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Pfaff 2481-980/30 PLUSLINE Adjustment Manual

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Enlarged version
2481
-3/01-980/30
ADJUSTMENT MANUAL
This instruction manual applies to machines
from the serial number 2 809 573 and
software version 0307/010 onwards.
296-12-19 273/002
Adjustment manual in English 05.16

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Summary of Contents for Pfaff 2481-980/30 PLUSLINE

  • Page 1 2481 -3/01-980/30 ADJUSTMENT MANUAL This instruction manual applies to machines from the serial number 2 809 573 and software version 0307/010 onwards. 296-12-19 273/002 Adjustment manual in English 05.16...
  • Page 2 Reprinting, reproduction and/or translation of PFAFF instruction manuals (including parts thereof) is only permitted with our prior agreement and citation of the source. PFAFF Industriesysteme und Maschinen GmbH Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern...

  • Page 3: Table Of Contents

    Table of Contents Contents ..................Page Adjustment ........................... 5 Notes on adjustment ......................5 Tools, gauges and other accessories ..................5 Abbreviations ......................... 5 Explanation of symbols ......................5 Checking and adjustment aid ....................6 Adjusting basic machine ......................7 .06.01 Machine drive home position ....................
  • Page 4 Sewing motor errors ......................48 Service menu ........................49 Internet update of machine software .................. 50 Circuit Diagrams ........................ 51 Block diagram of PFAFF 2481 with control unit P322 ED ............ 51 Circuit diagrams ........................52 Plug connections ......................... 57...

  • Page 5: Adjustment

    Risk of injury due to accidental machine start-up! No screw clamp may be fastened to the needle bar with the PFAFF 2481-980/30! This may damage the special needle bar coating. Notes on adjustment All adjustments in this manual are based on a fully assembled machine and may only be car- ried out by technical staff trained for this purpose.

  • Page 6: Checking And Adjustment Aid

    Adjustment Checking and adjustment aid The adjustment pin 1 (order no. 13-033 346-05) and the adjustment gauge 3 (order no. 61-111 639-73) if necessary can be used to fix the required positions during the adjustment. Fig. 15 - 01 Needle bar positioned 1.8 mm after b.d.c. O Turn the handwheel until the needle bar is approximately in the required position.

  • Page 7: Adjusting Basic Machine

    Adjustment Adjusting basic machine Machine drive home position .06.01 This setting is only required if the toothed belt 2 has been dismantled. Rule The markings 3 and 4 should be aligned if the needle bar is positioned 0.6 mm after b.d.c. Fig.

  • Page 8: Pre-Calibrating The Needle Height

    Adjustment Pre-calibrating the needle height .06.02 Rule The marking on the needle bar 1 should be flush with the lower edge of the needle bar frame 3 when the needle bar is positioned 1.8 mm after b.d.c. Fig. 15 - 03 O Move the needle bar to 1.8 mm after b.d.c.

  • Page 9: Bottom Transporter Zero Position

    Adjustment Bottom transporter zero position .06.03 Rule At stitch length regulation “0” 1. The marking on the toothed segment 1 should be in the centre of the shaft of the gear wheel 3, 2. The cranks 4 and 6 should be aligned and the bottom transporter should not move when turning the handwheel.

  • Page 10: Needle Transport Zero Position

    Adjustment Needle transport zero position .06.04 Rule The needle bar should not move when turning the handwheel with stitch length regulation “0”. Fig. 15 - 05 O Switch the machine on. O Set the stitch length to “0” using the control panel and turn the handwheel until the feed regulator motor responds.

  • Page 11: Bottom Transporter Sliding Movement

    Adjustment Bottom transporter sliding movement .06.05 Rule When the needle bar is positioned 0.6 mm after b.d.c., the bottom transporter should not move when the shaft 3 is rotated back and forth. Fig. 15 - 06 O Move the needle bar to a position 0.6 mm after b.d.c. O Turn the eccentric 1 ( screws 2 ), without moving it sideways according to the rule.

  • Page 12: Needle Transport Sliding Motion

    Adjustment Needle transport sliding motion .06.06 Rule When the needle bar is positioned 0.6 mm after b.d.c., the needle should not move when the shaft 4 is rotated back and forth. Fig. 15 - 07 O Move the needle bar to a position 0.6 mm after b.d.c. O Turn the eccentric 1 ( screws 2 ) until the adjustment pin 3 engages according to the rule.

  • Page 13: Bottom Transporter Lifting Movement

    Adjustment Bottom transporter lifting movement .06.07 Rule When the needle bar is positioned 0.6 mm after b.d.c. and with stitch length regulation “0”, 1. the bottom transporter should be in its upper turning point and 2. the control cam 3 should abut the feed lifting eccentric 1. Fig.

  • Page 14: Bottom Transporter Height / Position In Stitch Platen Cutout

    Adjustment Bottom transporter height / position in stitch platen cutout .06.08 Rule In its upper turning point and with stitch length regulation “0” the bottom transporter 1 should 1. be in the centre of the stitch platen cutout looking from the side and in the feeding di- rection and 2.

  • Page 15: Needle In Needle Hole Centre

    Adjustment Needle in needle hole centre .06.09 Rule The needle should pierce the centre of the needle hole exactly. Fig. 15 - 10 O Switch the machine on. O Set the stitch length to “0” using the control panel and turn the handwheel until the feed regulator motor responds.

  • Page 16: Hook Shaft Bearing And Spur Gear Clearance

    Adjustment Hook shaft bearing and spur gear clearance .06.10 Rule 1. The front edge of the hook shaft 5 should be 14.5 mm away from the needle midpoint; the groove in the hook shaft bearing 1 (see arrow) should be parallel to the bed plate and point away from the sewing direction.

  • Page 17: Hook Lubrication

    Adjustment Hook lubrication .06.11 Rule 1. The centrifugal disc 1 should be 1.5 mm in front of the oil distributor ring 3. 2. A light oil strip should appear on a paper strip held over the needle plate cutout after approximately 10 seconds when the machine is running at full speed.

  • Page 18: Needle Bar Rise, Hook-To-Needle Clearance, Needle Height And Bobbin Case Position Finger

    Adjustment Needle bar rise, hook-to-needle clearance, needle height and bobbin case .06.12 position finger Rule When the needle is positioned 1.8 mm after b.d.c., 1. The tip of the hook 6 should be at the needle midpoint and be a distance of 0.05 mm - 0.1 mm from the fillet of the needle and 2.
  • Page 19 Adjustment O Use the adjustment pin to move the needle bar to 1.8 mm after b.d.c. O Adjust the hook according to rule 1 O Tighten the screws 1. O Adjust the needle bar 2 ( screw 3 ), without twisting according to rule 2. O Align the bobbin case position finger 4 ( screw 5 ) according to rule 3.

  • Page 20: Thread Check Spring And Slack Thread Regulator

    Adjustment Thread check spring and slack thread regulator .06.13 Rule 1. The movement of the thread check spring should be finished when the needle point punctures the material (spring deflection: approx. 7 mm). 2. The thread check spring should have moved approx. 1 mm when forming the maxi- mum thread loop while passing the thread around the hook.

  • Page 21: Passage Under Sewing Foot

    Adjustment Passage under sewing foot .06.14 Rule 1. When the automatic presser foot lift is activated, the clearance between the sewing foot and needle plate should be should be 7 mm. 2. When the hand lever is raised, the clearance between the sewing foot and needle plate should be should be 5 mm.

  • Page 22: Adjusting The Feed Regulator Zero Position

    Adjustment Adjusting the feed regulator zero position .06.15 Rule The needle should always puncture the material at the same position at maximum speed (4500 min ) with stitch length regulation “0”. Fig. 15 - 16 O Unthread the machine. O Switch the machine on. O Place the workpiece under the sewing foot.

  • Page 23: Stitch Length Adjustment Forwards And Backwards

    Adjustment Stitch length adjustment forwards and backwards .06.16 Rule The stitch length selected on the control panel should not deviate from the actual stitch length when sewing forwards and backwards at a maximum speed of 400 min O Thread the machine. O Switch the machine on.

  • Page 24: Bobbin Winder

    Adjustment Bobbin winder .06.17 Rule 1. When the bobbin winder is switched on, the drive wheel should be moved easily, whereas when the bobbin winder is switched off, the friction wheel 5 must not touch the drive wheel 1. 2. The bobbin winder should switch off automatically if the thread fill is approx. 1 mm away from edge of the bobbin.

  • Page 25: Mechanical Stitch Length Limitation

    Adjustment Mechanical stitch length limitation .06.18 Rule 1. The feed dog must not strike against the needle plate cutout when sewing forwards and backwards at max. stitch length. 2. The screws of the stops 1 (forward sewing) and 3 (reverse sewing) should each have a clearance of 0.3 mm to the corresponding cast edge.

  • Page 26: Sewing Foot Pressure

    Adjustment Sewing foot pressure .06.19 Rule The material should be transported properly at all times; no pressure marks should appear on the material. Fig. 15 - 19 O Turn the screw 1 according to the rule.

  • Page 27: Adjusting Thread Trimmer -900/24

    Adjustment Adjusting thread trimmer -900/24 Pre-calibrating solenoid setting / control cam .07.01 Rule 1. When the solenoid 3 is completely extended, the roller lever 4 should be at the lowest point of the control cam. 2. When the needle bar is positioned 1.8 mm after b.d.c. (needle rise position), the roller lever 4 should engage in the corresponding control cam cutout.

  • Page 28: Aligning Thread Catcher Laterally

    Adjustment Aligning thread catcher laterally .07.02 Rule 1. The tip of the thread catcher 5 should point exactly at the needle midpoint. 2. The thread catcher 5 should be horizontal and not touch at any position as it moves. Fig. 15 - 21 O Remove the knife 1 ( screw 2 ).

  • Page 29: Knife Position

    Adjustment Knife position .07.03 Rule 1. There should be a clearance of 4 mm between the knife edge and the needle. 2. The right edge of the knife 1 should not protrude beyond the right edge of the thread catcher ( see arrow ). 4 mm Fig.

  • Page 30: Front Turning Point Of Thread Catcher

    Adjustment Front turning point of thread catcher .07.04 Rule When the thread catcher 4 is in the front turning point, the tip of the thread catcher cutout should be 1 mm in front of the bobbin case position finger 5. Fig.

  • Page 31: Manual Cutting Control

    Adjustment Manual cutting control .07.05 Rule Two threads must be cut cleanly on both the left and right in the thread catcher cutout 1. Fig. 15 - 24 O Manually move the thread catcher 1 to its front turning point. O Pull a double-up length of thread and hook it in the thread catcher cutout.

  • Page 32: Needle Thread Tension Release

    Adjustment Needle thread tension release .07.06 Rule 1. The magnet lift should be 1.5 mm. 2. When the solenoid 5 is operated manually, there should be a clearance of at least 0.5 mm between the tension discs 6. 0.5 mm Fig.

  • Page 33: Re-Calibrating Control Cam

    Adjustment Re-calibrating control cam .07.07 Rule When the thread lever is at t.d.c., the control cam 1 should have controlled the thread catcher 3. Fig. 15 - 26 O Turn the control cam 1 ( screws 2 ) according to the rule.

  • Page 34: Aligning Transmitted Light Transmitter

    Adjustment Aligning transmitted light transmitter Rule The receivers PS2 and PS1 should show the same value (same signal strength) when the sewing material is in place. Fig. 15 - 27 O Switch the machine on. O Call up entry mode. O Call up the service menu.

  • Page 35: Adjusting Transmitted Light Sensors

    Adjustment Adjusting transmitted light sensors Rule The difference between one and more material layers should be reliably detected. O Switch the machine on. O Call up entry mode. A 100 O Call up the menu to adjust the transmitted light sensors. 96 - 96 % 52 % 0 - 100 %...

  • Page 36: Functional Check Of Bobbin Thread Monitor

    Adjustment Functional check of bobbin thread monitor Rule The value under “Rx” must switch between “ON” and “OFF” when the thread is drawn off (perfect transmission of the bobbin thread sensor receiving signal). Fig. 15 - 28 O Insert the bobbin into the bobbin case and insert the bobbin case into the hook. O Switch the machine on.

  • Page 37: Adjusting Electric Edge Guide

    Adjustment Adjusting electric edge guide Rule The guide 3 should have a clearance of approx. 0.1 mm to the sewing foot 4 when se- lecting a 1.0 mm seam depth (via the control panel. Fig. 15 - 29 O Switch the machine on. O Set the edge guide position to 1.0 mm, see chapter 9.07 Entering edge guide position in instruction manual O Adjust the edge guide 1 ( screws 2 ) according to the rule.

  • Page 38: Parameter Settings

    Adjustment Parameter settings Overview of parameter functions .12.01 After switching on the machine, the input mode in which the individual parameters can be called up directly is called up by pressing the corresponding function. All parameter groups or also individual ones can be protected by a code against unauthorised access. Select parameter User level Mechanic level...

  • Page 39: Example Of A Parameter Entry

    Adjustment Example of a parameter entry .12.02 O Switch the machine on. O Call up entry mode. A 100 O e.g. Call up parameter “660” (bobbin thread monitor) A 660 A 660 O Switch on the bobbin thread monitor (value “1”). O Conclude the parameter input.

  • Page 40: Selecting User Level

    Adjustment Selecting user level .12.03 O Switch the machine on. O Call up entry mode. A 100 O Call up parameter ‘798’. A 798 O The user level is determined and displayed in front of the actual parameter by selecting the corresponding value for parameter 798: “0”...

  • Page 41: List Of Parameters

    Adjustment List of parameters .12.04 Bobbin thread monitor current level 8 - 16 Bobbin thread monitor stitch counter 0 - 255 (start value) Control panel contrast [%] 90 - 110 Control panel key response signal 0 - 1 0=tone off / 1=tone on Start backtack stitches forwards 0 - 9 Start backtack stitches in reverse...
  • Page 42 Adjustment Speed for 300 - 1500 1200 light barrier compensation stitches [min Seam interrupt with pedal -2 OFF - ON Speed level 12 (poti-reserve) [min 300 - 5000 4500 Speed limit for seam programs [min 300 - 5000 4500 Speed constant for seam programs [min 300 - 5000 3000 Number of reduced stitches...
  • Page 43 Adjustment Cutting: OFF - ON ON = forwards after semi end backtack OFF = in reverse too Speed display: OFF - ON ON = on / OFF = off Speed level 1 (min.) [min 30 - 550 Speed level 12 (max.) [min 300 - 5000 4500 Cutting speed [min...
  • Page 44 Adjustment Sewing foot holding current 0 - 50 Cutting holding current 0 - 50 Feed converter holding current 0 - 50 Acceleration ramp: 1 - 50 1 = flat / 50 = steep Brake ramp: 4 - 50 1 = flat / 50 = steep Start delay after 0 - 2550 lowering the sewing foot [ms]...
  • Page 45 Adjustment Machine class: 1 - 4 1 = 2481 (2 to 4 = other machine classes) Rotating direction of motor OFF - ON Reverse turning angle 5 - 106 (618 = ON) Start delay for 0 - 10 stepping motor 2 [increments] Needle position (feed start) 0 - 127 Needle position (feed end)
  • Page 46 Adjustment Starting current main drive 1 - 10 Filter parameter for position controller 0 - 12 Proportional amplification 1 - 50 of speed control (general) Integral amplification 0 - 50 of speed control Proportional amplification 1 - 50 of position controller Differential amplification 1 - 50 of position controller...

  • Page 47: Error Messages And Description

    Adjustment Error messages and description Error Description ERROR: 1 Pedal not at neutral position ERROR: 3 SM 1 Edge guide (for reference) ERROR: 4 SM 2 Feed regulator (for reference) ERROR: 5 Control panel ERROR: 6 ERROR: 7 Can node missing (if bobbin changer can node is missing) ERROR: 8 Zig-zag sensor ERROR: 9...

  • Page 48: Sewing Motor Errors

    Adjustment Sewing motor errors Error Description ERROR: 34 Brake path too short ERROR: 35 Communication ERROR: 64 Mains monitor ERROR: 65 Excess current directly after mains on ERROR: 66 Short circuit ERROR: 67 Mains off ERROR: 68 Excess current during operation ERROR: 69 No increments ERROR: 70...

  • Page 49: Service Menu

    Adjustment Service menu Information about machine inputs and outputs as well as values for the two pedals and the handwheel position are displayed in the service menu. In addition, the functions shown below can be performed. O Switch the machine on. O Call up entry mode.

  • Page 50: Internet Update Of Machine Software

    Adjustment Internet update of machine software The machine software can be updated using PFAFF flash-programming. The PFP-boot pro- gram as well as the corresponding control software for the machine type must be installed on a PC for this purpose. The PC and machine control unit must be connected to an appro- priate null modem cable (order no.

  • Page 51: Circuit Diagrams

    Circuit Diagrams Circuit Diagrams Block diagram of PFAFF 2481 with control unit P322 ED...

  • Page 52: Circuit Diagrams

    Circuit Diagrams Circuit diagrams Reference list for circuit diagrams 91-191 441-95 Control device P322 ED Control panel BDF P1 Incremental encoder ( included in M1 ) Key field Transmitted light transmitter Transmitter light receiver Bobbin thread monitor Sewing head detection Nominal value transmitter Single stitch ( included in A4 ) Hand operation front (bartack) ( included in A4 )
  • Page 53 Circuit Diagrams 91-191 441-95 Part 1 Version 01.05.15 Circuit diagram...
  • Page 54 Circuit Diagrams Circuit diagram Version 01.05.15 91-191 441-95 Part 2...
  • Page 55 Circuit Diagrams 91-191 441-95 Part 3 Version 01.05.15 Circuit diagram...
  • Page 56 Circuit Diagrams Circuit diagram 91-191 441-95 Part 4 Version 01.05.15...

  • Page 57: Plug Connections

    Circuit Diagrams Plug connections Pin no. Comment Function Connector name Signal name X11A.2 CAN- CAN_HIGH CAN_TxD X11A.3 X11A.7 CAN+ CAN_LOW CAN_RxD Nominal value transmitter Pin no. Comment Function Connector name Signal name X11B.4 Pedal X11B.5 Pedal X11B.6 Pedal X11B.7 Pedal 2 Setpoint SW2 (analog) X11B.8...
  • Page 58 Circuit Diagrams Pin no. Comment Function Connector name Signal name X1B.1 X1B.2 SSI-Out ( TxD) SSOut X1B.3 SSI-Clock SSClk X1B.4 +24V X1B.5 X1B.6 SSI-Strobe (Mode) SSStr X1B.7 SSI-In (RxD) SSIn X1B.8 (Light barrier 1) (LS1) X1B.9 Incremental encoder Pin no. Comment Function Connector name...
  • Page 59 Circuit Diagrams Outputs Pin no. Comment Function Connector name Signal name X13.01 FSL-solenoid(Y8) O1.1 X13.02 FSL-solenoid(Y8+) O1.2 X13.03 PFH-solenoid(Y4) O2.1 X13.04 PFH-solenoid(Y4+) O2.2 X13.05 WI-solenoid(Y3) X13.06 SN-solenoid(Y2) X13.07 X13.08 RAFI-LED(H1) X13.09 X13.10 X13.11 X13.12 (from DX) Power source DLS A10/PortA10 X13.13 X13.14 +24V...
  • Page 60 PFAFF Industriesysteme und Maschinen GmbH Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Tel.: +49 - 6301 3205 - 0 Fax: +49 - 6301 3205 - 1386 E-mail: info@pfaff-industrial.com Gedruckt in der BRD / Printed in Germany / Imprimé en la R.F.A. / Impreso en la R.F.A...

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