Pfaff 3588-04/020 Instruction Manual
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Pfaff 3588-04/020 Instruction Manual

Pfaff 3588-04/020 Instruction Manual

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3588
-04/020
Instruction Manual
296-12-18 145
Betriebsanleitung engl. 05.99

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Summary of Contents for Pfaff 3588-04/020

  • Page 1 3588 -04/020 Instruction Manual 296-12-18 145 Betriebsanleitung engl. 05.99...
  • Page 2 The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or in part, is only permitted with our previous permission and with written reference to the source. G.M. PFAFF Aktiengesellschaft Postfach 3020 D-67653 Kaiserslautern Königstr. 154 D-67655 Kaiserslautern...

  • Page 3: Table Of Contents

    Table of contents Contents ..................Chapter Register 01 Safety........................... 1 Register 02 Proper use ........................2 Specifications ....................... 3 Disposal of the machine ....................4 Transport, packaging and storage ................5 Explanation of the symbols ..................6 Register 03 Controls ........................7 Register 04 Mounting and commissioning the machine ..............

  • Page 4: Register 01

    Register 01 Contents ..................Chapter Safety ........................1 - 1 Directives ........................1 - 1 General notes on safety .................... Safety symbols ......................1 - 2 Important points for the user ..................1 - 2 Operating and specialist personnel ................1 - 3 .05.01 Operating personnel ....................

  • Page 5: Safety

    Safety Safety Directives This machine was built in accordance with the European regulations stated in the Conformity and Manufacturer’s Declaration. In addition to this Instruction Manual, also observe all generally accepted, statutory and other regulations and legal requirements - also those of the country in which the machine will be operated - and all valid environmental protection regulations! Applicable local regulations of the social insurance society for occupational accidents or other supervisory organizations are to be strictly adhered to!

  • Page 6: Safety Symbols

    Safety Safety symbols Danger! Points to be observed! Danger of injury to operating and specialist personnel! Important points for the user This Instruction Manual is a component part of the machine and must be available to the operating personnel at all times. The Instruction Manual must be read before operating the machine for the first time.

  • Page 7: Operating And Specialist Personnel

    Safety Operating and specialist personnel Operating personnel .05.01 Operating personnel are persons responsible for the preparation, operating and cleaning of the machine as well as taking care of problems arising in the sewing area. The operating personnel is obliged to observe the following points and must: always observe the Notes on Safety in the Instruction Manual! never use any working methods which could reduce the level of safety in using the machine!

  • Page 8: Danger

    Safety Danger A working area of 1 meter is to be kept free both in front of and behind the machine while it is in operation, so that it is always easily accessible. Never reach into the sewing area while sewing! Danger of injury by the needle! Never leave objects on the table while adjusting the machine settings! Objects can become trapped or be slung away!

  • Page 9: Register 02

    Register 02 Contents ..................Chapter Proper use ........................ 2 - 1 Specifications ......................3 - 1 Disposal of the machine ..................4 - 1 Transport, packaging and storage ................5 - 1 Transport to the customer’s premises ............... 5 - 1 Transport within the customer’s premises ..............

  • Page 10: Proper Use

    Proper use Proper use The PFAFF 3588-04/020 is used for folding and sewing on pockets on jeans, workwear and similar garments. Any and all uses of this machine which have not been approved of by the manufacturer are considered to be inappropriate! The manufacturer cannot be...

  • Page 11: Specifications

    Specifications Specifications Sewing head: ..PFAFF sewing head for mechanized sewing units with vertical hook Sewing speed: ................... max. 4000 spm Stitch length: ....................max. 6 mm Stitch type: ....................301 (lockstitch) Needle system: ....................134, 1955 Needle size: ................100 - 140 Nm / MR3 - MR5 Sewing motor: ..................

  • Page 12: Disposal Of The Machine

    Disposal of the machine Disposal of the machine The proper disposal of the machine is the responsibility of the customer. The materials used for the machine are steel, aluminium, brass and various plastics. The electrical equipment consists of plastics and copper. The machine must be disposed of in accordance with applicable local environmental protection regulations.

  • Page 13: Transport, Packaging And Storage

    Transport, packaging and storage Transport, packaging and storage Transport to the customer’s premises Within Germany, machines are delivered without packaging. Machines for export are packaged. Transport within the customer’s premises The manufacturer bears no liability for transport within the customer’s premises or to the location of use.

  • Page 14: Explanation Of The Symbols

    Explanation of the symbols Explanation of the symbols In this Instruction Manual, tasks to be carried out and important information are drawn to your attention by symbols. The symbols have the following meanings: Note, information Cleaning, care Lubrication Servicing, repairing, adjustment, maintenance (only to be carried out by specialist personnel) 6 - 1...

  • Page 15: Register 03

    Register 03 Contents ................Chapter - Page Controls ........................7 - 1 On/off switch ......................7 - 1 Stop switch ........................ 7 - 1 Switch for the inserting function ................7 - 2 Double-start keys ....................... 7 - 4 Handwheel ......................... 7 - 4 Control panel ......................

  • Page 16: Controls

    Controls Controls On/off switch Fig. 7 - 01 By turning on/off switch 1, the power supply to the machine is switched on or off. Stop switch By pressing the stop switch 1, the complete work cycle is stopped. Refer to chapter 10.04 Pro- gram interruption.
  • Page 17 Controls Switch for the loading function The function of the switch 1 can be adapted to the various requirements for loading the workpiece. The foot switch is adjusted via the menu. Refer to chapter 11.05 Functions in the INPUT mode. With the needle strip engaged (needles up) there is danger of injury near the needle strip due...
  • Page 18 Controls Menu combinations Switch functions BASIC POSITION POCKET PLATE BACK Actuation: PLAIN-MATERIAL OFF Fabric suction/needle strip on. actuation: Move pocket plate forward. and further actuations: Switch fabric suction/needle strip on/off. BASIC POSITION POCKET PLATE BACK actuation: PLAIN-MATERIAL OFF Move pocket plate forward/switch fabric suction/needle strip on.

  • Page 19: Double-Start Keys

    Controls Double-start keys Fig. 7 - 04 In MANUAL operation mode, when both double-start keys 1 are activated simultaneously the folder is moved forward and lowered. In AUTOMATIC operation mode, when both double-start keys 1 are activated simultaneously the entire program sequence is started. The double-start keys 1 also are used to continue the program after the bobbin has been replaced or the program has been interrupted.

  • Page 20: Control Panel

    Controls Control panel The control panel 1 consists of the display and two key panels. Clear 1 2 3 4 5 6 7 Enter Fig. 7 - 06 Display .06.01 In the basic screen the messages in the display are divided into three sections: Status bar The status bar is in the upper section of the display.

  • Page 21: Operation-Mode Keys

    Controls Operation-mode keys .06.02 By pressing the corresponding key, one of two possible operation modes can be selected. The selected mode is indicated by the light emitting diode in the respective key. SEWING mode INPUT mode Function keys .06.03 Arrow keys (right/left) - To jump to another menu page - To position the cursor when entering several values in one line Plus/Minus keys...

  • Page 22: Register 04

    Register 04 Contents ................Chapter - Page Mounting and commissioning the machine ............8 - 1 Mounting ........................8 - 1 Removing the transit support bracket ................ 8 - 2 Mounting the spool holder ..................8 - 2 Commissioning ......................8 - 3 Turning the machine on/off ..................

  • Page 23: Mounting And Commissioning The Machine

    Mounting and commissioning the machine After unpacking the machine, check it for any transport damage. In case of damage, inform the shipping company and the responsible PFAFF dealer. The machine must only be mounted and commissioned by qualified personnel! All relevant safety regulations are to be observed! Mounting At the machine’s location, there must be a stable and horizontal surface as well as suitable...

  • Page 24: Removing The Transit Support Bracket

    Mounting and commissioning the machine Removing the transit support bracket Before the machine is commissioned, transit support bracket 1 must be removed! Transit support bracket 1 serves to secure the sewing machine during transit and must not be used during sewing. Fig.

  • Page 25: Commissioning

    Mounting and commissioning the machine Commissioning Fig. 8 - 04 Clean the whole machine thoroughly and check the electrical leads and pneumatic connecting tubes for any damage. Make sure that the mains voltage corresponds to the connection voltage of the machine (see chapter 3 Specifications).

  • Page 26: Turning The Machine On/Off

    Mounting and commissioning the machine Turning the machine on/off Check air pressure on the manometer 1. If necessary, adjust the air pressure on adjusting knob 2. Turn On/Off switch 3 to position "I". After the machine has been switched on, it is always in the automatic sewing mode.

  • Page 27: Adjusting Zero Point

    Mounting and commissioning the machine Adjusting zero point It is necessary to adjust the zero point when the machine is commissioned and after replacing the Controller or one of the proximity switches of the sewing jig transport. Select INPUT mode. Select Input menu function (number key 0).
  • Page 28 Mounting and commissioning the machine ENTER GAUGE POSITION CONFIRM WITH ENTER KEY SM : -11 SM2 : 0 Clear Enter 1 2 3 4 5 6 7 Fig. 8 - 08 If required, correct the position of the sewing jig with the number keys (according to the function shown in the display).
  • Page 29 Mounting and commissioning the machine ENTER NEEDLE POSITION CONFIRM WITH ENTER KEY Clear Enter 1 2 3 4 5 6 7 Fig. 8 - 11 If required, correct the position of the sewing jig with the number keys (according to the function shown in the display).
  • Page 30 Mounting and commissioning the machine ENTER FOLDER POSITION CONFIRM WITH ENTER KEY X : 10 Clear Enter 1 2 3 4 5 6 7 Fig. 8 - 14 If necessary, correct the position of the sewing jig in the X-direction using the number keys according to the functions shown in the display.

  • Page 31: Register 05

    Register 05 Contents ................Chapter - Page Preparation ....................... 9 - 1 Inserting the needle ....................9 - 1 Winding the bobbin thread / adjusting the thread tension ........9 - 2 Changing the bobbin / adjusting the bobbin thread tension ........9 - 3 Threading the needle / adjusting the needle thread tension ........

  • Page 32: Preparation

    Preparation Preparation All regulations and instructions in this Instruction Manual are to be observed! Special attention is to be paid to the safety regulations! All preparation work is only to be carried out by appropriately trained personnel! Inserting the needle Turn the machine off! Danger of injury if the machine starts up suddenly!

  • Page 33: Winding The Bobbin Thread / Adjusting The Thread Tension

    Preparation Winding the bobbin thread / adjusting the thread tension Fig. 9 - 02 Place an empty bobbin 1 onto shaft 2. Thread the bobbin in accordance with Fig. 9-02 and wind it clockwise around bobbin 1 a few times. Cut thread end using thread cutter 3.

  • Page 34: Changing The Bobbin / Adjusting The Bobbin Thread Tension

    Preparation Changing the bobbin / adjusting the bobbin thread tension Fig. 9 - 03 Automatic SEWING If the number of the stitches previously entered via the BOBBIN-THREAD PRESELECT function (see chapter 11.05 Functions in the INPUT mode) has been carried out, the sewing jig automatically moves to the folder station and stops there.

  • Page 35: Threading The Needle / Adjusting The Needle Thread Tension

    Preparation Threading the needle / adjusting the needle thread tension Fig. 9 - 04 Lower presser foot 1 (number key 2). (Thread trapper 2 opens). Thread the needle according to Fig. 9-04. Adjust the needle thread tension by turning knurled screws 3. Raise presser foot 1 (number key 2).

  • Page 36: Selecting A Language

    Preparation Selecting a language Select INPUT mode by pressing the respective key. Depending on the setting and configuration of the machine the displayed status bar may differ from the following example. Clear Enter 1 2 3 4 5 6 7 Fig.

  • Page 37: Selecting A Seam Program

    Preparation Selecting a seam program When changing to a different seam program, please make sure that the part set (folder, pocket plate and sewing jig) correspond to the new seam program. If the wrong combination of parts and seam program is used, the machine may be damaged seriously! Select INPUT mode by pressing the respective key.

  • Page 38: Automatic Change In Program Station

    Preparation Automatic change in program station If you want to change back and forth between two seam programs, a program must be stored in each of both program stations (see chapter 9.06 Selecting a seam program). Select the INPUT mode by pressing the respective key. Depending on the setting and configuration of the machine the displayed status bar may differ from the following example.

  • Page 39: Edge Folder Configuration

    Preparation Edge folder configuration With this function enabled, the program stations (A and B) may have different edge-folder configurations assigned to them. Press the key to call up the INPUT mode. Depending on the machine position and configuration, the illustration of the status line may differ from the following example: Clear Enter...

  • Page 40: Jig Monitor (Optional)

    Preparation Jig monitor (optional) To make it possible to monitor the jig, the sewing jig is given a code using magnets which the control can recognize via an additional device. This is a means of preventing pairing a sewing program with the wrong sewing jig which could cause the needle to break. If the machine is equipped with this optional device, the JIG MONITOR function must be activated, and a jig code must be entered in the sewing program in order to use the jig monitor.

  • Page 41: Determining The Jig Code

    Preparation Determining the jig code .09.02 Fig. 9 - 11 The jig code is entered in the sewing program as a number value (0-99). The code is created on the jig as a binary number by arranging up to 8 magnets in a particular way on carrier 1.

  • Page 42: Changing The Part Set

    Preparation Changing the part set The seam program, parts program and parts (folding set, pocket plates and sewing jig) must match and always be used together! If the wrong combination of parts and seam program is used, the machine may be damaged seriously! Fig.

  • Page 43: Loading Of The Cuttings

    Preparation Loading of the cuttings Fig. 9 - 13 Select the SEWING mode. Fig. 9 - 12 Select the Basic position function. Lay the cutting for the trousers on the table and align it. Loading and alignment of the pocket cuttings depends on the menu combination selected (see chapter 7.03 ).

  • Page 44: Register 06

    Register 06 Contents ................Chapter - Page Sewing ........................10 - 1 Status bar ........................ 10 - 1 Error messages ....................... 10 - 1 Automatic SEWING ....................10 - 2 Program interruption ....................10 - 3 Manual SEWING ..................... 10 - 4 INPUT mode functions ..................

  • Page 45: Sewing

    Sewing Sewing In the SEWING mode you will find functions in automatic and manual SEWING which are used for production and its preparation. The mode can be selected via the corresponding keys on the control panel. Status bar In the upper section of the display the current machine status is displayed by means of symbols and corresponding values.

  • Page 46: Automatic Sewing

    Sewing Automatic SEWING Automatic SEWING is used primarily in this type of production. Press the double-start keys (see chapter 7.04 Double-start keys) or activate the inserting fuction switch (see chapter 7.03 ) to start the program cycle after you have inserted the workpiece. Depending on the stage of the cycle and the machine configuration, different symbols (functions) are displayed.

  • Page 47: Program Interruption

    Sewing Machine in operation BOBBIN : 481 / 10000 Clear Enter 1 2 3 4 5 6 7 Fig. 10 - 04 Symbols in the display: Stop (number key 1) Direct function for stopping the entire program cycle (see chapter 10.04 Program interruption).

  • Page 48: Manual Sewing

    Sewing Manual SEWING Manual SEWING is predominantly used for checking and setting up the machine as well as for altering the program cycle manually. Select the Manual SEWING function (number key 0). BOBBIN : 481 / 10000 Clear Enter 1 2 3 4 5 6 7 Fig.

  • Page 49: Input Mode Functions

    Input mode functions Input mode functions This chapter lists and describes the functions in the INPUT mode. In this mode you will find functions for program management, language selection, machine settings and configuration as well as for service and adjustment work. However, this chapter does not describe how to create seam programs.

  • Page 50: Summary Of The Functions In The Input Menu

    Input mode functions Summary of the functions in the input menu INPUT mode Input menu 1 - PROGRAM MANAGEMENT 1 - DIRECTORY 1 - DIRECTORY OF MEMORY 2 - DIRECTORY OF DISK 1 - READ ONE PROGRAM FROM DISK 2 - READ / WRITE PROGRAM 2 - READ ALL PROGRAMS FROM DISK 3 - WRITE ONE PROGRAM ON DISK 4 - WRITE ALL PROGRAMS ON DISK...

  • Page 51: Summary Of The Service Functions

    Input mode functions Summary of the service functions INPUT mode Input menu 6 - SERVICE 1 - SEWING DRIVE FUNCTIONS 1 - TURN SEWING MOTOR 2 - THREAD TRIMMING PROCEDURE 3 - CUTTING SPEED - PRE-SEL. 2 -STEPPING MOTOR FUNCTIONS 1 - STEPPING MOTOR 1 2 - STEPPING MOTOR 2 3 - MOVE CARRIAGE...

  • Page 52: Selecting Functions From The Menu

    Input mode functions Selecting functions from the menu By using an example, we will now explain how to move about within menu levels. Contrast setting of the display: Select INPUT mode by pressing the corresponding key (the LED in the key lights up). Clear Enter 1 2 3 4 5 6 7...
  • Page 55 Input mode functions 1 - WRITE MACHINE DATA ON DISK 2 - READ MACHINE DATA FROM DISK 3 - CARRY OUT COLD START 4 - DISPLAY SOFTWARE STATUS 5 - CONTRAST SETTING OF DISPLAY Clear 6 - CHANGE CODE NUMBER Enter 1 2 3 4 5 6 7 Fig.

  • Page 56: Functions In The Input Mode

    Input mode functions Functions in the INPUT mode Initial state in the INPUT mode Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 07 Explanation of the symbols in the display: Program station A (number key 1) When this function is active, a seam program previously assigned to this program station is called up for sewing.
  • Page 57 Input mode functions Head functions (number key 7) Opens a menu for selecting various head functions: 1 - STANDARD STITCH LENGTH: 3.2 mm 2 - MAXIMUM SPEED: 4000 RPM 3 - REDUCED SPEED: 4000 RPM 4 - DELAY ZIGZAG ON: 3 STITCHES 5 - DELAY ZIGZAG OFF: 3 STITCHES...

  • Page 58: Change Part Set

    Input mode functions Folder functions (number key 8) Opens a menu for selecting various folder functions: <- - - - > 1 - INTERMEDIATE STOP: 2 - UNI-MATERIAL : 3 - BASIC POSITION POCKET PLATE: FRONT 4 - ALTERNATING FOLDING: Clear 5 - ALTERNATING LABELLING: Enter...
  • Page 59 Input mode functions Parts program functions (number key 9) Opens a menu for entering values which refer to the material and size of the pieces to be worked (see chapter 9.09 Changing the part set). The values are automatically attributed to the selected parts program (see Chapter 11.05, section: Program Number Selection).
  • Page 60 Input mode functions TIME FOR STACK TRESTLE BACK For entering the delay time between the slow rolling movement of the stacker roller and the stack trestle back. TIME FOR EDGE FOLDERS BACK For entering the delay time for the edge folder. The time should be set in such a way that the edge folder only starts moving upwards after the folder plates have positioned in their furthest end position.

  • Page 61: Directory Of Disk

    Input mode functions Input menu (number key 0) Opens a menu for selecting diverse functions from other menu levels: 1 - PROGRAM MANAGEMENT ..2 - CREATE / MODIFY PROGRAM 3 - COUNTER ..4 - SWITCH FUNCTIONS ..5 - TIMES ..

  • Page 62: Read All Programs From Disk

    Input mode functions READ ONE PROGRAM FROM DISK One program to be selected is read into the machine memory from a disk. READ ALL PROGRAMS FROM DISK All programs on the disk are read into the machine memory. WRITE ONE PROGRAM ON DISK One program to be selected from the machine memory is written on disk.
  • Page 63 Input mode functions CREATE / MODIFY PROGRAM After the function has been selected, you can create and/or modify seam programs via the control panel (see chapter 11.06 Creating / modifying seam programs). COUNTER Opens a menu for customizing the counters: 1 - RESET PIECE-COUNTER 2 - THREAD MONITOR ..
  • Page 64 Input mode functions Needle at TDC Needle pierces material, Needle leaves the carriage stops, material, carriage command for carriage start approx. at start is output approx. at 270° 90° Needle in material, continuous area of 180° Fig. 11 - 23 The command for the carriage start is output when the needle pierces the material.
  • Page 65 Input mode functions NEEDLE THREAD MONITOR Switches the needle thread monitor on or off. BOBBIN THREAD MONITOR Switches the bobbin thread monitor on or off. BOBBIN THREAD SENSOR Switches the bobbin thread sensor on or off. LANGUAGE SELECTION Opens a menu where you can select different languages in the display (see chapter 9.05 Selecting a language).
  • Page 66 Input mode functions Version 3 The cut part is held on the table by suction air. After the start button is pressed a frame is lowered for loading the pre-folded pocket. When the start button is pressed again, both parts are transferred to the sewing station.
  • Page 67 Input mode functions SERVICE Opens a menu where you can select service functions: <- - - - > 1 - SEWING DRIVE FUNCTIONS ..2 - STEPPING MOTOR FUNCTIONS ..3 - SWITCH OUTPUTS 4 - DISPLAY INPUTS / OUTPUTS Clear 5 - ADJUST ZERO POINT ..
  • Page 68 Input mode functions SEWING DRIVE FUNCTIONS Opens a menu where you can test the sewing motor: 1 - TURN SEWING MOTOR 2 - THREAD TRIMMING PROCEDURE 3 - CUTTING SPEED - PRE-SEL.: 200 RPM Clear Enter 1 2 3 4 5 6 7 Fig.
  • Page 69 Input mode functions SWITCH OUTPUTS Sets and resets outputs (see chapter 14.03.03 Tables of outputs) DISPLAY INPUTS / OUTPUTS After this function has been selected, the states of the inputs and outputs are displayed: 1 Input actuated / output switched Input not actuated / Output not switched Use the arrow keys to toggle between the input and output display.
  • Page 70 Input mode functions OTHER FUNCTIONS Opens a menu with various other functions: 1 - WRITE MACHINE DATA ON DISK 2 - READ MACHINE DATA FROM DISK 3 - CARRY OUT COLD START 4 - DISPLAY SOFTWARE STATUS 5 - CONTRAST SETTING OF DISPLAY Clear 6 - CHANGE CODE NUMBER Enter...

  • Page 71: Creating / Modifying Seam Programs

    Input mode functions Creating / modifying seam programs The function CREATE / MODIFY PROGRAM allows you to modify seam programs directly on the machine via the control panel. Data records created in this way can still be processed and modified by SYS3000 (and vice versa). A newly created or modified seam program must be executed step by step on the machine to make sure that it matches the sewing jig! Seam program structure...

  • Page 72: Summary Of The Functions In The Initial State (Entering Seam Programs)

    Input mode functions Summary of the functions in the initial state (entering seam programs) .06.03 The function CREATE / MODIFY PROGRAM is only accessible when the machine is in its basic position. If required, a code number must be entered, a sewing pattern inserted and a program number must be selected.

  • Page 73: Explanation Of The Functions In The Initial State (When Entering Seam Programs)

    Input mode functions Explanation of the functions in the initial state (when entering seam .06.04 programs) X: 2500 Y: 0 1 : PROGRAM NUMBER # 500 Clear 1 2 3 4 5 6 7 Enter Fig. 11 - 36 Step-by-step forwards (number key 1) This function allows you to trace the seam pattern step by step in a forward direction;...
  • Page 74 Input mode functions 1 - SCALE UP FACTOR FOR X-AXIS: 1.00 2 - SCALE UP FACTOR FOR Y-AXIS: 1.00 3 - ROTATION ANGLE 0° 4 - MIRROR Clear 1 2 3 4 5 6 7 Enter Fig. 11 - 38 SCALE UP FACTOR FOR X-AXIS Enlarges a block.
  • Page 75 Input mode functions Reference point for coordinates (number key 6) Sets the coordinates in the display to "0", thus creating a new reference point. Delete (number key 8) Deletes the current section. Change (number key 9) Allows you to modify the current section. Activate Insert (number key 0) Allows you to switch between the Insert and Initial state mode.

  • Page 76: Summary Of The Functions In The Insert Mode

    Input mode functions Summary of the functions in the Insert mode .06.05 The Activate Insert can only be selected in the initial state of entering seam programs and after the program header has been traced (see chapter 11.06.03 Summary of the functions in the initial state (entering seam programs)).

  • Page 77: Explanation Of The Functions In The Insert Mode

    Input mode functions Explanation of the functions in the Insert mode .06.06 X: 0 Y: 0 5 : START POINT Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 40 Block (number key 1) Inserts a block at the current position in forward direction. Line (number key 2) A line (straight line) is defined as a direct link between two points.
  • Page 78 Input mode functions STANDARD STITCH LENGTH Determines the stitch length predominantly needed in the program. The standard stitch length is displayed in the status bar during sewing and can be changed at the stitch length control on the machine without having to go into the programming mode. STITCH LENGTH Determines a stitch length for a certain seam section.
  • Page 79 Input mode functions <- - - - > 6 - PROGRAMMABLE OUTPUTS ..7 - SEAM INTERRUPTIONS ..Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 43a ZIG-ZAG Allows you to enter a section for which the zig-zag device at the sewing head is additionally switched on.
  • Page 80 Input mode functions Deactivate Insert (number key 0) Allows you to switch between the Insert and Initial state mode. When the function is active (i.e. displayed on a dark background), the Insert mode is active. The CREATE / MODIFY PROGRAM function can be ended at any time by pressing the operation mode keys (INPUT/SEWING).

  • Page 81: Example For Programming A Seam

    Input mode functions Example for programming a seam .06.07 In the following, the programming of a seam is explained by means of an example. As a pattern for programming we will use a drawing with the corresponding coordinates (see Fig. 11-44). In order to use the seam program, the sewing jig and the corresponding part set must match.
  • Page 82 Input mode functions PROGRAM NUMBER : 4034 Clear PERMISSIBLE 0 - 9999 Enter 1 2 3 4 5 6 7 Fig. 11 - 46 Enter the desired program number via the number keys (e. g. 500 for a seam program to be created) Enter Confirm by pressing Enter.
  • Page 83 Input mode functions X: 2500 Y: 0 2 : JIG CODE # 99 Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 50 Select the Step-by-step forwards function (number key 1). The sewing jig now positions in the starting position. X: 0 Y: 0 5 : START POINT...
  • Page 84 Input mode functions Select the Start sewing function (number key 7). X: -610 Y: 0 6 : START SEWING Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 55 Select Graphical functions (number key 6). <- - - - > 1 - STANDARD STITCH LENGTH 2 - STITCH LENGTH 3 - STITCH WIDTH...
  • Page 85 Input mode functions Confirm by pressing Enter. Enter Press Esc to end entering data for the straight line. X: -546 Y: 0 8 : LINE Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 60 Select Machine functions (number key 9). <- - - - >...
  • Page 86 Input mode functions Select the Line function (number key 2). Move to the line end point (number keys 1 - 4). Enter Press Enter. Press Esc. X: -610 Y: 0 11: LINE Clear 1 2 3 4 5 6 7 Enter Fig.
  • Page 87 Input mode functions X: -610 Y: 1270 14: LINE LINE END POINT ( X: -610 Y: 1270 Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 67 Move to the next end point of the line. Enter Press Enter.
  • Page 88 Input mode functions X: 610 Y: 0 18: ZIGZAG ON S-PAR: Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 71 Select Graphical functions. Select STITCH LENGTH function. Enter the value for the stitch length (e. g. 0.23 mm) Press Enter.
  • Page 89 Input mode functions X: 546 Y: 0 21: ZIGZAG OFF S-PAR: Clear Enter 1 2 3 4 5 6 7 Fig. 11 - 74 Thread trimming Thread trimming Switch on Thread trimming Thread trimming Thread trimming. X: 546 Y: 0 22: THREAD TRIMMING Clear Enter...

  • Page 90: Register 07

    Register 07 Contents ................Chapter - Page Care and maintenance ................... 12 - 1 Cleaning the machine ....................12 - 2 Cleaning the hook ....................12 - 3 Cleaning the blower air filter ..................12 - 3 Cleaning the air filter of the air filter/lubricator unit ..........12 - 4 Checking / regulating air compression ..............
  • Page 91 Register 07 Contents ................Chapter - Page Adjusting the folding, feed and stacker devices ..........13 - 32 .06.01 Aligning the sewing jig ..................... 13 - 32 .06.02 Height of the pocket plate guide ................13 - 33 .06.03 Aligning the pocket plate arm .................. 13 - 34 .06.04 Aligning the pocket plate guide ................

  • Page 92: Care And Maintenance

    Care and maintenance Care and maintenance Clean the entire machine ..................weekly Clean the hook compartment .............. several times daily Clean needle area ................several times daily Check oil level for sewing head lubrication ..........daily before use Lubricate needle bar frame eccentric ............every 2 months Lubricate jig guides ...................

  • Page 93: Cleaning The Machine

    Care and maintenance Cleaning the machine The required cleaning cycle for the sewing machine is dependent on the following factors: Single or multi-shift operation Accumulation of dust from the various fabrics Thus, appropriate cleaning instructions can only be determined on an individual basis for each machine.

  • Page 94: Cleaning The Hook

    Care and maintenance Cleaning the hook Unscrew screws 1. Remove hook gib 2. Turn handwheel until the tip of the bob- bin case 3 penetrates the hook race groove by approx. 5 mm. Remove the bobbin case 3. Clean the hook race. Reinsert bobbin case 3.

  • Page 95: Cleaning The Air Filter Of The Air Filter/Lubricator Unit

    Care and maintenance Cleaning the air filter of the air filter/lubricator unit The filter element 1 must be cleaned whenever the working pressure of 6 bar is no longer achieved. Switch off the machine and ensure that it cannot be switched on accidentally! Turn off compressed air! Unscrew drum 2.

  • Page 96: Checking The Oil Level Of The Sewing Head Lubrication

    Before the machine is first operated or whenever the machine has been at a standstill for a longer period of time, also add a few drops of oil to the hook race. We recommend PFAFF sewing machine oil, Fig. 12 - 06 part no. 280-1-120 144.

  • Page 97: Lubricating Sewing Jig Feed

    Care and maintenance Lubricating sewing jig feed Clear Enter 1 2 3 4 5 6 7 Fig. 12 - 08 Switch off the machine and ensure that it cannot be switched on accidentally! Only use Isoflex Topas L32, high-performance grease, part No. 280-1-120 210. Unscrew the cover of the sewing jig feed.

  • Page 98: Lubricating The Pocket Plate Guide

    Care and maintenance Lubricating the pocket plate guide Switch off the machine and ensure that it cannot be switched on accidentally! Only use Isoflex Topas L32, high-performance grease, part No. 280-1-120 210. Grease the guide at grease nipple 1 using a grease gun every two months for sin- gle-shift operation and monthly for two- shift operation.
  • Page 99 Care and maintenance 12 - 8...

  • Page 100: Adjustment

    Adjustment Adjustment Before beginning any adjustment work, take note of the safety regulations found in chapter 1 Safety of this instruction manual! Notes on adjustments All adjustments in these adjustment instructions are based on a completely assembled machine and must only be carried out by appropriately trained specialists. Covers on the machine which have to be removed for checks and adjustment work and later remounted are not mentioned.

  • Page 101: Removing/Inserting Sewing Head

    Adjustment Removing/inserting sewing head Turn off compressed air! Switch off main switch and ensure that it cannot be turned back on accidentally. Fig. 13 - 01 To remove the sewing head, remove the protective cover 1 (screws 2). Remove the cover plate 3 (screws 4; 6 screws altogether) Unplug pneumatic power supply 5 and electrical power supply 6.

  • Page 102: Adjusting The Sewing Head

    Adjustment Adjusting the sewing head Spacing between sewing head and bedplate .05.01 Requirement When the sewing head is lowered, the distance from the lower edge of the shaft 1 to the bedplate must be 132.8 mm. Fig. 13 - 02 Check the distance between the shaft 1 and the bedplate using adjustment gauge 2.

  • Page 103: Sewing Head Position In Relation To The Bedplate

    Adjustment Sewing head position in relation to the bedplate .05.02 Requirement When the sewing head is lowered, after the screws 3 have been loosened, the presser bar 4 must pass exactly through the corresponding hole in the adjustment gauge 1. Fig.

  • Page 104: Upper And Lower Toothed Belt Guards

    Adjustment Upper and lower toothed belt guards .05.03 Requirement The upper and lower toothed belt guards must be positioned as close as possible over the toothed belt sprockets without touching them. Fig. 13 - 04 Move the upper 1 (screw 2) and lower toothed belt guards 3 (screws 4) at the underside of the sewing head according to the requirement.

  • Page 105: Counterweight

    Adjustment Counterweight .05.04 Requirement In needle bar position BDC the largest eccentricity of the counterweight 1 must be at the top. Fig. 13 - 05 Move needle bar to BDC. Turn counterweight 1 (screws 2) according to the requirement. 13 - 6...

  • Page 106: Preadjusting The Needle Height

    Adjustment Preadjusting the needle height .05.05 Requirement At needle bar position TDC, the distance between the needle point and the adjustment gauge must be approx. 22 mm. 22 mm Fig. 13 - 06 Move needle bar 1 (screws 2) without twisting it according to the requirement. 13 - 7...

  • Page 107: Zero Stitch

    Adjustment Zero stitch .05.06 Requirement When the cylinder plunger 1 is fully extended (straight stitch position), the crank 2 must not carry out any movement when the handwheel is turned. Fig. 13 - 07 Pull out cylinder plunger 1 fully. Turn crank 2 (screw 3) according to the requirement.

  • Page 108: Centering The Needle In The Needle Hole

    Adjustment Centering the needle in the needle hole .05.07 Requirement When the cylinder plunger 5 is fully extended (straight stitch position), adjustment pin 1 must fit precisely into the corresponding adjustment hole of the adjustment gauge 8. Fig. 13 - 08 Insert adjustment pin 1 into the needle bar and screw tight.

  • Page 109: Zigzag Stitch Movement

    Adjustment Zigzag stitch movement .05.08 Requirement When the needle is in TDC, the needle bar 1 must not carry out any movement when the lever 4 is operated. Fig. 13 - 09 Bring needle bar 1 to TDC. Turn eccentric 2 (screw 3), without twisting it, according to the requirement. 13 - 10...

  • Page 110: Needle Bar Rise, Hook-To-Needle Clearance, Needle Height And Needle Guard

    Adjustment Needle bar rise, hook-to-needle clearance, needle height and needle guard .05.09 Requirement In straight stitch position and with the needle bar 2.4 past BDC, 1. the hook point must be at the middle of the needle; the distance between the needle and the hook point must be from 0.05 to 0.1 mm.
  • Page 111 Adjustment 0.05 - 0.1 mm Fig. 13 - 10 Position the hook point at the center of the needle and move the hook bearing according to requirement 1. Make sure that the needle is not pressed against by the needle guard 4. Tighten screws 2.

  • Page 112: Bobbin Case Opener Stroke

    Adjustment Bobbin case opener stroke .05.10 Requirement 1. The front edges of the retaining spring 1 and the retaining trip 7 must be flush with each other. 2. When the bobbin case opener 5 is at its rear point of reversal, the distance between the bobbin case base 6 and the retaining spring 1 must be equal to the thread thickness.

  • Page 113: Counter Presser Lifting Stroke

    Adjustment Counter presser lifting stroke .05.11 Requirement At needle bar position BDC, the counter presser 3 must be positioned at its top point of reversal. Fig. 13 - 12 Move needle bar to BDC. Turn eccentric 1 (screws 2) according to the requirement. 13 - 14...

  • Page 114: Counter Presser Height

    Adjustment Counter presser height .05.12 Requirement When the needle bar is at BDC, the top edge of the counter presser 6 must be 1 mm over the closed hook compartment cover 3. Fig. 13 - 13 Position lever 1 (nut 2) at its lower stop (see arrow). Fit hook compartment cover 3 and turn bracket 4 (screw 5) according to the requirement.

  • Page 115: Counter Presser Position

    Adjustment Counter presser position .05.13 Requirement In straight stitch position, when the needle penetrates, it must be centered in the needle hole of the counter presser 2. Fig. 13 - 14 Pull out plunger 1 until it stops (straight stitch position). Adjust the counter presser 2 (screws 3) according to the requirement.

  • Page 116: Zigzag Stitch Width

    Adjustment Zigzag stitch width .05.14 Requirement At the maximum zigzag stitch width, the needle must not strike against the edge of the counter presser. Fig. 13 - 15 Turn screw 1 (nut 2) according to the requirement. By turning screw 1, the bartack width can be adjusted. 13 - 17...

  • Page 117: Resting Position Of The Roller Lever / Radial Position Of The Control Cam

    Adjustment Resting position of the roller lever / radial position of the control cam .05.15 Requirement 1. When the plunger 1 is retracted, there must be a distance of 0.1 mm between the outer edge of the control cam 6 and the roller of the roller lever 5. 2.

  • Page 118: Thread Catcher Height

    Adjustment Thread catcher height .05.16 Requirement The lower edge of the thread catcher 3 must be positioned at a distance of 0.8 mm above the bobbin case 4. Fig. 13 - 17 Loosen screws 1 and 2. Position the thread catcher 3 above the bobbin case 4. Move the thread catcher 3 (screw 5) according to the requirement.

  • Page 119: Thread Catcher Position And Knife Height

    Adjustment Thread catcher position and knife height .05.17 Requirement When the thread trimmer is in resting position, 1. the front edges of the thread catcher 3 and the knife 5 must be flush with each other. 2. the upper edges of the thread catcher 3 and the knife 5 must be even. Fig.

  • Page 120: Knife Pressure

    Adjustment Knife pressure .05.18 Requirement When the point of the thread catcher 4 is 6 mm in front of the front edge of the knife 4, the cutting edge of the knife must lightly press against the thread catcher 4. 6 mm Fig.

  • Page 121: Bobbin Thread Clamp Spring

    Adjustment Bobbin thread clamp spring .05.19 Requirement The clamp spring 1 must 1. not be pressed down during the movement of the thread catcher. 2. clamp the bobbin thread reliably after it is cut 3. not obstruct insertion and removal of the bobbin case. Fig.

  • Page 122: Manual Cutting Test

    Adjustment Manual cutting test .05.20 Requirement 1. When it is moving forward, the thread catcher 1 must not push along the bobbin thread 3 in front of it. 2. At the front point of reversal of the thread catcher 1, the bobbin thread 3 must lie approx.

  • Page 123: Presser Height

    Adjustment Presser height .05.21 Requirement 1. When the take-up lever is at TDC, the needle point must not extend under the presser 1 when the presser 1 is raised. 2. The presser 1 must be aligned laterally so that the sewing thread is blown out from under the presser 1 when the sewing jig is moved into position.

  • Page 124: Bobbin Winder

    Adjustment Bobbin winder .05.22 Requirement 1. When the bobbin winder is switched on, the bobbin winder spindle must move securely with the winder. 2. When the bobbin winder is switched off, friction wheel 5 must not be driven by drive wheel 1.

  • Page 125: Needle Thread Tension Release

    Adjustment Needle thread tension release .05.23 Requirement For the tension release, the distance between the tension disks must be 0.5 mm. 0.5 mm Fig. 13 - 24 Turn screw 1 (nut 2) according to the requirement. 13 - 26...

  • Page 126: Thread Check Spring And Slack Thread Regulator

    Adjustment Thread check spring and slack thread regulator .05.24 Requirement 1. The stroke of thread check spring 5 must be completed when the needle point penetrates the material (travel of the spring approx. 7 mm). 2. When the thread loop is at its largest when going round the hook, the thread check spring 5 must be lifted slightly above support 1.

  • Page 127: Sewing Head Lifting Cylinder

    Adjustment Sewing head lifting cylinder .05.25 Requirement The up and down movement of the sewing head must be uniform. Fig. 13 - 26 Insert the sewing head and connect. (See chapter 13.04 Removing/inserting sewing head). Adjust the speed (screw 1) and shock absorbing action (screw 2) of the upwards movement of the sewing head, and the speed (screw 3) and shock absorbing action (screw 4) of the downwards movement of the sewing head according to the requirement.

  • Page 128: Synchronizer

    Adjustment Synchronizer .05.26 Requirement After the sewing operation has been completed, the machine is to position at TDC of the take-up lever. Fig. 13 - 27 Allow sewing machine to carry out positioning (switch on/off). Loosen screws 1. Hold synchronizer 2 firmly and bring take-up lever 3 to TDC by turning the handwheel 4. Tighten screws 1.

  • Page 129: Hook Lubrication

    Adjustment Hook lubrication .05.27 Requirement When the machine is running, after approx. 10 seconds a fine line of oil must form on a paper strip 4 held next to the hook. Fig. 13 - 28 Cover sensor 1 with metal ruler. Turn on machine.
  • Page 130 Adjustment Select TURN SEWING MOTOR function. Set the speed to 4000 min using the number keys. When the sewing motor is running, do not reach into the needle area! Danger of injury by the moving parts! Enter Confirm input with the Enter key. Select the start function.

  • Page 131: Adjusting The Folding, Feed And Stacker Devices

    Adjustment Adjusting the folding, feed and stacker devices Aligning the sewing jig .06.01 Requirement The lowered sewing jig must lie evenly and lightly on the table top at both the folding and the sewing stations, and hold the workpiece securely. Fig.

  • Page 132: Height Of The Pocket Plate Guide

    Adjustment Height of the pocket plate guide .06.02 Requirement The lowered pocket plate must be parallel to the top edge of the table. Fig. 13 - 30 Check the requirement using a metal ruler. Loosen screws 1 and 2. Adjust the height of the guide 3 with screw 4 (nut 5) according to the requirement. Turn the plunger (lock nut) of cylinder 6 until the guide 3 is parallel to the table top.

  • Page 133: Aligning The Pocket Plate Arm

    Adjustment Aligning the pocket plate arm .06.03 Requirement When the pocket plate is lowered, it must lie evenly on the table. Fig. 13 - 31 Loosen screws 1. Turn screws 2 (nuts 3) according to the requirement. Tighten screws 1. 13 - 34...

  • Page 134: Aligning The Pocket Plate Guide

    Adjustment Aligning the pocket plate guide .06.04 Requirement Guide 7 must be positioned perpendicular to guide 8 of the sewing jig feed. 90° Fig. 13 - 32 Select the Sewing mode. Machine moves to basic position. Remove pocket plate and insert pocket plate gauge 1. Select INPUT mode.
  • Page 135 Adjustment 90° Fig. 13 - 32 Slide pocket plate gauge 1 to the back and mark front position. Loosen screws 3 and 4. Turn screw 5 (nut 6) according to the requirement. 13 - 36...

  • Page 136: Front Pocket Plate Position

    Adjustment Front pocket plate position .06.05 Requirement When the folder is positioned at zero point, the adjustment holes of the pocket plate and the sewing jig must be aligned. Fig. 13 - 33 Switch on the machine. Select the INPUT mode. Select the FOLDER POSITION function from the service menu (see chapter 11.03 Summary of the service functions).

  • Page 137: Monitoring The Sewing Jig Feed

    Adjustment Monitoring the sewing jig feed .06.06 Requirement 1. In the y-direction, the sewing jig 5 must not be able to move from its zero point more than 5 mm toward the bottom and 260 mm to the top. 2. The proximity switch 3 must be 0.2 mm below the switch vane 1. Clear Enter 1 2 3 4 5 6 7...

  • Page 138: Positioning The Edge Folding Unit

    Adjustment Positioning the edge folding unit .06.07 Requirement When the edge folding unit and pocket plate are lowered 1. Folder arm 4 must be parallel with pocket plate arm 3 and the table top. 2. The pins in folder arm 4 and the bushes 2 in pocket plate gauge 1 must be aligned, and 3.
  • Page 139 Adjustment 19 mm Fig. 13 - 35a Loosen screws 5. Position folder arm 4 by turning and pushing it and by turning screws 6 according to requirements 1 and 2. Tighten screws 5 securely. Turn shock absorber 7 (nut 8) according to requirement 3. Remove pocket plate gauge 1 and fit the folding unit.

  • Page 140: Aligning The Die

    Adjustment Aligning the die .06.08 Requirement When the folder is lowered and the pocket plate is raised at the same time, 1. the bottom edges of the die’s 1 strips must be at a distance of approx. the thickness of the fabric under the underside of the pocket plate. 2.

  • Page 141: Control Sequence Of The Folder Plates

    Adjustment Control sequence of the folder plates .06.09 Pocket style 1.Switching a + b a + b a + b a + b a + b position 2.Switching c + d c + d + e c + d c + d + e c + d position 3.Switching...

  • Page 142: Position Of Folder Plates

    Adjustment Position of folder plates .06.10 Requirement 1. The front edges of the folder plates 1 must be parallel to the die 4. 2. In the initial position, the folder plates 1 must be positioned on all sides approx. 0.1 mm under the lower edges of the strips of the die 4. Fig.

  • Page 143: Position Of Corner Folders

    Adjustment Position of corner folders .06.11 Requirement 1. In folder position, the corner folders 4 must be parallel under the slanted side of the folder plate and overlap by 1 to 2 mm. 2. The corner folders 4 must be positioned 1 to 2 mm under the folder plates depending on the fabric thickness.

  • Page 144: Aligning The Seam In Relation To The Pocket

    Adjustment Aligning the seam in relation to the pocket .06.12 Requirement The seam is to be at the same distance on all sides to the pocket edge. Clear Enter 1 2 3 4 5 6 7 Fig. 13 - 40 Switch on the machine.

  • Page 145: Seam Backtack Distance

    Adjustment Seam backtack distance .06.13 Requirement The distance between the seam backtack and the pocket opening is to be approx. 1 mm. Fig. 13 - 41 Adjust stops 1 (screws 2) on the pocket plate according to the requirement. 13 - 46...

  • Page 146: Stacking Device

    Adjustment Stacking device .06.14 Requirement When it is in operating position, the stacking device 2 must hold the workpiece with the least amount of pressure possible. Fig. 13 - 42 Adjust the pressure at pressure reducing valve 1 according to the requirement. To carry out the adjustments, the outputs Y 52 and Y 51 must be switched.

  • Page 147: Aligning The Feed Rollers

    Adjustment Aligning the feed rollers .06.15 Requirement The lowered feed follers 4 must rest lightly and evenly on the table top, and be positioned parallel to the front edge of the table. Fig. 13 - 43 Turn screws 1 (loosen screws 2 slightly) and the plunger of the cylinder 3 according to the requirement.

  • Page 148: Shaping Folder Plates

    Adjustment Shaping folder plates New installation / self-manufacture of folder plates .07.01 Fig. 13 - 44 Make and/or install the folder plates according to Fig. 13-44. When newly installing or making the folder plates, make sure that they lie behind the corners of the pocket plate by at least the amount of the fabric thickness on the marked spots.

  • Page 149: Slanting The Lateral Folder Plates

    Adjustment Slanting the lateral folder plates .07.02 Do not begin with this work process until the adjustments in chapters 13.06.12 Aligning the seam in relation to the pocket and 13.06.13 Seam backtack distance have been carried out! 30° 30° Fig. 13 - 45 With the folder plates fully extended, transfer the front edges of the stops 1 and the outer edge of the pocket plate 2 to the lateral folder plate.

  • Page 150: Register 08

    Register 08 Contents ................Chapter - Page Controller ........................ 14 - 1 Basic settings/diagnosis/pin assignments ..............14 - 1 .01.01 Base control unit A20 ....................14 - 1 .01.02 Sewing drive A22 ..................... 14 - 4 .01.03 List of parameters - Sewing drive ................14 - 6 .01.04 Stepping motor drive A21 ..................

  • Page 151: Controller

    Controller Controller Basic settings/diagnosis/pin assignments Base control unit A20 .01.01 In the factory, the base control unit is equipped with the necessary operating and ramp software. The software may only be replaced by appropriate specialist personnel. The setting of the rotary switch is for commissioning and/or trouble shooting of the CAN bus systems.
  • Page 152 Controller Diagnostic function 31-38 Indicate number of the node 1-8 to be monitored at the diagnostic LEDs DO8-DO1. Indicate status of the node 1-8 at the diagnostic LEDs DI8-DI1. DI8 = amplifier error (short-circuit) DI7 = - DI6 = - DI5 = Waiting for remote input object (receive status) DI4 = Transmitting output object (transmit status) DI3 = -...
  • Page 153 Controller Operation indicators/Voltage supply LEDs for various operating voltages are provided on top of the device (see sticker on the device). These LEDs are for + 12V, + 15.1V and + 24V. Fuses Mains fuse SI0 (front of device) 3.15 AT +24V supply (front of device) 8 AT +12V supply (front of device)

  • Page 154: Controller

    Controller X 11 (main drive) Signal Signal screening TxD_A RxD_A TxD_B RxD_B A_OC R1_A B_OC R1_B I_OC R2_A R2_B Sewing drive A22 .01.02 Before leaving the factory, the sewing drive controller is equipped with the necessary operating software. This software may only be replaced by appropriate specialist personnel.
  • Page 155 Controller X 3 (Interface) Signal Signal TxD\ RxD\ Index Index\ REF1 REF1\ REF2 REF2\ X 6 (mains) Signal X 14 (motor) Signal 14 - 5...

  • Page 156: List Of Parameters - Sewing Drive

    Controller List of parameters - Sewing drive .01.03 Default Parameter Description Range min. max. (Quick) 3588 (606) 0D minimum speed (in 10 min ( 20 ) (607) 0E maximum speed (in 100 min ( 15 ) (609) 10 positioning speed (in 10 min ( 20 ) (718) 07 rest brake power...

  • Page 157: Stepping Motor Drive A21

    Controller Stepping motor drive A21 .01.04 The stepping motor controller has the following initial setting: DIP switch Step no.: 1000 Step no.: Current reduction active Enable Rotary switch Position B ==> phase current 5.4 A For information on the status indications via LED please refer to chapter 14.02.03 Errors - Stepping motor drive.

  • Page 158: Stacker Motor Drive

    Controller Stacker motor drive .01.05 Before leaving the factory, the stacker motor drive has been set and/or programmed to meet the requirements of this machine. It may only be replaced by a programmed drive. Operation controls LED H1 (yellow) LED H2 (green) Meaning Power off, no function Power on, after approx.

  • Page 159: Error Description

    Controller Error description If an error occurs at the machine, the current operation is interrupted and an error message is displayed. Depending on the gravity of the error displayed, an error-free operation can be achieved by adjusting, checking, different handling etc. If necessary, individual components must be replaced.

  • Page 160: Errors - Sewing Drive

    Controller Errors - Sewing drive .02.02 If an error occurs during an operation with the sewing motor, the operation is canceled and an error message is displayed. The error message is generated by the motor controller and appears on the display of the control panel;...

  • Page 161: Errors - Stepping Motor Drive

    Controller Errors - Stepping motor drive .02.03 If problems occur with the stepping motor drive during the operation, an error might have occurred in the stepping motor controller. The error message is indicated by LEDs on the stepping motor controller. Meaning 01 ROT.
  • Page 162 Controller Additional problems Problem Cause Correction no LEDs are lit - supply voltage missing check supply voltage - supply voltage incorrect connect properly motor is not rotating - signal input current controller and does not have active a holding torque set input to inactive - signal input Enable not active - motor connected incorrectly...

  • Page 163: Errors - Stacker Drive

    Controller Errors - Stacker drive .02.04 If problems occur with the stacker drive during operation, an error might have occurred in the motor drive. In this case, a flashing LED on the motor controller indicates the error. H1(yellow) Condition/ Correction/ flashes cause Comment...

  • Page 164: Errors - Disk Drive

    Controller Errors - Disk drive .02.05 If an error at the disk drive occurs during an operation, the operation is canceled and an error message is displayed. The error message is given out by the disk drive. Some errors are displayed in clear text, others are given in number form (decimal).

  • Page 165: Errors - Stitch Generation

    Controller Errors - Stitch generation .02.06 If an error occurs during the calculation of the stitch data, the operation is canceled and an error message will be displayed. The error message appears in clear text and possibly with a number in brackets. This number indicates the section where the error occurred. Additionally, errors may occur which have not been assigned a special text.

  • Page 166: Tables

    Controller Tables Tables for lock/release functions .03.01 Ref. no. Function Program station A Program station B Program number selection / Station keys programming Automatic change of program station Frame up / down Bobbin thread functions RESET STITCH-COUNTER BOBBIN-THREAD PRESELECT Head functions STITCH LENGTH MAXIMUM SPEED REDUCED SPEED...
  • Page 167 Controller Ref.no. Function Input menu PROGRAM MANAGEMENT DIRECTORY DIRECTORY OF MEMORY DIRECTORY OF DISK READ / WRITE PROGRAM READ ONE PROGRAM FROM DISK READ ALL PROGRAMS FROM DISK WRITE ONE PROGRAM ON DISK WRITE ALL PROGRAMS ON DISK DELETE PROGRAM DELETE ONE PROGRAM IN MEMORY DELETE ALL PROGRAMS IN MEMORY DELETE ONE PROGRAM ON DISK...
  • Page 168 Controller Index Function number LANGUAGE SELECTION GERMAN ENGLISH FRENCH SPANISH ITALIAN POLISH OPTIONS TILT HEAD (BEDPLATE) JIG MONITOR FOLDER VERSION LABEL FEED JIG VERSION CONTINUOUS CARRIAGE MOVEMENT LOCK / RELEASE FUNCTIONS TIMES TIME FOR LABEL CLAMP CLOSED SERVICE SEWING DRIVE FUNCTIONS TURN SEWING MOTOR THREAD TRIMMING PROCEDURE CUTTING SPEED - PRE-SEL.
  • Page 169 Controller Index Function number CONFIGURE MACHINE TILTABLE HEAD VERTICAL HOOK JIG MONITOR LABEL FEED HEIGHT ADJUSTMENT OTHER FUNCTIONS WRITE MACHINE DATA ON DISK READ MACHINE DATA FROM DISK CARRY OUT COLD START DISPLAY SOFTWARE STATUS CONTRAST SETTING OF DISPLAY CHANGE CODE NUMBER 14 - 19...

  • Page 170: Table Of Machine Data (Mdat)

    Controller Table of machine data (MDAT) .03.02 The following input functions are stored: program station A program station B parts program number automatic program change Bobbin thread functions: bobbin thread pre-select Head functions: maximum speed reduced speed delay zigzag on delay zigzag off sewing Folder functions:...

  • Page 171: Tables Of Outputs

    Controller Tables of outputs .03.03 Node A11/X300 Output Denomination Index number OUT1 Y1.1 pocket plate forwards OUT2 Y1.2 pocket plate backwards OUT3 Y2.1 pocket plate up OUT4 Y2.2 pocket plate down OUT5 lift pocket plate on OUT6 Pocket-die solenoid on OUT7 not assignet OUT8...
  • Page 172 Controller Node A13/X300 Ausgang Bezeichnung Index number OUT1 ETSTART start label feed OUT2 no pressure on label retaining clamp or it is open (on edge folder version 4: swivel edge folders 3) OUT3 flap positioning on / variable sewing slot narrow OUT4 flap positioning off/ variable sewing slot...
  • Page 173 Controller Special jobs Node A13/X300 Output Denomination Index number OUT9 stacker motor slowly forwards OUT10 OUT11 S1IND OUT12 S2IND OUT13 OUT9 stacker motor slowly backwards OUT10 OUT11 S1IND OUT12 S2IND OUT13 OUT9 stacker motor fast forward OUT10 OUT11 S1IND OUT12 S2IND OUT13 OUT9...
  • Page 175 Controller Node A13/X400 Input Denomination JIGCODE Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 BOBERR bobbin thread disturbance IN10 ETERR label feed error IN11 ETRDY label feed completed IN12 ETINKL label in clamp IN13 not assigned IN14...

  • Page 176: Reference List

    Reference list Stepping motor 1 71-5200-0517 Stepping motor 2 71-5200-0517 Sewing motor 71-5235-5534 Stacker motor 71-5200-0519 Height-adjustment motor 71-5200-0520 Vacuum blower motor -2/01 71-9100-0051 Vacuum blower motor -4/01 71-9100-0052 Fan - control box 71-9100-0035 CAN node 1 91-291 362-96 CAN node 2 91-291 362-96 CAN node 3 91-291 362-96...

  • Page 177: Inputs

    Inputs E1.1 Pocket plate at front E1.2 Pocket plate at rear E2.2 Pocket plate down E5.1 Folder up E5.2 Folder down E12.2 Flap position off / sewing slot wide Linkage monitoring Presser foot up E31.1 Sewing head lifted E31.2 Sewing head lowered E35.1 Jig up E35.2...

  • Page 178: Connections

    Connections Distribution strip 230 V and 24 V Neutral position SM1 Neutral position SM2 Feed roller down (stacker) Feed roller up (stacker) Central electric plug sewing head E31.1 (sewing head lifted) E31.2 (sewing head lowered) K32 (Thread tension is released) tdopp1 and tdopp2 (double-start keys) E54.1 and E54.2 (frame up/down) tsaug (inserting function switch - suction key)

  • Page 179: Outputs

    Outputs Y1.1 Pocket plate at front Y1.2 Pocket plate at back Y2.1 Pocket plate on Y2.2 Pocket plate off Pocket plate airing on Y5.1 Folder up Y5.2 Folder down Corner folder at front Edge folder 1 at front Edge folder 2 at front Edge folder 3 at front Suction on No pressure on label retaining clamp, or it is open...

  • Page 180: Circuit Diagram - Overview Part 1

    91-191 386-95 Circuit diagram - Overview Part 1 Version 24.07.97 15 - 5...

  • Page 181: Circuit Diagram - Overview Part 2

    Circuit diagram - Overview 91-191 386-95 Version 14.02.97 Part 2 15 - 6...

  • Page 182: Circuit Diagram - Overview Part 3

    91-191 386-95 Circuit diagram - Overview Part 3 Version 24.07.97 15 - 7...
  • Page 183 Circuit diagram - Overview 91-191 386-95 Version 24.07.97 Part 4 15 - 8...

  • Page 184: Circuit Diagram - Overview Part 4

    91-191 386-95 Circuit diagram - Overview Part 5 Version 24.07.97 15 - 9...

  • Page 185: Mains Supply 230 V

    Mains supply 230 V 91-191 360-95 Version 23.07.97 15 - 10...

  • Page 186: Terminals X1

    91-191 367-95 Terminals X1 Version 24.07.97 15 - 11...

  • Page 187: Circuit Diagram A20 + A21

    Circuit diagram A20 + A21 91-191 387-95 Version 14.02.97 15 - 12...

  • Page 188: Circuit Diagram A20 + A22

    91-191 388-95 Circuit diagram A20 + A22 Version 14.02.97 15 - 13...

  • Page 189: Circuit Diagrams

    Circuit diagram A11/L1 Version 05.03.99 15 - 14...

  • Page 190: Circuit Diagram A11/L1

    Circuit diagram A11/L2 Version 24.07.97 15 - 15...
  • Page 191 Circuit diagram A12/L3 Version 24.07.97 15 - 16...
  • Page 192 Circuit diagram A12/L4 Version 24.07.97 15 - 17...
  • Page 193 Circuit diagram A13/L5 Version 05.03.99 15 - 18...
  • Page 194 Circuit diagram A13/L6 Version 05.03.99 15 - 19...
  • Page 196 G.M. PFAFF Aktiengesellschaft Postfach 3020 D-67653 Kaiserslautern Königstr. 154 D-67655 Kaiserslautern Telefon: (0631) 200-0 Telefax: (0631) 172 02 Telex: 45753 PFAFF D Gedruckt in der BRD Printed in Germany Imprimé en R.F.A. Impreso en la R.F.A.

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