Dürkopp Adler 512 Assembly Instructions Manual
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Dürkopp Adler 512 Assembly Instructions Manual

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512/532
Operating Instructions

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  • Page 1 512/532 Operating Instructions...
  • Page 2 All rights reserved. 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...

  • Page 3: Table Of Contents

    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 Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 4 6.2.1 Checking the oil level ................64 6.2.2 Lubricating with grease ............... 66 Seam appearances ................69 Standard seam appearances for class 512 ......... 69 Standard seam images for class 532 ..........73 Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 5 Connecting the cables to the controller ..........84 8.3.11 Mount the hood ................... 85 8.3.12 Fit the eye protection ................86 Fit the button container (class 532) ............. 87 Sewing test ..................88 Disposal ..................... 89 Appendix .................... 91 Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 6 Table of Contents Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 7: About These Instructions

    About these instructions 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 ...

  • Page 8: Representation Conventions - Symbols And Characters

    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. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 9: Other Documents

    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. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 10: Liability

    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.
  • Page 11 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. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 12 About these instructions Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 13: Technical Specifications

    Technical Specifications Technical Specifications The Dürkopp Adler 512 is a CNC double lockstitch bartack sewing machine. Die Dürkopp Adler 532 is a button sewing machine. Characteristics of the 512 The existing programs are scalable and can be saved in this modified form.

  • Page 14: Characteristics Of The 532

    100 min 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. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 15: Declaration Of Conformity

    Sewing field size [mm] max. in X direction: max. in X max. in X direction: direction: 8,0 max. in Y direction: max. in Y max. in Y direction: direction: 4,0 Number of standard patterns Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 16 600 / 450 / 300 600 / 450 / 300 600 / 450 / 300 (controller incl. packaging) Weight (controller [kg] only) Dimensional data Class Voltage Frequency [Hz] 50 / 60 50 / 60 Power Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 17: Safety Information

    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. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 18 Safety Safety equipment should not be removed or deactivated. If this equipment cannot be avoided for a repair operation, the safety equipment must be refitted and put back into service immediately afterwards. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 19: Signal Words And Symbols Used In Warnings

    ATTENTION Can result in property damage. Symbols The following symbols indicate the type of risk to personnel: Symbol Type of danger General risk Risk of electric shock Risk of puncturing Risk of crushing Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 20 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. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 21 Safety Information CAUTION Type and source of risk Consequences of non-observance Measures for avoiding the risk This is a warning note for a hazard that could result in environmental damage if not complied with. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 22 Safety Information Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 23: Operation

    (2) - Guide Pull the needle thread approx. 4 cm through the needle after threading. This ensures reliable sewing-on. When using silicone oil, also thread the needle thread through the optional silicone oiler (1). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 24: Setting The Needle Thread Tension

    With thin sewn material, excessive thread tension can lead to undesired ruffing and thread bre- akages. Opening the needle thread tensioner The primary tensioner (2) is automatically opened during thread cutting. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 25: Setting The Thread Regulator

    An optimum sewing result is only possible when the thread regulator is exactly adjusted. With the correct setting the needle thread loop must slide over the thickest part of the hook at low tension. Loosen the screw (3). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 26: Winding The Hook Thread

    Pull the thread through the guide (5) and around the tensioner (6). Wind the thread counterclockwise approx. 5 x around the bob- bin core (2). Press the bobbin lever (4) into the bobbin. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 27: Replacing The Hook Thread Bobbin

    ③ ⑥ ② (1) - Bobbin housing flap (5) - Tension spring (2) - Bobbin housing upper section (6) - Bobbing (3) - Hook cover (7) - Bobbin housing slot (4) - Hole Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 28 Pull the hook thread approx. 2.5 cm out of the bobbin housing upper (2).  The bobbin must rotate in the direction of the arrow when pulling out the hook thread. Insert the bobbin housing upper (2). Close the hook cover (3). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 29: Setting The Hook Thread Tension

    Remove the bobbin housing upper section (3) with the bobbin. Adjust the tensioning spring (1) via the adjustment screw (2) until the correct tension is set. Insert the bobbin housing upper section (3). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 30: Changing Needle

    (1) faces the hook tip. Tighten the screw (2). Always adjust the clearance between the hook and the needle after changing to a different needle thickness (see  Service Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 31 Operation manual). Otherwise the following errors can occur: • Changing to a thinner needle: Missing stitches, thread damage • Changing to a thicker needle: Damage to the hook tip, damage to the needle Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 32: Adjusting The Button Mount Of The Button Clamp (Class 532)

    Fig. 8: Adjusting the button mount – standard clamp ① ④ ② ③ (1) - Button mount, left (3) - Knurled screw (2) - Lever (4) - Button mount, right Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 33 Press the Ready button.  Clamp remains raised, pedal is disabled. Loosen the knurled screw (3). Open the button amount to the correct distance using the lever (2). Insert the button. Tighten the knurled screw (3). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 34: Shank Shaper (Optional)

    Manually swing the pivoting lever (2) with shank shaper (3) in and out, with the button clamp raised. Setting the shank length Turn the adjusting screw (1): • Clockwise = Shank becomes longer. • Counterclockwise = Shank becomes shorter. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 35: Sewing

    The sewing machine stops. The clamps remain lowered. Continuing the sewing Press the pedal briefly fully forwards or press process in the middle the Reset button. of the sewing cycle Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 36: Customer Service

    Contact for repairs if machine is damaged: Dürkopp Adler AG Fig. 11: Potsdamer Str. 190 33719 Bielefeld Tel. +49 (0) 180 5 383 756 Fax +49 (0) 521 925 2594 Email: service@duerkopp-adler.com Internet: www.duerkopp-adler.com Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 37: Programming

    Clamps the needle thread on the first stitch. LED on = Needle thread clamp on LED off = Needle thread clamp off Memory button Perform memory functions. Reset button Delete an error and restore settings. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 38: Switching On The Sewing Machine

    Seam appearance memory Save the seam appearance. Switching on the sewing machine Main power switch ON.  The last seam appearance sewn is loaded and the seam appearance number is shown in the Program display. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 39: Referencing The Machine

    Press the Select button until the X axis symbol LED illumi- nates. Press the +/– Function buttons until the desired X axis value is reached. 100 % corresponds to the specified dimensions of the selected seam appearance. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 40: Scaling The X Axis (From Software Version M2.14)

    The button hole clearance is preset to 3.4 mm (3.4 mm = 100 %). The button hole clearance can be set by changing the percentage value. Button hole Button hole Button hole Value [%] Value [%] Value [%] clearance [mm] clearance [mm] clearance [mm] Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 41: Recalculate The Button Hole Clearance (Class 532) (From Software Version M2.10)

    Example Preset dimension in the X direction = 16 mm Desired value in the X direction = 10 mm Value to be set = (100 % : 16 mm) * 10 mm = 62.5 % Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 42: Recalculate The Bartack Dimensions (Class 512) (From Software Version M2.14)

    Press the +/– Function buttons to sew 1 stitch respectively.  The Function display shows the current number of stitches. Press the Reset button.  The clamp raises. Press the Select button until the Seam appearance form symbol LED illuminates. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 43: Changing The Seam Appearance

    Press the pedal forwards.  The bobbin winding process starts. Press the pedal fully forwards to stop the bobbin winding pro- cess. Press the Ready button.  The button LED goes out, the clamp raises. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 44: Sewing

    Each end of sewing decrements the counter by 1. A message is shown in the display when the cycle number is reached. Insert a new bobbin. Press the Reset button.  Counter is reset. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 45: Pausing Sewing

    The memory locations are called up via the +/– Function buttons, the memory locations up to number 25 can also be called up using single seam appearance buttons and combinations of these. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 46: Assigning The Memory Buttons

    • Press the +/– Function buttons and set the values: –5/+5. • Press the Select button until the Y axis symbol LED flashes. • Press the +/– Function buttons and set the values: –4 / Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 47: Sewing With The Memory Buttons

    Press the Ready button to confirm the memory location. Press the Reset button to delete the memory assignment. Press the Ready button to confirm the deletion. Press the Memory button to exit the memory mode. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 48: Saving Seam Appearance Sequences

    Press the Ready button to confirm the seam appearance sequence.  The Program shows the memory location, the Function display shows the number of seam appearances. Press the Memory button to exit the memory mode. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 49: Sewing With A Seam Appearance Sequence

    Press the Ready button to confirm the seam appearance sequence. Press the Reset button to delete the seam appearance sequence. Press the Ready button to confirm the deletion. Press the Memory button to exit the memory mode. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 50: Finishing Sewing

    Function display shows the parameter value. Press the +/– Program buttons to select a different parameter. Press the Ready button to confirm the parameter.  The button LED illuminates. Press the +/– Function buttons to change values. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 51: Editing Parameters At The M2 Level

    Press the Reset button to return a changed value to the ori- ginal value. Press the Ready button to save a change.  The button LED goes out. Press the Memory button.  The button LED goes out. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 52: Resetting Parameters To Factory Defaults

     The button LED illuminates. Use the +/– Program buttons to set parameter number U085. Press the Ready button. Use the +/– Function buttons to enter a function value of 1.  Press the Select button. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 53: Externally Editing Seam Appearances

    ( S. 43). Fig. 13: Sample stitch appearance coordinates in MS Excel or a text editor ① ② (1) - Starting point/first stitch (2) - End point/last stitch Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 54: Working With A Usb Stick

    USB stick. Prerequisite: • Machine is in programming mode, Ready button LED is off. Plug the USB stick into the USB port on the controller.  The controller beeps briefly. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 55 Press the Reset button twice. Deleting a seam appearance from the controller: Value 3 Use the +/– Function buttons to set a value of 3. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 56 Repeat steps 3 to 5 for all further stitches. Press the Ready button to save the edited seam appearance. Press the Reset button.  The button LED goes out. 10. Press the USB button.  The button LED goes out. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 57: Error Messages

    Data not present or stored in • Store the data anew on the wrong format the USB stick. USB read error MOT file faulty • Store the data anew on the USB stick. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 58 • Check the USB stick. USB stick. • Plug in the USB stick again. Data write error Flash memory transfer error • Main power switch OFF. • Repeat the procedure. • Replace the mainboard. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 59 • Main power switch OFF. search error responding • Check the sensor. Thread catcher Thread catcher motor not • Main power switch OFF. motor error running correctly • Check the motor and connections. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 60: Loading Software From A Usb Stick

    The download is finished when no more values are shown in the Function display. You must now wait at least 25 seconds before continuing, otherwise the controller can be damaged! Switch off the controller. Pull out the USB stick. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 61: Loading Seam Appearances

     The button LED illuminates. Use the +/– Program buttons to set parameter number U085. Press the Ready button. Use the +/– Function buttons to enter a function value of 1. Press the Select button. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 62: Checking The Software Version

    • T X.XX = Servo motors • A X.XX = Seam appearances Press the +/– Function buttons and check the respective soft- ware version. Press the Ready button. Press the Memory button.  The button LED goes out. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 63: Maintenance

    Lint and thread remnants should be removed after every 8 hours of operation using a compressed air gun or a brush. When sewing very fluffy material, the machine should be cleaned more frequent- A clean sewing machine provides protection from faults. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 64 • Area around the hook (2) • Bobbin housing and interior • Thread cutter • Area around the needle Fig. 16: Cleaning and checking ① ② (1) - Underside of throat plate (2) - Hook Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 65: Lubrication

    The special grease for lubricating the machine components is provided in the accessory pack. It can also be obtained from DÜRKOPP ADLER AG sales offices using the following part number: • 9047 098004 Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 66: Checking The Oil Level

    The oil level in the oil reservoir (1) must not drop below the lower red marking or be above the upper red marking. Fill oil through the oil filler opening (2) up to the upper red marking. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 67  For lubricating the gear maximum 110 ml are necessary. Fig. 19: Refilling oil (3) ⑤ (5) - Oil gauge glass  When oil splashes at the oil gauge glass during operation enough oil is filled in. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 68: Lubricating With Grease

    Apply an adequate amount of grease to the fleece (2) to lubri- cate the outer side of the cam disk (1). Apply a small amount of grease to the joints (3) to ensure they remain flexible. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 69 (5) - Guide groove Apply a small amount of grease to the inner guide groove (5) and the roller (4) from the outside. Apply a small amount of grease to the joints (6). Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 70 (7) - Thread lever guide (9) - Cross head backside (8) - Groove (10) - Connectors Apply grease to cross head backside (9) and the connectors (10). Lubricate the groove (8). Lubricate the thread lever guide (7). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 71: Seam Appearances

    24 x 3 10 x 2 16 x 2 10 x 2 16 x 2.5 24 x 3 24 x 3 6 x 2.5 6 x 2.5 6 x 2.5 8 x 2 Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 72 Size (mm) X x Y stitches 8 x 2 8 x 2 10 x 0.1 10 x 0.1 25 x 0.1 25 x 0.1 25 x 0.1 35 x 0.1 4 x 20 Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 73 0.1 x 20 0.1 x 10 0.1 x 20 0.1 x 20 10 x 7 12 x 7 10 x 6 12 x 6 7 x 10 7 x 10 24 x 3 Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 74 Stitch diagram Size (mm) X x Y stitches 8 x 2 Ø 12 2.5 x 20 2.5 x 25 2.5 x 25 2.5 x 30 2.5 x 30 2.5 x 30 Ø 8 Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 75: Standard Seam Images For Class 532

    15 / 42 6 - 6 3.4 x 3.4 32 / 50 5 - 5 - 5 3 x 2.5 16 / 43 8 - 8 8 - 8 - 8 10 - 10 Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 76 Seam appearances Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 77: Setup

    Accessory pack containing: • Thread stands • Protective cover • Fastening material Controller parts set: • Main switch • Control panel • Controller Additional equipment: • Frame with table plate, drawer and rods • Pedal Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 78: Removing The Transport Securing Devices

    Crushing is possible. Ensure that the table plate has sufficient load- bearing capacity and strength. The cutouts in self-manufactured table plates must conform to the dimensions specified in the drawing (see Appendix). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 79: Assembling The Frame

    Screw the pedal (2) to the frame brace (3). Slide the pedal (2) so that it sits in the middle of the frame brace (3). The frame brace (3) has elongated holes to allow alignment. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 80: Completing The Table Plate

    Screw the main power switch (3) to the left of the underside of the table plate. Fasten the cables (1) and (2) to the control cabinet (5) on the table plate, using cable fastening nails and strain-relief clamps. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 81 Place the control cabinet (2) on the underside of the table plate. Screw the control cabinet (2) to the underside of the table plate using 3 screws (1), washers, retaining rings and nuts. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 82: Mounting The Upper Section Support

    Mounting the upper section support Fig. 26: Mounting the upper section support ① ② (1) - Upper section support (2) - Hole Insert the upper section support (1) into the hole (2) in the table plate. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 83: Setting The Working Height

    To avoid jamming, slide the table plate in or out evenly at both sides. The scales (1) on the outer sides of the bars serve as an adjustment aid. Tighten both screws (2). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 84: Mounting Upper Machine Section

    Place the sewing machine (3) on the table plate. Fasten the sewing machine (3) at the left and right using the retainers (1) and (2). Screw the retainers in place using the screws (4), hanger (5) and nuts. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 85: Fitting The Oil Collection Reservoir

    3 screws (1). Screw the oil collection reservoir (5) into the retainer (2). Pug the oil line (3) into the oil collection reservoir (5). Plug the rubber mounts (4) into the table plate (6). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 86: Electrical Connection

    8.3.10 Connecting the cables to the controller Fig. 30: Connecting the cables to the controller Connect the cables. All cables are labelled appropriately. Lay the cables to the control cabinet and bundle together with cable ties. Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 87: Mount The Hood

    8.3.11 Mount the hood Fig. 31: Mount the hood ① ② (1) - Hood (2) - Screws Screw the hood (1) to the upper section using 4 screws (2). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 88: Fit The Eye Protection

    8.3.12 Fit the eye protection Fig. 32: Fit the eye protection ② ① (1) - Screws (2) - Eye protection Screw the eye protection (2) to the upper section using 2 screws (1). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 89: Fit The Button Container (Class 532)

    (1) - Screw (3) - Button container (2) - Retainer Screw the retainer (2) to the table plate. Plug the button container (3) into the retainer (2) and secure with a screw (1). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 90: Sewing Test

    Start the sewing test at low speed and then continuously increase the speed. 10. Check that the seams conform to the desired requirements. If not, see chapter setting the needle thread tension ( S. 22). Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 91: Disposal

    ALWAYS observe the legally prescribed regulations for disposal of oil. When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Observe the applicable national regulations for disposal. Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 92 Disposal Operating Instructions 512/532 - 04.0 - 08/2016...

  • Page 93: Appendix

    Appendix 10 Appendix Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 94 Appendix Operating Instructions 512/532 - 04.0 - 08/2016...
  • Page 96 DÜRKOPP ADLER AG Potsdamer Straße 190 33719 Bielefeld GERMANY Phone +49 (0) 521 / 925-00 service@duerkopp-adler.com E-mail www.duerkopp-adler.com...

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