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Pfaff 2481-3/01-980/30 Instruction Manual

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2481
-3/01-980/30

INSTRUCTION MANUAL

This instruction manual applies to machines
from the serial number 2 809 573 and
software version 0307/010 onwards.
296-12-19 272/002
Instruction Manual engl. 05.16

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Summary of Contents for Pfaff 2481-3/01-980/30

  • Page 1: Instruction Manual

    2481 -3/01-980/30 INSTRUCTION MANUAL This instruction manual applies to machines from the serial number 2 809 573 and software version 0307/010 onwards. 296-12-19 272/002 Instruction Manual engl. 05.16...
  • Page 2 As an alternative to the Internet download, the adjustment manual can also be ordered as a hard copy under order no. 296-12-19 273/001. Reprinting, reproduction and/or translation of PFAFF instruction manuals (including parts thereof) is only permitted with our prior agreement and citation of the source.

  • Page 3: Table Of Contents

    Danger warnings ........................9 Proper Use .......................... 10 Technical Data ........................ 11 PFAFF 2481-980/30 ......................11 Disposal of the Machine ....................12 Transport, Packaging and Storage ................... 13 Transport to the customer's premises ................13 Transport within the customer's premises ................13 Disposal of the packaging materials ..................
  • Page 4 Table of Contents Contents ..................Page Set-up ..........................25 Inserting the needle ......................25 Winding the bobbin thread, adjusting the thread tension ............ 26 Removing / inserting the bobbin case ................. 27 Inserting the bobbin case / adjusting the bobbin thread tension ......... 27 Threading the needle thread / adjusting the needle thread tension ........
  • Page 5 Table of Contents Contents ..................Page Maintenance and Care ....................... 64 Maintenance intervals ......................64 Cleaning the machine ......................64 Topping up the oil tank ......................65 Cleaning the blower air filter ....................65 Table Top ..........................66 Table top cutout ........................66 Table top assembly ......................

  • Page 6: Safety

    Fitting or using these products may therefore have negative effects on features which depend on the machine design. We are not liable for any damage caused by the use of non-Pfaff parts.

  • Page 7: Safety Symbols

    Safety Safety symbols Hazard point! Special points of attention. Risk of injury to operating personnel or technical staff! Electric voltage! Danger to operating personnel or technical staff Caution! Do not operate without finger guard and safety covers! Turn off the main switch before threading, changing the bobbin or needle, cleaning, etc.! Special points of attention for the owner-operator O This instruction manual is a part of the machine and must be made available to the...

  • Page 8: Operating Personnel And Technical Staff

    Safety Operating personnel and technical staff Operating personnel .05.01 Operating personnel are persons responsible for equipping, operating and cleaning the ma- chine and for fault clearance in the sewing area. The operating personnel are obligated to comply with the following points: O The safety instructions provided in the instruction manual must be followed for all work! O Any work method jeopardising machine safety must be refrained from! O Tight-fitting clothing must be worn.

  • Page 9: Danger Warnings

    Safety Danger warnings A work area of 1 m must be kept free in front of and behind the machine to en- sure unobstructed access at all times. Do not reach into the needle range during the sewing operation! Risk of injury from the needle! Do not allow any objects to be placed on the table during the adjustment work! The objects could become jammed or be slung away! Risk of injury from parts flying around!

  • Page 10: Proper Use

    Proper Use Proper Use The PFAFF 2481-980/30 is an ultra high-speed, single-needle seamer with a needle and drop feed as well as a seam-program controlled edge guide and edge sensor. The machines are used for sewing lockstitch seams in the clothing industry.

  • Page 11: Technical Data

    Technical Data Technical Data PFAFF 2481-980/30 Stitch type: ......................301 (lockstitch) Needle system: .......................134 KK Model BN3.5: ............... for the machining of medium materials Needle size in 1/100 mm ....................90 - 110 Thread thickness max.: ......................120 Stitch length max: ......................3.5 mm Needle bar stroke: ......................30 mm...

  • Page 12: Disposal Of The Machine

    Disposal of the Machine Disposal of the Machine O It is up to the customer to dispose of the machine properly. O The materials used for the machine include steel, aluminium, brass and various plastics. The electrical equipment consists of plastics and copper. O The machine must be disposed of in accordance with the locally valid environmental pro- tection regulations, with a specialised company being contracted if necessary.

  • Page 13: Transport, Packaging And Storage

    Transport, Packaging and Storage Transport, Packaging and Storage Transport to the customer's premises All machines are completely packed for delivery. Transport within the customer's premises The manufacturer assumes no liability for transport within the customer's premises or to the individual usage sites. Please ensure that the machines are only transported in a vertical position.

  • Page 14: Work Symbols

    Work Symbols Work Symbols Activities to be performed or important information in this instruction manual are emphasised by symbols. The symbols used have the following meaning: Note, information Cleaning, care Lubrication Maintenance, repairs, adjustment, service work (only to be carried out by technical staff)

  • Page 15: Operating Controls

    Operating Controls Operating Controls Main switch Before switching on the machine, raise the take-up lever as far as possible. O Turning the main switch 1 switches the machine on and off. Fig. 7 - 01 Keys on the machine head O The following functions are carried out by operating the respective keys.

  • Page 16: Pedal

    Operating Controls Pedal O With the main switch turned on = Neutral position = Sewing = Raise sewing foot = Trim thread/reset bobbin thread monitor or bobbin rest thread count function Fig. 7 - 03 Hand lever to raise the sewing foot O Turning the hand lever 1 raises the sewing foot.

  • Page 17: Knee Switch

    Operating Controls Knee switch O When the knee switch 1 is operated, one stitch is sewn with a reduced stitch length (standard). The value for the reduced stitch length is set with parameter "835", see chapter 11.04 Parameter settings. O If the edge guide connector is inserted into the bushing X47, the edge guide can be moved back using the knee switch.
  • Page 18 Operating Controls functions that can be called up by pressing on the respective point on the monitor. Pressing the respective function causes its immediate actuation or activation/deactivation or another menu will appear, e.g. for entering a value. Activated functions are indicated by pictograms shown inversely.

  • Page 19: Set-Up And Initial Commissioning

    Set-up and Initial Commissioning Set-up and Initial Commissioning The machine may only be set up and started up by qualified personnel! All of the relevant safety regulations must always be complied with in this process! If the machine was delivered without a table, then the stand and the table top provided must safely support the weight of the machine and its motor.

  • Page 20: Inserting The Sewing Machine Into The Stand

    Set-up and Initial Commissioning Inserting the sewing machine into the stand .01.02 Fig. 8 - 02 O The hinge 1 is screwed to the sewing head base plate. O Insert the sewing machine into the table top. O Insert the sewing head support 2 into the table top hole. Do not operate the machine without the support 2! Risk of damage due to the top-heavy sewing head! Machine can tip over backwards when moving it!
  • Page 21 Set-up and Initial Commissioning Assembling the start inhibitor .01.03 Fig. 8 - 03 O Insert the machine into the table top, see chapter 8.01.02 Inserting the sewing machine into the stand O After loosening the screws 2, adjust the switch 1 in such a way that the switch 1 is actuated when the sewing head is mounted.

  • Page 22: Connecting The Plug-In Connections And Ground Cable

    Set-up and Initial Commissioning Connecting the plug-in connections and ground cable Fig. 8 - 04 O Insert all plugs on the control box 2 in accordance with their designation. O Insert the "motor" into the bushing X 3 and the bushing X 8. Caution Inserting the plug incorrectly can damage the control unit! O Attach the following ground cables in order to discharge static electricity.

  • Page 23: Assembling The Reel Stand

    Set-up and Initial Commissioning Assembling the reel stand O Assemble the reel stand as shown in the adjacent illustration. O Then insert the stand into the O hole in the table top and secure it with the enclosed nuts. Fig. 8 - 05...

  • Page 24: Initial Start-Up

    Set-up and Initial Commissioning Initial start-up O Remove the plug 1 of the oil reservoir 2 before the initial commissioning. Danger of machine damage! The plug 1 serves solely for transit support and may not be used during the sewing opera- tions.

  • Page 25: Set-Up

    Set-up Set-up Observe and comply with all regulations and instructions in this instruction manual. Pay particular attention to all safety regulations! All set-up work may only be carried out by appropriately instructed personnel. Disconnect the machine from the electricity mains for all set-up work by operat- ing the main switch or by removing the mains plug! Inserting the needle Switch off the machine!

  • Page 26: Winding The Bobbin Thread, Adjusting The Thread Tension

    Set-up Winding the bobbin thread, adjusting the thread tension Fig. 9 -02 O Fit the empty bobbin 1 onto the bobbin winder spindle 2 with the rest thread chamber on the outside. O Thread in the thread as shown in Fig. 9 - 02 and wind it round the bobbin 1 a few times in an anti-clockwise direction.

  • Page 27: Removing / Inserting The Bobbin Case

    Set-up Removing / inserting the bobbin case Switch off the machine! Risk of injury due to accidental machine start-up! Removing the bobbin case: O Tilt machine backwards. O Raise the lever 1 and remove the bobbin case 2. Inserting the bobbin case: O Press the bobbin case 2 until you feel it snap into the bobbin case base.

  • Page 28: Threading The Needle Thread / Adjusting The Needle Thread Tension

    Set-up Threading the needle thread / adjusting the needle thread tension Fig. 9 - 06 Switch off the machine! Risk of injury due to accidental machine start-up! O Thread the needle thread as shown in Fig. 9 - 06. Please ensure that the needle is threaded from the left.

  • Page 29: Entering The Stitch Length

    Set-up Entering the stitch length The stitch length can be entered or altered directly in manual sewing mode. O Switch the machine on. O Call up the stitch length input menu. O Enter the stitch length with the number keys. O or O Alter the stitch length step by step.

  • Page 30: Entering The Edge Guide Position

    Set-up Entering the edge guide position The edge guide position can be entered or altered directly in the manual sewing mode. O Switch the machine on. O Call up the edge guide position input menu. O Enter the edge guide position with the number keys. O or O Alter the edge guide position step by step.

  • Page 31: Entering The Start And End Backtacks

    Set-up Entering the start and end backtacks The start and end backtacks can be entered or altered directly in the manual sewing mode. O Switch the machine on. O Switch on start backtack and/or end backtack (the corresponding symbol is shown as an inverse symbol).

  • Page 32: Entering The Number Of Compensation Stitches

    Set-up Entering the number of compensation stitches In the manual sewing mode it is possible to enter the number of compensation stitches, which will be sewn after the recognition of the material edge till the machine stops. O Switch the machine on. O Switch on the edge sensor and call up the compensation stitches input menu.

  • Page 33: Setting The Number Of Remaining Stitches For The Bobbin Thread Monitor

    Set-up Setting the number of remaining stitches for the bobbin thread monitor There is still an amount of remaining thread on the bobbin when the bobbin thread monitor signals that the bobbin thread has been used up. O Switch the machine on. O Call up "Entry"...
  • Page 34 Set-up O Call up parameter '760'. A 760 1200 O Set the number of remaining stitches, which can still be sewn after the signal from the bobbin thread monitor (depends on the thread size). O End input entry. The number of remaining stitches can be altered in 200-steps.

  • Page 35: Selecting The Seam Program

    Set-up Selecting the seam program With the seam program selection function it is possible to select either manual or programmed sewing. The programmed sewing function is called up by selecting a seam program number from 0 - 65. O Switch the machine on. O Call up the seam program selection menu.

  • Page 36: Setting The Control Panel

    Set-up Setting the control panel O Switch the machine on. O Call up "Entry" mode. A 100 O Select user level "C", see chapter 14.11.02 Selecting the user level in the adjustment manual. O Call up the service menu. O Call up the control panel functions.
  • Page 37 Set-up O Change the display contrast. O Switch the key tone off or on. O End input entry. Never reduce the display contrast to such an extent that the display can no longer be read!

  • Page 38: Inserting And Removing The Sd Memory Card

    Set-up Inserting and removing the SD memory card Insert the SD card O Slide the cover 1 upwards to open it. O Insert the SD card 2 into the card slot with the label facing forwards. O Slide the cover 1 upwards to close it. 2 GB Only use FAT 16 format max.

  • Page 39: Sewing

    Sewing Sewing In the sewing mode a difference must be made between manual sewing and programmed sewing. In the manual sewing mode, in addition to the functions such as edge guide, stitch length, seam securing, needle functions, presser foot functions and seam end conditions, the parameter for securing seams are also displayed and can be altered directly.
  • Page 40 Sewing Start backtack Switches the start backtack function on or off. End backtack Switches the end backtack function on or off. Needle position raised When this function is activated, the needle is positioned at top dead centre after sewing stops. Sewing foot raised When this function is activated, the sewing foot is raised after sewing stops.

  • Page 41: Programmed Sewing

    Sewing Programmed sewing In the programmed sewing mode the seam parameters are set in a seam program. The program number selection function is used to call up a seam program. The selected program number, a sketch of the seam with the number of programmed seam zones, the current seam zone and the parameters for the current seam zone are displayed.

  • Page 42: Error Messages

    Sewing Input mode Calls up the input mode. Depending on the seam program, further symbols showing corresponding values or selected functions may appear on the display. In addition, when the bobbin thread monitoring function is activated, the number of remaining stitches is shown, and when the speed display function is activated the current speed is shown, see chapter 11.04.03 List of parameters.

  • Page 43: Input

    Input Input This chapter describes the input mode functions and how to enter seam programs. Input mode When the machine is in its initial state, it is possible to enter the parameters and the cor- responding values directly in the control unit. The functions information, adjustment of the transmitted light sensors and service can be called up.

  • Page 44: Entering Seam Programs

    Input Entering seam programs Seam programs are created by establishing seam zones which are allocated certain functions and values. It is possible to store up to 65 seam programs each with 15 seam zones. The maximum number of seam zones in each seam program and the maximum number of seam programs can be limited by setting appropriate parameters, see chapter 11.04 Parameter settings.
  • Page 45 Input Needle position raised When this function is activated, the needle is positioned at top dead centre after sewing stops. Sewing foot raised When this function is activated, the sewing foot is raised after sewing stops. Sewing foot raised after thread trimming When this function is activated, the sewing foot is raised after thread trimming.
  • Page 46 Input Selecting the seam types .02.01 For better information during programming and sewing, it is possible to show a diagram of different seam types. To do so, the seam types must be allocated to the seam programs. With the exception of the free seam, for each seam type the number of seam zones and the starting point is set.
  • Page 47 Input O Select the desired seam type. When a seam type has been selected, the machine switches to the seam program input function. O Overview of the seam groups with their corresponding seam types: Free seam Flap Cuffs Collars Shoulder flaps...
  • Page 48 Input Entering the seam depth .02.02 As the edge sensors are arranged for sewing at right angles, if other angles to the edge have to be sewn, a correction value must be entered. O Switch the machine on. O Select the program number, see chapter 9.11 Selecting the seam program. O Call up seam program input...
  • Page 49 Input O Using the number keys call up the correction value input menu and enter the correction value O or O Place the workpiece on the angle outline on the display and adjust the angle. The correction value is calculated automatically from the adjusted angle. O Conclude the input and take over the correction value.

  • Page 50: Example For Seam Program Input

    Input Example for seam program input This is a description of how to enter a seam program, using a seam with corner stitches as an example. Program number 16 Programmnummer: 16 Stitch length = 2.2 mm Stichlänge = 2,2 mm 45°...
  • Page 51 Input O Seam zone 0 All values entered in this seam zone are valid for all other seam zones in the seam program, unless they are altered in the individual seam zones. O Call up the stitch length input menu and enter the stitch length "2.2", see chapter 9.06 Entering the stitch length.
  • Page 52 Input O Select the seam zone two. O Call up the correction value input menu. O Place the workpiece on the angle outline on the display and adjust the angle. The correction value is calculated automatically from the adjusted angle. O Conclude the input and take over the correction value.
  • Page 53 Input O Select the seam zone five. O Switch on the thread trimming function. O Select the seam zone six. O Call up the stitch length input menu and enter the stitch length "0", see chapter 9.06 En- tering the stitch length. The fifth seam zone is then recognised as the last seam zone.

  • Page 54: Parameter Settings

    Input Parameter settings Overview of parameter functions .04.01 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 55: Example Of A Parameter Entry

    Input Example of a parameter entry .04.02 O Switch the machine on. O Call up "Entry" mode. A 100 O e.g. Select parameter "660" (bobbin thread monitor) A 660 O Switch on the bobbin thread monitor (value "1"). O Conclude the parameter input.

  • Page 56: List Of Parameters

    Input List of parameters .04.03 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 57 Input 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 300 - 5000 4500 for seam programs [min Speed constant 300 - 5000 3000 for seam programs [min...
  • Page 58 Input 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 59 Input 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 presser foot [ms]...
  • Page 60 Input 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 61 Input 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 62: Error Messages And Description

    Input 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 63: Sewing Motor Errors

    Input 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 64: Maintenance And Care

    Maintenance and Care Maintenance and Care Maintenance intervals Cleaning ............daily, several times if in continuous operation Clean the hook area ........daily, several times if in continuous operation Check oil level ..................daily, before start-up Lubricate the bevel gears ..................once as year Clean the blower air filter ...................

  • Page 65: Topping Up The Oil Tank

    /s at 40 °C and a density of 0.865 g/cm at 15 °C. We recommend PFAFF sewing machine oil part no. 280-1-120 144. Cleaning the blower air filter O Remove the cover 1. O Remove the filter element and blow it out with compressed air.

  • Page 66: Table Top

    Table top assembly Table Top Table top cutout...

  • Page 67: Table Top Assembly

    Table top cutout Table top assembly...

  • Page 68: Wearing Parts

    This list shows the most important wearing parts. A detailed parts list for the complete machine can be downloaded at www. pfaff-industrial.de/de/service-support/downloads/technical. As an alternative to the Internet download, the parts list can also be requested as a hard copy under order no.
  • Page 69 Wearing Parts 11-108 087-15 91-264 235-15 91-264 338-91 91-264 240-05 11-108 084-15 (2x) 11-108 222-15 99-137 151-45 91-171 049-05 91-171 042-05 95-774 464-25 91-700 996-15...
  • Page 70 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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