any claims against the transport
company.
Report all other complains to Dürkopp Adler immediately after
receiving the product.
1.5.2 Proper use
The Dürkopp Adler 512/532 is intended for sewing light to
moderately 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 this operating manual
Operating Manual 512/532 Version 00.0 - 12/2013 9
The machine may only be set up and operated in dry conditions
on well-maintained premises. If the machine is operated on
premises that are not dry and well-maintained, then further
measures may be required which must be compatible with EN
60204-31:1999.
Only authorized/trained personnel may operate the machine.
The manufacturer cannot be held liable for damages resulting from
improper use.
WARNING
Risk of electric shock, crushing and punctures!
Improper use can result in injury.
Please observe all instructions in the manual.
ATTENTION
Improper use can result in property damage.
Please observe all instructions in the manual.

About this operating manual
Operating Manual 512/532 Version 00.0 - 12/201310

Technical Specifications
Operating Manual 512/532 Version 00.0 - 12/2013 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
direction (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
danger 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
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.
• 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
Operating Manual 512/532 Version 00.0 - 12/201312
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
direction (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
danger 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 Manual 512/532 Version 00.0 - 12/2013 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 512 532
Stitch type 301 301
Hook type Oscillating hook Oscillating hook
Number of needles 1 1
Needle system 134 | DPx5 135x17 | DPx17
Needle thicknesses 80 - 130 | 12 - 20 80 - 110 | 12 - 18
Stitch length [mm] Depends on seam
appearance
(0.1 - 10 mm)
Depends on seam
appearance
(0.1 - 10 mm)
Max. speed [min-1]3000 3000
Speed on delivery [min-1]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 seam appearances
per sequence
30 30
Soft start Can be switched
in and out
Can be switched
in and out

Technical Specifications
Operating Manual 512/532 Version 00.0 - 12/201314
Dimensional data
Operating pressure [bar] -- --
Air consumption [NL] -- --
Length, width, height
(upper section incl. packaging)
[mm] 870 /430 / 890 870 /430 / 890
Length, width, height
(upper section only)
[mm] 660 / 230 / 430 660 / 230 / 430
Weight
(upper section, excluding
controller)
[kg] 69 69
Length, width, height
(controller incl. packaging)
[mm] 600 / 450 / 300 600 / 450 / 300
Weight (controller only) [kg] 18 18
Class 512 532
Class 512 532
Voltage [V] 230 230
Frequency [Hz] 50 / 60 50 / 60
Power [W] 500 500

Safety Information
Operating Manual 512/532 Version 00.0 - 12/2013 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 manual 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
Operating Manual 512/532 Version 00.0 - 12/201316
Obligations
of the operator Observe the country specific safety and accident prevention
regulations 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 Manual 512/532 Version 00.0 - 12/2013 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:
Examples Examples of the layout of the warnings in the text:
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
Operating Manual 512/532 Version 00.0 - 12/201318
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.
ATTENTION
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that could result
in material damage if not complied with.