Pfaff 2481-980/30 PLUSLINE Instruction Manual
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Pfaff 2481-980/30 PLUSLINE Instruction Manual

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®
Industrial
2481
-980/30

INSTRUCTION MANUAL

This instruction manual applies to machines from the
following serial numbers 2 216 531 and software
version 0307/001 onwards:
296-12-18 760/002
Betriebsanleitung engl. 03.10

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Summary of Contents for Pfaff 2481-980/30 PLUSLINE

  • Page 1: Instruction Manual

    ® Industrial 2481 -980/30 INSTRUCTION MANUAL This instruction manual applies to machines from the following serial numbers 2 216 531 and software version 0307/001 onwards: 296-12-18 760/002 Betriebsanleitung engl. 03.10...
  • Page 2 This Instruction Manual is valid for all models and subclasses listed in the chapter "Specifications ". The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or in part, is only permitted with our previous authorization and with written reference to the source.

  • Page 3: Table Of Contents

    Danger ........................... 1 - 4 Proper use ........................2 - 1 Specifications ......................3 - 1 PFAFF 2481-980/30 ....................... 3 - 1 Work aids for the various models .................. 3 - 2 Disposal of Machine ....................4 - 1 Transport, packaging and storage ................5 - 1 Transportation to customer's premises .................

  • Page 4: Contents

    Contents Contents ................. Chapter – Page Preparation ........................9 - 1 Inserting the needle ....................... 9 - 1 Winding the bobbin thread, adjusting the thread tension ..........9 - 2 Removing/Inserting the bobbin case ................9 - 3 Inserting the bobbin case / Adjusting the bobbin thread tension ........9 - 3 Threading the needle thread / Adjusting the needle thread tension .........
  • Page 5 Contents Contents ................. Chapter – Page .05.09 Needle in needle hole centre ..................13 - 11 .05.10 Hook shaft bearing and toothed belt tension ..............13 - 12 .05.11 Hook lubrication ......................13 - 13 .05.12 Needle rise, hook-to-needle clearance, needle height and bobbin case position finger .. 13 - 14 .05.13 Thread check spring and slack thread regulator ............13 - 16 .05.14...

  • Page 6: Safety

    Safety Safety Directives This machine is constructed in accordance with the European regulations contained in the conformity and manufacturer’s declarations. In addition to this Instruction Manual, also observe all generally accepted, statutory and other regulations and legal requirements and all valid environmental protection regulations! The regionally valid regulations of the social insurance society for occupational accidents or other supervisory organizations are to be strictly adhered to! General notes on safety...

  • Page 7: Safety Symbols

    It is the obligation of the user to ensure that none of the safety mechanisms are removed or deactivated. It is the obligation of the user to ensure that only authorized persons operate and work on the machine. Further information can be obtained from your PFAFF agent. 1 - 2...

  • Page 8: Operating And Specialist Personnel

    Safety Operating and specialist personnel Operating personnel .05.01 Operating personnel are persons responsible for the equipping, operating and cleaning of the machine as well as for taking care of problems arising in the sewing area. The operating personnel is required to observe the following points and must: always observe the Notes on Safety in the Instruction Manual! never use any working methods which could adversely affect the safety of the machine! not wear loose-fitting clothing or jewelery such as chains or rings!

  • Page 9: 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! Danger of injury!

  • Page 10: Proper Use

    Proper use Proper use The PFAFF 2481-980/30 is an ultra high-speed, single-needle sewing machine with compound feed, a seam-program controlled edge guide and edge sensor. The machines are used in industry for sewing lockstitch seams. Any and all uses of this machine which have not been approved of by the...

  • Page 11: Specifications

    Specifications PFAFF 2481-980/30 Stitch type: ....................301 (lockstitch) Needle system: ......................134 KK Needle size in 1/100 mm:....................Model A: ........................60 - 70 Model B: ......................... 80 - 100 Handwheel eff. dia.: ....................65 mm Presser foot clearance: ..................9 - 13 mm Clearance width: ....................

  • Page 12: Work Aids For The Various Models

    Specifications Work aids for the various models Model A: ................for sewing with fine materials Model B: ..............for sewing medium-weight materials Work aids: Sub-class -909/04 ................Thread wiping device 3 - 2...

  • Page 13: Disposal Of Machine

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

  • Page 14: Transport, Packaging And Storage

    Transport, packaging and storage Transport, packaging and storage Transportation to customer's premises The machines are delivered completely packed. Transport within the customer’s premises The manufacturer bears no liability for transport within the customer’s premises or to the indi- vidual locations of use. Make sure that the machines are always transported upright. Disposal of the packaging The packaging of these machines consists of paper, cardboard and VCE fiber.

  • Page 15: Explanation Of The Symbols

    Explanation of the symbols Explanation of the symbols In the following section of this Instruction Manual, certain tasks or important pieces of information are accentuated by symbols. The symbols used have the following meanings: Note, information Cleaning, care Lubrication, greasing Servicing, repairing, adjustment, maintenance (only to be carried out by specialist personnel) 6 - 1...

  • Page 16: Control Elements

    Control elements Control elements On/off switch Before switching on the machine, raise the take-up lever as far as possible. The machine can be switched on or off by turning the on/off switch 1. Fig. 7 - 01 Keys on machine head By operating the respective keys, the following functions are carried out: Key 1:...

  • Page 17: Pedal

    Control elements Pedal Neutral position Sewing Raise presser foot Cut thread / reset bobbin thread monitor or bobbin rest thread count function Fig. 7 - 03 Lever for lifting the presser foot The presser foot is raised by turning lever 1. Fig.

  • Page 18: Knee Switch

    Control elements Knee switch When the knee switch 1 is operated, one stitch is sewn with a reduced stitch length. The value for the reduced stitch length is set with parameter "835", see Chapter 13.11 Parameter settings. Fig. 7 - 05 7 - 3...

  • Page 19: Control Panel

    Control elements Control panel Fig. 7 - 07 The current operating conditions are displayed on control panel 1. Operation takes place in a constant dialogue between the control unit and the operator. For this purpose, depending on the operating condition of the machine, different symbols and/or texts are displayed. If the symbols or texts are framed, these show functions which can be selected by pressing the appropriate position on the monitor.

  • Page 20: Mounting And Commissioning The Machine

    Mounting and commissioning the machine Mounting and commissioning the machine The machine must only be mounted and commissioned by qualified personnel! All relevant safety regulations are to be observed! If the machine is delivered without a table, be sure that the frame and the table top which you intend to use can hold the weight of the machine and the motor.

  • Page 21: Connecting The Plug-In Connections And Earth Cables

    Mounting and commissioning the machine Connecting the plug-in connections and earth cables .01.02 Fig. 8 - 02 Connect plugs 1- 7 as labelled to the control box. Screw the earth cable from the sewing head to earth point A. Fasten the earth cable 8 from the motor to earth point B. Connect earth point C to earth point A with an earth cable.

  • Page 22: Mounting The Spool Holder

    Mounting and commissioning the machine Mounting the spool holder .01.03 Mount the spool holder as shown in Fig. 8-03. Insert the spool holder into the hole in the table top and fasten it with the nuts enclosed. Fig. 8 - 03 Mounting the start inhibitor .01.04 Fig.

  • Page 23: Commissioning

    Mounting and commissioning the machine Commissioning Before commissioning the machine remove plug 1 from the oil tank 2. Danger of damage to the machine! Plug 1 serves as a safety device for transportation and should not be used during sewing operations. Examine the machine, in particular the electric cables for any damage.

  • Page 24: Table Top Cutout

    Mounting and commissioning the machine Table top cutout 8 - 5...

  • Page 25: 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. Before all preparation work, the machine is to be separated from the electricity supply by removing the plug from the mains or switching off the On/Off switch! Inserting the needle Switch off the machine!

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

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

  • Page 27: Removing/Inserting The Bobbin Case

    Preparation Removing/Inserting the bobbin case Switch off the machine! Danger of injury due to unintentional starting of the machine! Removing the bobbin case: Tilt back the machine. Raise latch 1 and remove bobbin case 2. Bild aus Inserting the bobbin case: Press bobbin case 2 until you feel it snap into the bobbin case base.

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

    Preparation Threading the needle thread / Adjusting the needle thread tension Fig. 9 - 05 Switch off the machine! Danger of injury due to unintentional starting of the machine! Thread the machine as shown in Fig. 9-05. Adjust the needle thread tension by turning disk 1. 9 - 4...

  • Page 29: Entering The Stitch Length

    Preparation Entering the stitch length In the manual sewing mode the stitch length can be entered or altered directly. Switch on the machine. Call up the stitch length input menu. Enter the stitch length with the number keys. Alter the stitch length step by step. Conclude the input and take over the altered value.

  • Page 30: Entering The Edge Guide Position

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

  • Page 31: Entering The Start And End Backtacks

    Preparation Entering the start and end backtacks In the manual sewing mode the start and end backtacks can be entered or altered directly. Switch on the machine. Switch on start backtack and/or end backtack (the corresponding symbol is shown as an inverse symbol).

  • Page 32: Entering The Number Of Compensating Stitches

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

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

    Preparation Setting the number of remaining stitches for the bobbin thread control When the bobbin thread monitor signals that the bobbin thread has been used up, there is still an amount of remaining thread on the bobbin. Switch on the machine. Call up the input mode.
  • Page 34 Preparation Call up parameter "760". 1200 A 760 Set the number of remaining stitches, which can still be sewn after the signal from the bobbin thread monitor (depends on the thread size). Conclude the input. The number of remaining stitches can be altered in 200-steps. 9 - 10...

  • Page 35: Selecting The Seam Program

    Preparation 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 pro- gram number from 0-65. Switch on the machine. Call up the seam program selection menu.

  • Page 36: Adjusting The Control Panel

    Preparation Adjusting the control panel Switch on the machine. Call up the input mode. A 100 Select user lever "C", see Chapter 13.11.02 Selecting the user level. Call up the service menu. Call up the control panel functions. 9 - 12...
  • Page 37 Preparation Change the display contrast. Switch the key tone on or off. Never reduce the display contrast to such an extent, that the display can no longer be read! 9 - 13...

  • Page 38: 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 39 Sewing Number of stitches for the start and end backtacks With the use of this input area the number of stitches for the start and end backtacks are entered, see Chapter 9.08 Entering the start and end backtacks. Start backtacks Switches the start backtack function on or off.

  • Page 40: Programmed Sewing

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

  • Page 41: Error Messages

    Sewing Entering the seam program Opens the menu for entering and altering seam programs, see Chapter 11.02 Entering the seam program. 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 13.11.03 List of parameters.

  • Page 42: 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 corresponding values directly in the control unit. The functions information, adjustment of the transmitted light sensors and service can be called up.

  • Page 43: Entering The Seam Program

    Input Entering the seam program Seam programs are created by establishing seam sections which are allocated certain functions and values. It is possible to store up to 65 seam programs each with 15 seam sections. The maximum number of seam sections in each seam program and the maximum number of seam programs can be limited by setting appropriate parameters, see Chapter 13.11 Parameter settings.
  • Page 44 Input Needle position raised When this function is activated, the needle is positioned at t.d.c. after sewing stops. Presser foot raised When this function is activated, the presser foot is raised after sewing stops. Presser foot raised after thread trimming When this function is activated, the presser foot is raised after thread trimming.

  • Page 45: Selecting The Seam Types

    Input Selecting the seam types .02.01 For better information during programming and sewing, it is possible to show a diagram of dif- ferent 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 sections and the starting point is set.
  • Page 46 Input Select the desired seam type. When a seam type has been selected, the machine switches to the seam program input function. Overview of the seam groups with their corresponding seam types: Free seam Flap Cuffs Collars Shoulder flaps 11 - 5...

  • Page 47: Entering The Seam Depth

    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. Switch on the machine. Select a program number, see Chapter 9.11 Selecting a seam program. Call up the seam program input function.
  • Page 48 Input Using the number keys call up the correction value input menu and enter the correction value Place the workpiece on the angle outline on the display and adjust the angle. The correction value is calculated automatically from the adjusted angle. Conclude the input and take over the correction value.

  • Page 49: Example Of How To Enter A Seam Program

    Input Example of how to enter a seam program This is a description of how to enter a seam program, using a seam with corner stitches as an example. Program number: 16 Stitch length = 2.2 mm 45° Switch on the machine. Call up the seam program number input menu and select program number "16", see Chapter 9.11 Selecting the seam program.
  • Page 50 Input Seam section 0 All values entered in this seam section are valid for all other seam sections in the seam program, unless they are altered in the individual seam sections. Call up the stitch length input menu and enter the stitch length "2.2", see Chapter 9.06 Entering the stitch length.
  • Page 51 Input Select second seam section. Call up the correction value input menu. Place the workpiece on the angle outline on the display and adjust the angle. The correction value is calculated automatically from the adjusted angle. Conclude the input and take over the correction value. Switch on the automatic sewing stop at the end of the seam section function.
  • Page 52 Input Select the fifth seam section. Switch on the thread trimming function. Select sixth seam section. Call up the stitch length input menu and enter the stitch length "0", see Chapter 9.06 Entering the stitch length. The fifth seam section is then recognised as the last seam section. Conclude the seam program input by taking over the inputs and change to the programmed sewing mode.

  • Page 53: Care And Maintenance

    Care and Maintenance Care and Maintenance Cleaning ............daily, several times if in continuous operation Checking the oil level ................every 3 months These maintenance intervals are calculated for the average running time of a sin- gle shift operation. If the machine is operated more than this, shorter intervals are recommended.

  • Page 54: Topping Up The Oil Tank

    Fig. 12 - 02 Only use oil with a mean viscosity of 10.0 mm /s at 40°C and a density of 0.847 g/cm at 15°C. We recommend PFAFF sewing machine oil, part no. 280-1-120 105. 12 - 2...

  • Page 55: Adjustment

    Adjustment Adjustment No C-clamp should be fastened to the needle bar of the PFAFF 2481-980/30. This could cause damage to the special coating of the needle bar. Notes on adjustment All following adjustments are based on a fully assembled machine and may only be carried out by expert staff trained for this purpose.

  • Page 56: Control And Adjustment Aids

    Adjustment Control and adjustment aids The positions required during adjustment can be fixed with the help of adjustment pin 1 (part no. 13-033 346-05) and, if necessary, adjustment gauge 3 (part no. 61-111 639-73). Fig. 13 - 01 Needle bar position 1.8 mm past b.d.c. Turn the balance wheel until the needle bar is approximately in the required position.

  • Page 57: Adjusting The Basic Machine

    Adjustment Adjusting the basic machine Basic position of the machine drive unit .05.01 This adjustment is only necessary, if toothed belt 2 was removed. Requirement When the needle bar is positioned 0.6 mm past b.d.c., the markings 3 and 4 should be in alignment.

  • Page 58: Preadjusting The Needle Height

    Adjustment Preadjusting the needle height .05.02 Requirement When the needle bar is positioned 1.8 mm above BDC, the mark on the needle bar 1 must be flush with the bottom edge of the needle bar frame 3. Fig. 13 - 03 Set needle bar at 1.8 mm past b.d.c.

  • Page 59: Neutral Position Of The Bottom Feed Dog

    Adjustment Neutral position of the bottom feed dog .05.03 Requirement With the stitch length set at ”0” 1. The marking on the toothed segment 1 should be positioned in the centre of the toothed wheel shaft 3. 2. Cranks 4 and 6 should be in alignment and there should be no feeding motion of the bottom feed dog when the balance wheel is turned.

  • Page 60: Zero Position Of The Needle Feed

    Adjustment Zero position of the needle feed .05.04 Requirement When the stitch length is set at ”0”, there should be no feeding motion of the needle bar when the balance wheel is turned. Fig. 13 - 05 Switch on the machine. On the control panel set the stitch length at "0"...

  • Page 61: Feeding Motion Of The Bottom Feed Dog

    Adjustment Feeding motion of the bottom feed dog .05.05 Requirement With the needle bar positioned 0.6 mm past b.d.c. the bottom feed dog should not move, when shaft 3 is turned backwards and forwards. Fig. 13 - 06 Position the needle bar at 0.6 mm past b.d.c. Adjust eccentric 1 (screws 2) according to the requirement, without moving it sideways.

  • Page 62: Feeding Motion Of The Needle Feed

    Adjustment Feeding motion of the needle feed .05.06 Requirement With the needle bar positioned 0.6 mm past b.d.c. the needle should not move, when shaft 3 is turned backwards and forwards. 57-36 Fig. 13 - 07 Position the needle bar at 0.6 mm past b.d.c. Adjust eccentric 1 (screws 2) according to the requirement.

  • Page 63: Lifting Stroke Of The Bottom Feed Dog

    Adjustment Lifting stroke of the bottom feed dog .05.07 Requirement When the needle bar is positioned 0.6 mm past b.d.c. and the stitch length is set at ”0” 1. The bottom feed dog should be at the top of its stroke and 2.

  • Page 64: Height Of The Bottom Feed Dog / Position In The Needle Plate Cutout

    Adjustment Height of the bottom feed dog / Position in the needle plate cutout .05.08 Requirement At the top of its stroke, when the stitch length is set at ”0”, the bottom feed dog 1 1. Should be positioned in the centre of the needle plate cutout as seen from the side and in feeding direction and 2.

  • Page 65: Needle In Needle Hole Centre

    Adjustment Needle in needle hole centre .05.09 Requirement The needle should enter the needle hole exactly in the centre. 57-035 93-007 Fig. 13 - 10 Switch on the machine. On the control panel set the stitch length at ”0” and turn the balance wheel until the stitch length control motor reacts.

  • Page 66: Hook Shaft Bearing And Toothed Belt Tension

    Adjustment Hook shaft bearing and toothed belt tension .05.10 Requirement 1. The front edge of the hook shaft 5 should be at a distance of 14.5 mm from the centre of the needle, whereby the groove in the hook shaft bearing 1 (see arrow) should be parallel to the bed-plate and point in the opposite direction to the sewing direction.

  • Page 67: Hook Lubrication

    Adjustment Hook lubrication .05.11 Requirement 1. The centrifugal disk 1 must be positioned 1.5 mm in front of the oil ring 3. 2. When the machine is running at full speed, after approx. 10 seconds a mark should be made by a fine stripe of oil on the strip of paper placed over the needle plate cutout. Fig.

  • Page 68: Needle Rise, Hook-To-Needle Clearance, Needle Height And Bobbin Case Position Finger

    Adjustment Needle rise, hook-to-needle clearance, needle height and bobbin case position finger .05.12 Requirement With the needle at 1.8 mm after BDC, 1. the hook point 6 must point to the middle of the needle and be at a distance of 0.05 mm - 0.1 mm to the clearance cut of the needle, and 2.
  • Page 69 Adjustment Using the adjustment pin, position the needle bar at 1.8 mm after BDC. Adjust the hook according to requirement 1. Tighten screw 1. Move needle bar 2 (screw 3) without turning it according to requirement 2. Align bobbin case position finger 4 (screw 5) according to requirement 3. 13 - 15...

  • Page 70: Thread Check Spring And Slack Thread Regulator

    Adjustment Thread check spring and slack thread regulator .05.13 Requirement 1. The motion of the thread check spring must be completed when the needle point enters the material (spring stroke approx. 7 mm). 2. When the thread loop is at its largest when going around the hook, the thread check sp- ring must have moved by approx.

  • Page 71: Presser Foot Clearance

    Adjustment Presser foot clearance .05.14 Requirement 1. When the automatic presser foot lift is operated, the clearance between the presser foot and the needle plate should be 7 mm. 2. When the hand lever is raised, the clearance between the presser foot and the needle plate should be 5 mm.

  • Page 72: Setting The Zero Point Of The Feed Regulator

    Adjustment Setting the zero point of the feed regulator .05.15 Requirement When the stitch length is set at "0", at maximum speed (4500 spm) the needle should always penetrate in the same place. Fig. 13 - 16 Unthread the machine. Switch on the machine.

  • Page 73: Stitch Length Adjustment Forwards And In Reverse

    Adjustment Stitch length adjustment forwards and in reverse .05.16 Requirement At a maximum speed of 400 spm, the stitch length selected on the control panel should not differ from the actual stitch length when sewing forwards or in reverse. Thread the machine. Switch on the machine.

  • Page 74: Bobbin Winder

    Adjustment Bobbin winder .05.17 Requirement 1. With the bobbin winder on, the drive wheel 1 must engage reliably. 2. With the bobbin winder off, the friction wheel 5 must not be driven by the drive wheel 1. 3. The eccentric pin 3 should be positioned in the centre of the large bobbin chamber. Fig.

  • Page 75: Mechanical Limiting Of The Stitch Length

    Adjustment Mechanical limiting of the stitch length .05.18 Requirement 1. With the maximum stitch length set, the feed dog should not touch the needle plate cut- out when sewing forwards and in reverse. 2. The screws of the stops 1 (forwards sewing) and 3 (reverse sewing) should each have a clearance of 0.3 mm to the corresponding metal edge.

  • Page 76: Presser Foot Pressure

    Adjustment Presser foot pressure .05.19 Requirement The material must be fed reliably. In the process, pressure marks on the material must not be made. Fig. 13 - 20 Turn screw 1 in accordance with the requirement. 13 - 22...

  • Page 77: Adjusting The Thread Trimming Device -900/24

    Adjustment Adjusting the thread trimming device -900/24 Adjusting the solenoid / preliminary adjustment of the control cam .06.01 Requirement 1. When solenoid 3 is completely extended, roller lever 4 should be at the lowest point of the control cam. 2. When the needle bar is positioned at 1.8 mm after b.d.c. (needle rise position), roller lever 4 should engage in the appropriate recess of the control cam.

  • Page 78: Lateral Alignment Of The Thread Catcher

    Adjustment Lateral alignment of the thread catcher .06.02 Requirement 1. The tip of the thread catcher 5 must point exactly to the center of the needle. 2. The thread catcher 5 must be horizontal. It must not graze anything when it is operating. Fig.

  • Page 79: Knife Position

    Adjustment Knife position .06.03 Requirement 1. There must be a distance of 4 mm between the cutting edge of the knife and the needle. 2. The right edge of the knife 1 must not extend beyond the right edge of the thread catcher (see arrow).

  • Page 80: Front Point Of Reversal Of The Thread Catcher

    Adjustment Front point of reversal of the thread catcher .06.04 Requirement At the front point of reversal of thread catcher 4, the tip of the thread catcher cutout should be 1 mm in front of the bobbin case position finger 5. 89-025 Fig.

  • Page 81: Manual Trimming Check

    Adjustment Manual trimming check .06.05 Requirement Two threads must be cut perfectly both left and right in the cutout of thread catcher 1. Fig. 13 - 25 Move thread catcher 1 by hand to its front point of reversal. Double the thread and insert into catcher cutout. Carry out trimming operation manually.

  • Page 82: Needle Thread Tension Release

    Adjustment Needle thread tension release 06.06 Requirement 1. The solenoid stroke should be 1.5 mm. 2. When the solenoid 5 is operated by hand, there should be a distance of at least 0.5 mm between the tension disks 6. 0,5 mm 57-05 Fig.

  • Page 83: Readjusting The Control Cam

    Adjustment Readjusting the control cam .06.07 Requirement When the take-up lever is in its t.d.c., control cam 1 should have moved thread catcher 3. Fig. 13 - 27 Adjust control cam 1 (screws 2) according to the requirement. 13 - 29...

  • Page 84: Aligning The Light Transmitter

    Adjustment Aligning the light transmitter Requirement When the workpiece is positioned, the transmitters PS2 and PS1 should display the same value (same receiving power). Fig. 13 - 28 Switch on the machine. Call up the input mode. Call up the service menu. Call up the sensor menu.

  • Page 85: Adjustment Of The Transmitted Light Sensors

    Adjustment Adjustment of the transmitted light sensors Requirement The difference between one and several material plies should be recognised. Switch on the machine. Call up the input mode. A 100 Call up the menu for adjusting the transmitted light sensors. 0 - 100 % 20 % 0 - 100 %...

  • Page 86: Function Control Of The Bobbin Thread Monitor

    Adjustment Function control of the bobbin thread monitor Requirement When the thread is pulled, the value under "Rx" must change from "ON" to "OFF" (perfect transmission of the incoming signal of the bobbin thread sensor). Fig. 13 - 29 Place the bobbin in the bobbin case and the bobbin case in the hook. Switch on the machine.

  • Page 87: Adjusting The Electric Edge Guide

    Adjustment Adjusting the electric edge guide Requirement When a seam depth of 1.0 mm is selected (using the control panel), guide unit 3 should be at a distance of approximately 0.1 mm from sewing foot 4. Fig. 13 - 30 Switch on the machine.

  • Page 88: Parameter Settings

    Adjustment Parameter settings Example of a parameter input .11.01 Switch on the machine. Call up the input mode. A 100 Select parameter "660" (bobbin thread control). A 660 Switch on the bobbin thread control (value "1"). Conclude the parameter input. 13 - 34...

  • Page 89: Selecting The User Level

    Adjustment Selecting the user level .11.02 Switch on the machine. Call up the input mode. A 100 Call up parameter "798". A 798 By selecting the appropriate value for parameter 798, the user level is determined and shown in the display in front of the current parameter. "0"...

  • Page 90: List Of Parameters

    Adjustment List of parameters .11.03 Bobbin thread monitor-current level 8 - 16 Bobbin thread monitor-stitch counter (starting 0 - 255 value) Control panel contrast [%] 90 - 110 Control panel key response signal 0 - 3 0=tone off/1=tone off/key inverted 2=tone on/3=tone on/key inverted Start backtacks forwards 0 - 9...
  • Page 91 Adjustment Speed for light barrier 300 - 1500 1200 compensating stitches [min-1] Seam interruption with Pedal -2 ON - OFF Speed level 12 (Poti-reserve) [min-1] 300 - 5000 4500 Speed limitation for seam programs [min-1] 300 - 5000 4500 Speed constant for seam programs [min-1] 300 - 5000 3000 Number of reduced stitches...
  • Page 92 Adjustment Speed level 1 (min.) [min-1] 30 - 550 Speed level 12 (max.) [min-1] 300 - 5000 4500 Cutting speed [min-1] 60 - 500 Reversing angle ON - OFF Start inhibitor: ON - OFF Presser foot – time from switch-on to tension 10 - 50 reduction (tacting) Automatic lowering of presser foot...
  • Page 93 Adjustment Start delay after lowering presser foot [ms] 0 - 2550 Lift delay for presser foot after seam end [ms] 0 - 2550 Stitch count delay for end backtack 0 - 2550 Delay time for cutting after single end backtack 0 - 2550 [ms] Delay time from switch on feed conversion...
  • Page 94 Adjustment Feed regulator-balance -5 - 5 [1 semi-step = 5/100mm] Reduced single stitch [%] 0 - 100 Distance sensor 1 to sensor 2 [1/10mm] 75 - 85 Distance sensor 1 to needle [2/10mm] 80 - 300 Speed-controlled stitch length adjustment 0 - 3 [% pro 1000 min-1] ▲...
  • Page 95 Adjustment Cutting release-speed 180 - 500 Current for stepping motor axis 2 30 - 63 Current for current reduction of stepping 15 - 48 motor axis 2 Current reduction time stepping motor axis 2 0 - 2500 2000 Delay power off stepping motor 2 0 - 99 Delay power off stepping motor 1 0 - 99...

  • Page 96: Explanation Of The Error Messages

    Adjustment Explanation of the error messages Message Description E001 Pedal not in neutral position E003 SM 1 (for reference) E004 SM 2 (for reference) E009 Start inhibitor at standstill E010 Incorrect machine class E040 Transmitted light sensors E045 Bobbin thread monitoring E062 Short circuit 24V E063...
  • Page 97 Adjustment Message Description E158 Stepping motor frequency E170 Incorrect main drive transmission E171 Logical zero mark invalid E172 Communication error main drive E175 Main drive start E200 Brake path too short E201 Main drive position E222 Time-out monitoring 13 - 43...

  • Page 98: Service Menu

    Adjustment Service menu In the service menu information is displayed about the machine’s inputs and outputs, the values of both pedals and the balance wheel position. In addition the following functions can also be carried out. Switch on the machine. Call up the input mode.
  • Page 99 Adjustment Plug assignment Pin-No. Comment Function Plug marking Signal marking X11A.2 CAN- CAN_HIGH CAN_TxD X11A.3 X11A.7 CAN+ CAN_LOW CAN_RxD Set value transmitters Pin-No. Comment Function Plug marking Signal marking X11B.4 pedal X11B.5 pedal X11B.6 pedal X11B.7 pedal 2 set value SW2 (analog) X11B.8 pedal 1...
  • Page 100 Adjustment Pin-No. Comment Function Plug marking Signal marking 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 transmitter Pin-No. Comment Function Plug marking Signal marking X3.1 incr.transm.
  • Page 101 Adjustment Outputs Pin-No. Comment Function Plug marking Signal marking 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) current source DLS A10/PortA10 X13.13 X13.14 +24V +24V X13.15...

  • Page 102: Internet Update Of The Machine Software

    Adjustment Internet update of the machine software The machine software can be updated with PFAFF flash programming. For this purpose the PFP boot program and the appropriate control software for the machine type must be installed on a PC. To transfer the data to the machine, the PC and the machine control unit must be connected with an appropriate null modem cable ( part no.

  • Page 103: Wearing Parts

    Wearing parts Wearing parts This list indicates the most important wearing parts. You can request a detailed parts list for the complete machine under parts number 296-12-18 760. 91-100 296-25 (2x) 11-330 085-15 11-108 174-25 91-701 179-15 (2x) System 134 KK 91-262 250-91 91-262 377-91 99-137 192-05...
  • Page 104 Wearing parts 11-108 087-15 91-262 235-15 91-264 240-15 91-171 853-15 11-108 084-15 (2x) 91-108 222-15 99-137 151-45 91-171 049-05 91-171 042-05 14 - 2...

  • Page 105: Circuit Diagrams

    Circuit diagrams Circuit diagrams Reference list for circuit diagrams Controller Quick P322MS Control panel BDF T1 Incremental transmitter (included in M1) Keyboard Light transmitter Light receiver Light receiver Bobbin thread monitor Sewing head identification Set value transmitter Single stitch (included in A4) Backtacking by hand (backtack) (included in A4) Needle position (included in A4) Knee switch (single stitch)
  • Page 106 View Version 27.01.03 15 - 2...
  • Page 107 91-191 441-95 Circuit diagram Part 1 Version 24.01.02 15 - 3...
  • Page 108 Circuit diagram 91-191 441-95 Version 24.01.02 Part 2 15 - 4...
  • Page 109 91-191 441-95 Circuit diagram Part 3 Version 24.01.02 15 - 5...
  • Page 110 Circuit diagram 91-191 441-95 Version 24.01.02 Part 4 15 - 6...
  • Page 111 Note...
  • Page 112 PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Phone: +49 - 631 200-0 Fax: +49 - 631 17202 E-mail: info@pfaff-industrial.com Hotlines: Technical service: +49 - 175/2243-101 Application consultance: +49 - 175/2243-102 Spare-parts hotline: +49 - 175/2243-103...

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