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Pfaff 3519-5/01 Instruction Manual

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Enlarged version
3519
-5/01

INSTRUCTION MANUAL

This instruction manual applies to machines
from the serial number 2 814 134 and
software version 0361/021 onwards.
296-12-19 384/002
Instruction manual engl. 12.17

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Summary of Contents for Pfaff 3519-5/01

  • Page 1: Instruction Manual

    3519 -5/01 INSTRUCTION MANUAL This instruction manual applies to machines from the serial number 2 814 134 and software version 0361/021 onwards. 296-12-19 384/002 Instruction manual engl. 12.17...
  • 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 Safety ............................ 7 Directives ..........................7 General safety instructions ....................7 Safety symbols ........................8 Special points of attention for the owner-operator ..............8 Operating personnel and technical staff ................9 .05.01 Operating personnel ......................9 .05.02 Technical staff ........................
  • Page 4 Table of Contents Contents ..................Page Set-up ..........................27 Inserting the needle ......................27 Threading the needle thread / adjusting the needle thread tension ........28 Winding the bobbin thread / adjusting the bobbin thread tension ........29 Changing the bobbin / adjusting the bobbin thread tension ..........30 Changing the insert for darts ....................
  • Page 5 Table of Contents Contents ..................Page Tools, gauges and other accessories .................. 66 Abbreviations ........................66 Sewing head service position ....................67 Adjusting the sewing head ....................69 .05.01 Adjustment aid ........................69 .05.02 Machine drive home position ....................70 .05.03 Needle in needle hole centre ....................
  • Page 6 Table of Contents Contents ..................Page .17.01 Zero point of the workholder bar ..................103 .17.02 Workholder bar stop ......................104 Setting the pneumatic table pressure ................105 Adjusting the pressure controller ..................106 Adjusting the stacker ......................107 Adjusting the small parts stacker ..................108 Boot key ..........................

  • Page 7: Safety

    Fitting and/or using these products may therefore have neg- ative 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 8: Safety Symbols

    Safety Safety symbols Hazard point! Special points of attention Risk of injury to operating personnel and technical staff! Danger area due to laser beam! Attention! Do not operate without the finger guard and safety cov- ers! Turn off the main switch before set-up, maintenance and cleaning work! Only one person in the work area! Only one person may be in the work area of the machine during operation!

  • Page 9: Operating Personnel And Technical Staff

    Safety Operating personnel and technical staff Operating personnel .05.01 Operating personnel are persons responsible for setting up, operating and cleaning the machine, and for error clearance in the work area. The operating personnel are obligated to comply with the following points: ●...

  • Page 10: Danger Warnings

    Safety Danger warnings A work area of 1 m must be kept free in front of and behind the machine to ensure unobstructed access at all times. Do not reach into the work area of the machine during the sewing operation! Risk of injury from the needles in the sewing head and feed unit! Do not allow any objects to be placed on the table during the adjustment work! The objects could become jammed or be slung away!

  • Page 11: Proper Use

    Proper Use Proper Use The PFAFF 3519-5/01 is an automatic sewing machine and is used for sewing single and double-point breast darts on jackets. Any usage not approved by the manufacturer is deemed misuse! The manufacturer shall assume no liability for damage caused by misuse! Proper...

  • Page 12: Technical Data

    Technical Data Technical Data ▲ Stitch type: ......................301 (lockstitch) Needle system: ........................134 Needle size in 1/100 mm: ..................... 80 - 100 Stitch length: ......................0.5 - 3.0 mm Max. stitch count: ..................4300 stitches/min Start backtack stitch length: ....Standard stitch length of half of standard stitch length Start backtack stitch count: ....................

  • Page 13: Disposal Of The Machine

    Disposal of the Machine Disposal of the Machine ● It is up to the customer to dispose of the machine properly. ● The materials used for the machine include steel, aluminium, brass and various plastics. The electrical equipment consists of plastics and copper. ●...

  • Page 14: Transportation, Packaging And Storage

    Transportation, Packaging and Storage Transportation, 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 15: 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 16: Operating Controls

    Operating Controls Operating Controls Main switch ● Turning the main switch 1 switches the power supply on or off. Fig. 7 - 01 Push-buttons on the machine control unit ● Pressing the push-button 1 after switching on the power supply via the main switch, see chapter 7.01 Main switch, switches the machine control unit on and the machine is ready for...

  • Page 17: Switch For The Suction Air Blower (Option)

    Operating Controls Switch for the suction air blower (option) The suction blower integrated into the machine is only required if there is no vacuum network at the erection site. ● Pressing the push-button 1 switches the suction air blower on. ●...

  • Page 18: Control Panel

    Operating Controls Control panel The current operating statuses are indicated on the control panel 1. The machine is operated with constant dialogue between the control unit and the operator; different pictograms and / or texts are displayed for this purpose according to the operating status of the machine.

  • Page 19: Start Keys

    Operating Controls Start keys Fig. 7 - 07 ● The sewing cycle is started by pressing the two start keys 1 at the same time. After processing the sewing cycle, the lit start keys 1 show that the next sewing cycle can be started. ●...

  • Page 20: Set-Up And Initial Start-Up

    Set-up and Initial Start-up Set-up and Initial Start-up 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! Set-up Suitable electrical and compressed air supply connections must be provided at the erection site, see chapter 3 Technical Data.

  • Page 21: Removing The Transit Support On The Infeed Table

    Set-up and Initial Start-up Removing the transit support on the infeed table .01.02 ● Unscrew the screw 1. ● Loosen the screw 2 and remove the angle bracket 3. ● Tighten the screw 2 again. Fig. 8 - 02 Removing the sewing machine transit support .01.03 ●...

  • Page 22: Removing The Loading Clamp Transit Support

    Set-up and Initial Start-up Removing the loading clamp transit support .01.04 Fig. 8 - 04 ● Open the cover 1. ● Unscrew the screws 2. ● Close the cover 1 again.

  • Page 23: Assembling The Reel Stand

    Set-up and Initial Start-up Assembling the reel stand .01.05 ● Assemble the reel stand as shown in the adjacent illustration. ● Then insert the stand into the hole on the machine stand and secure it with the enclosed nuts. Fig. 8 - 05 Connecting the pedal .01.06 ●...

  • Page 24: Initial Start-Up

    Set-up and Initial Start-up Initial start-up ● Before the initial start-up, clean the machine thoroughly and lubricate or fill the oil, see chapter 12 Maintenance and Care! ● Inspect the machine and in particular the electric lines and pneumatic connecting hoses for possible damage.

  • Page 25: Switching The Machine On / Off

    Set-up and Initial Start-up Switching the machine on / off Switch the machine on ● Switch on the main switch, see chapter 7.01 Main switch. ● Switch on the machine control unit, see chapter 7.02 Push-buttons on the machine control unit. ●...

  • Page 26: Setting The Control Panel (Only For The Control Panel Bdf T1)

    Set-up and Initial Start-up Setting the control panel (only for the control panel BDF T1) ● Switch the machine on. ● Call up "Input" mode. ● Call up the service menu. ● Change the display contrast. Never reduce the display contrast to such an extent that the display can no longer be read! ●...

  • Page 27: Set-Up

    Set-up Set-up Observe and comply with all regulations and information 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 operating the main switch or by removing the mains plug! Inserting the needle Only use needles of the system...

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

    Set-up Threading the needle thread / adjusting the needle thread tension Fig. 9 - 02 ● Switch on the machine, see chapter 8.03 Switching the machine on / off. ● Call up the threading aid function. The workholder bar moves out of the needle area, the presser foot is lowered and the sewing start is disengaged.

  • Page 29: Winding The Bobbin Thread / Adjusting The Bobbin Thread Tension

    Set-up Winding the bobbin thread / adjusting the bobbin thread tension Fig. 9 - 03 ● Switch on the machine, see chapter 8.03 Switching the machine on / off. ● Fit the empty bobbin 1 onto the bobbin winder spindle 2 with the rest thread chamber on the outside.

  • Page 30: Changing The Bobbin / Adjusting The Bobbin Thread Tension

    Set-up Changing the bobbin / adjusting the bobbin thread tension Fig. 9 - 04 ● Switch on the machine, see chapter 8.03 Switching the machine on / off. ● Call up the threading aid function. The workholder bar moves out of the needle area, the presser foot is lowered and the sewing start is disengaged.

  • Page 31: Changing The Insert For Darts

    Set-up Changing the insert for darts Fig. 9 - 05 ● Screw the pin 1 provided into the threaded hole of the insert 2. ● Pull out the insert 2. ● Insert a new insert according to the dart depth. Use the blind insert 3 for double-point darts.

  • Page 32: Adjusting The Ironing Compensation Strip Feeder

    Set-up Adjusting the ironing compensation strip feeder Fig. 9 - 06 ● Loosen the screw 1. ● Adjust the ironing compensation strip feeder according to the dart length.

  • Page 33: Selecting A Program Number

    Set-up Selecting a program number ● Switch the machine on. ● Call up the menu to input the program number. ● Select the desired program number. The program numbers are allocated as follows: Program numbers 0 - 199: Single-point darts Program numbers 200 - 299: Double-point darts Program numbers 300 - 399:...

  • Page 34: Selecting / Compiling Program Groups

    Set-up Selecting / compiling program groups Selecting a program group .08.01 The corresponding group of seam programs can also be se lected instead of a program number. This assumes that the individual seam program has been assigned to a group, see chapter 9.08.02 Compiling a program group.

  • Page 35: Compiling A Program Group

    Set-up Compiling a program group .08.02 Up to 10 seam programs can be assigned to a program group. The seam programs in a se- lected program group appear as a function on the display when sewing and can be selected directly.

  • Page 36: Sewing

    Sewing Sewing The machine may only be operated by properly instructed personnel! The oper- ating personnel must make sure that only authorised persons are in the danger zone of the machine! The sewing mode is available for the production in particular in addition to input mode, see chapter 11 Input.

  • Page 37: Inserting The Workpiece

    Sewing Inserting the workpiece Inserting the workpiece using the positioning tube .01.01 Workpieces with a striped or checked patter can be aligned with the aid of the laser beam. Do not look at the laser beam with or without optical aids! Risk of retinal injuries to the eye from the concentrated light! Single-point darts 0 - 320 mm...
  • Page 38 Sewing Double-point darts Insertion mark 0 - 320 mm Insertion mark 0 - 320 mm Fig. 10 - 02...

  • Page 39: Inserting The Workpiece Using The Infeed Table

    Sewing Inserting the workpiece using the infeed table .01.02 Double-point darts Insertion mark 0 - 320 mm Insertion mark 0 - 320 mm Fig. 10 - 03...

  • Page 40: Sewing In Automatic Mode

    Sewing Sewing in automatic mode Automatic sewing mode is always called up first after switching on the machine. O Switch the machine on. O Switch on the suction of the positioning tube or infeed table, see chapter 7.06 Pedal. O Insert the workpiece, see chapter 10.01 Inserting the workpiece. O Press the start keys to start the sewing process, see chapter 7.07 Start keys.

  • Page 41: Sewing In Manual Mode

    Sewing Threading aid function This function activates the threading aid function, for example, see chapter 9.01 Inserting the needle. Stacker up/down This function is used to move the stacker up or down. Stop (The function appears only during the sewing process.) This function is used to stop the sewing process.
  • Page 42 Sewing Program selection These functions are used to select a program from the associated group, see also chapter 9.08 Selecting / compiling program groups. Material thickness This function opens a menu to change the material thickness. Manual mode This function displays the current operating mode and switches between manual and automatic mode.

  • Page 43: Error Messages

    Sewing Error messages General The display will show a error code if a malfunction occurs. An error message is generated by incorrect handling, malfunctions on the machine or by overload conditions. (For an explana- tion of the error codes, see chapter 14.02 Explanation of the error messages.) Error when switching outputs If an error occurs when switching an output, the relevant output is displayed with the de- sired switching state (0) or (I).

  • Page 44: Input

    Input Input Input mode contains the functions for displaying information, program management, machine adjustment and configuration (incl. the choice of country and access rights), as well as for supporting service and adjustment work in addition to the functions for inputting or altering seam programs.
  • Page 45 Input Info This function opens a menu to display the following information: - Current software status of the machine - Current firmware status of the machine - Current firmware status of the control panel - Daily piece counter - Bobbin thread monitor stitch counter - Operating hours counter - Production hours counter The daily piece counter and bobbin thread monitor counter can be reset using...

  • Page 46: Creating / Altering Seam Programs

    Input Creating / altering seam programs A distinction is made between three different seam types when creating or altering the seam programs: ● Single-point darts L3 = L4; program numbers 0 - 199 ● Double-point darts L3 < 4.5 mm; is not cut, program numbers 200 - 299 ●...
  • Page 47 Input Description of the functions Input mode This function is used to change the initial status of input mode. Conclude input This function is used to conclude the input and the machine switches to sewing mode. Single-point darts This function is used to call up the entry of single-point darts, see chapter 11.02.01 Creating / altering single-point darts .

  • Page 48: Creating / Altering Single-Point Darts

    Input Creating / altering single-point darts .02.01 ● Switch the machine on. ● Call up input mode. ● Call up seam program input. ● Call up the entry for single-point darts. ● Select the program number, see chapter 9.07 Selecting a program number. ●...

  • Page 49: Creating / Altering Double-Point Darts

    Input Creating / altering double-point darts .02.02 ● Switch the machine on. ● Call up input mode. ● Call up seam program input. ● Call up the entry for double-point darts. ● Select the program number, see chapter 9.07 Selecting a program number. ●...

  • Page 50: Creating / Altering Tapered Darts

    Input Creating / altering tapered darts .02.03 ● Switch the machine on. ● Call up input mode. ● Call up seam program input. ● Call up the entry for tapered darts. ● Select the program number, see chapter 9.07 Selecting a program number. ●...

  • Page 51: Entering A Comment

    Input Entering a comment .02.04 A comment can be added to the seam program after calling up the appropriate function within seam programming. The comment is displayed as information about the appropriate seam program in the program selection and program management functions. ●...

  • Page 52: Entering Correction Values

    Input Entering correction values .02.05 You can enter correction values for the current seam program after calling up the appropriate function within seam programming. The value for the uncut material fold length can also be specified for single-point and tapered darts. ●...

  • Page 53: Concluding Seam Programming

    Input Concluding seam programming .02.06 The seam programming can be concluded by pressing the appropriate function once all the details for the programming have been entered. Description of the functions The input is interrupted and the machine moves back to the initial status of the programming function.

  • Page 54: Program Management

    Input Program management The program management function is used to manage seam programs as well as configura- tion and machine data. Files can be selected, copied and deleted from the machine memory or from an SD card. ● Switch the machine on. ●...
  • Page 55 Input Description of the functions Input mode This function is used to change the initial status of input mode. Update drives This function is used to update (reimport) the drives. Conclude input This function is used to conclude the input and the machine switches to sewing mode. Data selection These functions are used to mark the desired files in the current drive.

  • Page 56: Rights Of Access

    Input Rights of access The functions that can be called up with the control panel are classified by code numbers and can be protected from unauthorised access. To this end, the control unit differentiates between three user groups (user 1, 2 and 3), all of which can be assigned a corresponding PIN.
  • Page 57 Input Allocation of the code numbers Code Standard setting Function Symbol num- User 1 User 2 User 3 Program number selection Correct program Input Create program Program management Parameter settings Parameter group 100 General settings Parameter group 200 Seam parameters Parameter group 300 Sewing motor positions Parameter group 400...
  • Page 58 Input Code Standard setting Function Symbol num- User 1 User 2 User 3 Service Run cold start Configure machine Load software Set control panel contrast Thread trimmer sequence Needle position...

  • Page 59: Maintenance And Care

    Maintenance and Care Maintenance and Care Maintenance intervals Clean the whole machine ..................weekly Clean the needle area ................several times a day Clean the hook area ................several times a day Clean the blower air filter ..................as required Clean the maintenance unit air filter (air filter) ............

  • Page 60: Cleaning The Needle Area And Hook Area

    Maintenance and Care Cleaning the needle area and hook area Fig. 12 - 01 ● Switch the machine on. ● Call up the threading aid function. The transport rail moves out of the needle area, the presser foot is lowered and the sewing start is disengaged.

  • Page 61: Cleaning The Blower Air Filter

    Maintenance and Care Cleaning the blower air filter As required: ● Remove the cover 1. ● Remove the filter element and blow it out with compressed air. ● Insert the cleaned filter element and replace the cover 1. Fig. 12 - 02 Cleaning the maintenance unit air filter Switch off the machine! Push the slide closure on the...

  • Page 62: Checking / Setting The Air Pressure

    Maintenance and Care Checking / setting the air pressure ● Check the air pressure on the manometer 1 before every start-up. ● The manometer 1 must show a pressure of 6 bar. ● Adjust this value if needed. ● To do this, pull up the button 2 and turn it so that the manometer 1 shows a pressure of 6 bar.

  • Page 63: Checking The Oil Level

    The oil tank 3 serves solely for topping up the oil reservoir 1 and not for displaying the oil level. Only use oil with a centre viscosity of 22.0 mm²/s at 40 °C and a density of 0.865 g/cm³ at 15 °C. We recommend PFAFF-sewing machine oil part no. 280-1-120 144.

  • Page 64: Lubricating The Trimmer

    Risk of injury due to accidental machine start-up! ● Add a drop of silicone oil through the hole 1 into the trimmer before every start-up. Only use oil with a density of 0.810 g/cm³ at 21 °C. We recommend PFAFF sewing machine oil part no. 280-1-120 217.

  • Page 65: Lubricating The Stacker Drive

    Maintenance and Care Lubricating the stacker drive Fig. 12 - 07 Switch off the machine! Risk of injury due to accidental machine start-up! ● Clean and then lubricate the track 1 twice a year. Only use Isoflex Topas L32 high-performance grease, order no. 280-1-120 210.

  • Page 66: Adjustment

    Adjustment Adjustment No screw clamp may be fastened to the needle bar with the PFAFF 3519-4/01! 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 carried out by technical staff trained for this purpose.

  • Page 67: Sewing Head Service Position

    Adjustment Sewing head service position The sewing head can be pulled out of the machine stand for maintenance and adjustment work. Fig. 13 - 01 Switch off the machine! Risk of injury due to accidental machine start-up! Move the sewing head into home position. ●...
  • Page 68 Adjustment Move the sewing head to the operating position. Move the sewing head to its upright position using both hands! Risk of crushing between the sewing head and the machine stand! ● Move the sewing head to its upright position and push into the machine stand until it stop.

  • Page 69: Adjusting The Sewing Head

    Adjustment Adjusting the sewing head Adjustment aid .05.01 The adjustment gauge 1 (order no. 95-752 474-05) can be used to fix the needle bar in the needle rise position (needle bar is positioned 1.8 mm after b.d.c.). Fig. 13 - 02 ●...

  • Page 70: Machine Drive Home Position

    Adjustment Machine drive home position .05.02 This setting is only made if the toothed belt 2 has been dismantled. Rule The markings 3 and 4 should be aligned if the needle bar is positioned 1.8 mm after b.d.c. Fig. 13 - 03 ●...

  • Page 71: Needle In Needle Hole Centre

    Adjustment Needle in needle hole centre .05.03 Rule The needle should pierce the centre of the needle hole exactly. Fig. 13 - 04 ● Move the needle directly over the needle hole. ● Loosen the screws 1, 2 and 3. ●...
  • Page 72 Adjustment Hook shaft bearing and spur gear clearance .05.04 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 73: Hook Lubrication

    Adjustment Hook lubrication .05.05 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 74: 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 .05.06 position finger Rule With the needle bar 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 scarf of the needle and 2.

  • Page 75: Thread Check Spring And Slack Thread Regulator

    Adjustment Thread check spring and slack thread regulator .05.07 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 maximum thread loop while passing the thread around the hook.

  • Page 76: Bobbin Winder

    Adjustment Bobbin winder .05.08 Rule 1. When the bobbin winder is switched on, the drive wheel 1 should be moved easily. 2. When the bobbin winder is switched off, the friction wheel 5 must not touch the drive wheel 1. 3.

  • Page 77: Adjusting The Thread Trimmer

    Adjustment Adjusting the thread trimmer Pre-adjusting the control cam .06.01 Rule When the needle bar is at t.d.c. the surface 1 of the control cam should be parallel to the bed plate. Fig. 13 - 10 ● Turn the control cam (screws 2) according to the rule.

  • Page 78: Roller Lever Setting

    Adjustment Roller lever setting .06.02 Rule 1. When the cylinder 3 is fully extended, the roller of the roller lever 4 should be a distance of 0.1 mm from the highest point of the control cam 5. 2. The cylinder 3 should be parallel to the front edge of the bed plate. Fig.

  • Page 79: Aligning The Thread Trimmer Laterally

    Adjustment Aligning the thread trimmer laterally .06.03 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.

  • Page 80: Knife Position

    Adjustment Knife position .06.04 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 81: Front Turning Point Of The Thread Catcher

    Adjustment Front turning point of the thread catcher .06.05 Rule When the thread catcher 5 is in the front turning point, the rear edge of the thread catcher cutout should be 1 mm in front of the bobbin case position finger 6. Fig.

  • Page 82: Manual Cutting Control

    Adjustment Manual cutting control .06.06 Rule Two threads must be cut cleanly on both the left and right in the thread catcher cutout 1. Fig. 13 - 15 ● Fit the needle plate. ● Manually move the thread catcher 1 to its front turning point. ●...

  • Page 83: Control Cam (Recalibrating)

    Adjustment Control cam .08.07 (recalibrating) Rule If the end of the thread guard 3 is positioned 2 mm behind the centre of the lug on the bobbin case position finger 4, there should also be a clearance of 2 mm between the tip of the thread catcher 6 and the centre of the lug.

  • Page 84: Adjusting The Loading Plate

    Adjustment Adjusting the loading plate Basic setting of the loading plate height .07.01 Rule The loading plate 3 should be centred between the strips 4 and 5 and be parallel to the bars 4 and 5. Fig. 13 - 17 ●...

  • Page 85: Loading Plate Position

    Adjustment Loading plate position .07.02 Rule The loading plate 1 should be parallel to the rail 3. Fig. 13 - 18 ● Remove the cover plate of the loading plate 1. ● Retract the loading plate 1 manually. ● Adjust the loading plate 1 (screws 2) according to the rule. ●...

  • Page 86: Insertion Depth Of The Loading Plate

    Adjustment Insertion depth of the loading plate .07.03 Rule 1. There should be a clearance of 12 mm between the front edge of the plate and the needle hole centre when the loading plate is retracted. 2. The screws 1 should rest on the stops when the loading plate is extended. Fig.

  • Page 87: Aligning The Sewing Head

    Adjustment Aligning the sewing head Sewing head height .08.01 Rule The upper edge of the sewing machine bed plate should have a clearance of 0.5 mm to the surface plate 5. Fig. 13 - 20 ● Move the sewing head to the service position, see chapter 13.04 Sewing head service position.

  • Page 88: Aligning The Sewing Head Laterally

    Adjustment Aligning the sewing head laterally .08.02 Rule 1. There should be a clearance of 50 mm between the front edge of the spreader 5 and the needle hole centre. 2. The sewing head should be at a right angle to the loading plate. Fig.

  • Page 89: Aligning The Surface Plate

    Adjustment Aligning the surface plate Rule 1. The surface plate 1 should be parallel to the front edge of the loading plate. 2. There should be a clearance of 1 mm between the needle plate insert and the surface plate 1. 1 mm Fig.

  • Page 90: Adjusting The Positioning Tube

    Adjustment Adjusting the positioning tube Presetting the positioning tube .10.01 Rule The bracket 1 should be parallel to the bracket 3 when the positioning tube is in the upper position. Fig. 13 - 23 ● Adjust the bracket 1 (screw 2) according to the rule.

  • Page 91: Front Final Position Of The Positioning Tube

    Adjustment Front final position of the positioning tube .10.02 Rule The positioning tube 1 should rest parallel on the loading plate in its front final position. Fig. 13 - 24 ● Adjust the positioning tube 1 (screws 2) according to the rule.

  • Page 92: Height And Alignment Of The Positioning Tube

    Adjustment Height and alignment of the positioning tube .10.03 Rule When the positioning tube 3 is in the front final position 1. its top edge should maintain a distance of 18.9 mm to the upper edge of the loading plate and 2.

  • Page 93: Height Of The Needles

    Adjustment Height of the needles Rule There should be a clearance of 4 mm between the needle points and the front edge of the loading plate 1 when the needles are extended. Fig. 13 - 26 ● Remove the cover plate of the loading plate 1. ●...

  • Page 94: Adjusting The Spreader

    Adjustment Adjusting the spreader Rule 1. When retracted, the spreader 1 should be flush with the front edge of the loading plate 2. When extended, the spreader 1 should be recessed by 3 mm. Fig. 13 - 27 ● Adjust the spreader 1 (screws 2) according to rule 1. ●...

  • Page 95: Adjusting The Table Extension

    Adjustment Adjusting the table extension Rule When extended, the front edge of the table extension 1 should be flush with the front edge of the loading plate. Fig. 13 - 28 ● Adjust the table extension 1 (screws 2) according to the rule. If necessary, the clearance between the retracted table extension 1 and the loading plate can be changed according to the incision depth on the screw 3 (nut 4).

  • Page 96: Adjusting The Loading Clamp

    Adjustment Adjusting the loading clamp Loading clamp height .14.01 Rule 1. The claws of the loading clamp should touch the retracted loading plate simultaneously from the top and bottom. 2. The claws should be parallel to the loading plate. Fig. 13 - 29 ●...

  • Page 97: Position Of The Loading Clamp

    Adjustment Position of the loading clamp .14.02 Rule 1. The inner claws of the loading clamp should touch the retracted loading plate 6 - 7 mm behind the front edge. 2. The clearance between the left claw edge of the loading clamp and the needle hole centre should be 50 mm.

  • Page 98: Adjusting The Brushes

    Adjustment Adjusting the brushes Adjusting the long brushes .15.01 Rule 1. The closed brushes 1 should rest parallel on the loading plate and close far enough that the material ail so that the material is smoothed out properly; in doing so, the loading plate should retract directly in the middle between the brushes 1.

  • Page 99: Adjusting The Short Brushes

    Adjustment Adjusting the short brushes .15.02 Rule 1. The upper and lower brush should rest directly on or against the loading plate when the brushes are closed. 2. The upper and lower brush should each have a clearance of approx. 4 mm to the loading plate when the brushes are open.

  • Page 100: Adjusting The Knife Unit

    Adjustment Adjusting the knife unit Presetting the knife unit .16.01 Rule 1. The rear edge of the retracted thread catcher should tilt forward approx. 2°. (The centre of the screw 6 is almost flush with the outer edge of the screw 7.) 2.

  • Page 101: Knife Unit Height

    Adjustment Knife unit height .16.02 Rule The thread catcher should retract in the centre of the open spreader. Fig. 13 - 34 ● Loosen the screws 1. ● Adjust the plate 2 (screw 3) according to the rule. ● Press against the bar 4 in the direction of the arrow and tighten the screws 1.

  • Page 102: Changing The Knife

    Adjustment Changing the knife .16.03 Rule The knife must be replaced when the cutting performance deteriorates. Fig. 13 - 35 ● Open the tensioning lever on the loading clamp. ● Loosen the star knob screws and push the loading clamp in the direction of the arrow. ●...

  • Page 103: Aligning The Workholder Bar

    Adjustment Aligning the workholder bar Zero point of the workholder bar .17.01 Rule 1. A gap of 5 mm should be maintained between the front edge of the workholder bar and the needle midpoint. 2. A gap of approx. 0.5 mm should be maintained between the rear edge of the workholder bar and the front edge of the presser foot.

  • Page 104: Workholder Bar Stop

    Adjustment Workholder bar stop .17.02 Rule The lowered workholder bar must rest evenly over its entire length. Fig. 13 - 37 ● Turn screws 1 (nuts 2) on both sides according to the rule.

  • Page 105: Setting The Pneumatic Table Pressure

    Adjustment Setting the pneumatic table pressure Rule The material should not move when the infeed table is extended. Fig. 13 - 38 ● Turn the piston rod 1 (nut 2) according to the rule.

  • Page 106: Adjusting The Pressure Controller

    Adjustment Adjusting the pressure controller Rule The pressure controller should switch off the machine at a pressure of 4.5 bar. Fig. 13 - 39 ● Remove the cover 1. ● Turn the screw 2 (nut 3) according to the rule. ●...

  • Page 107: Adjusting The Stacker

    Adjustment Adjusting the stacker Rule 1. The stacker support should move safely to its rear final position. 2. The stacker should move evenly and safely to its top position when loaded. Fig. 13 - 40 ● Adjust the throttle 1 according to rule 1. ●...

  • Page 108: Adjusting The Small Parts Stacker

    Adjustment Adjusting the small parts stacker Rule 1. The stacker should be adjusted so that the material is placed cleanly on the depositing table 1. Fig. 13 - 41 ● Open the screws 2. ● Adjust the stop 3 according to the rule. ●...

  • Page 109: Boot Key

    Adjustment Boot key Fatal danger from electric voltage! Fig. 13 - 43 The boot key 1 in the control box 2 is used to boot-up the machine control unit, see chapter 13.23.03 Loading / updating the operating program.

  • Page 110: Service Menu

    Adjustment Service menu The status of the digital and analogue inputs are displayed in the service menu. The outputs can be set or reset manually. In addition, it is also possible to call up functions for carrying out a cold start, for the machine configuration, for loading the operating program and for set- ting the control panel.
  • Page 111 Adjustment Loading the operating program (only on machines with the control panel BDF T1) This function is used to load the machine operating program, see chapter 13.23.03 Loading / updating the operating program. Control panel settings (only on machines with the control panel BDF T1) This function is used to call up a menu for changing the display contrast and for switching the key tone on or off, see chapter 8.04 Setting the control panel.

  • Page 112: Cold Start

    Adjustment Cold start .23.01 All newly created or modified programs as well as all changed parameter set- tings are deleted when performing a cold start! The machine memory is deleted or reset to the factory setting. ● Switch on the machine and call up input mode. ●...

  • Page 113: Machine Configuration

    Adjustment Machine configuration .23.02 The machine control unit receives the necessary information about the attached components with the machine configuration. Care must be taken to make the appropriate adjustments in the machine configuration if the machine components are changed. ● Switch on the machine and call up input mode. ●...

  • Page 114: Loading / Updating The Operating Program

    Adjustment Loading / updating the operating program .23.03 An SD card with the necessary boot files must be inserted in the SD card slot on the control panel when the machine is switched on in order to load the operating program. All data in the machine memory is deleted when the operating program is loaded! ●...

  • Page 115: Sewing Motor Menu

    Adjustment Sewing motor menu The sewing motor functions are tested and the needle position is set to t.d.c. in this menu. ● Switch the machine on. ● Call up input mode. ● Call up the sewing motor menu. Description of the functions Input mode This function is used to change the initial status of input mode.

  • Page 116: Parameter Settings

    Adjustment Parameter settings All adjustable parameters are listed in the list of parameters (chapter 13.25.02). Parameter selection as well as changing the values is described below. Selecting and changing parameters .25.01 ● Switch on the machine and call up input mode. ●...

  • Page 117: List Of Parameters

    Adjustment List of parameters .25.02 Bobbin thread monitor 0 - 2 0 = off, 1 = counter, 2 = sensor Bobbin thread counter 0 - 999 Needle thread monitor 0 - 1 Needle thread monitor hide stitches 0 - 99 The number of stitches at which the needle thread monitor is not activated when sewing is changed.
  • Page 118 Adjustment Stitch length for starting stitch condensation [0.1 mm] 10 - 30 Stitch count for starting stitch condensation 1 - 9 Stitch length for end stitch condensation [0.1 mm] 10 - 30 Stitch count for end stitch condensation 1 - 9 Angle seam end [°] 0 - 90 Stitch count for angle seam end...

  • Page 119: Control

    Control Control Home position / diagnostics / pin assignment Power supply A30 .01.01 Voltage Fuse Mains ....230V AC F6 ....(6,3 A T) Processor ... 5V DC F1 ....(2 A T) Control panel ..18 V DC F2 ....(500 mA T) I/O ......
  • Page 120 Control X2 (BS3) Signal Signal 1 ....GND 5 V 4 ......5 V 2 ....GND 5 V 5 ......5 V 3 ....GND 5 V 6 ......5 V 7 ....18 V AC 8 ......18 V AC 9 ....

  • Page 121: Basic Control Unit A20

    Control Basic control unit A20 .01.02 Supply floppy PC 104 floppy Flat cable floppy Plug connection X103 (COM1) X101 (COM2) Signal Signal 1 ....Vterm1 2 ....RxD 7 ......RTS 3 ....TxD 8 ......CTS ......9 ......Vterm2 5 ....
  • Page 122 Control X301 (X-axis / motor 1) X302 (Y-axis / motor 2)) Signal Signal 1 ....Pulse + 9 ......Pulse - 2 ....Direction + 10 ......Direction - 3 ....Gate/enable + 11 ......Gate/enable - 4 ....Current control + 12 ......

  • Page 123: Sewing Drive A22

    Control Sewing drive A22 .01.03 The sewing drive control unit is supplied from the factory with the necessary operating software already installed. This should only be replaced by the appropriate technical staff. The “Power on” LED indicates that it is ready for operation. Diagnostic functions and fuses are not provided.

  • Page 124: Stepping Motor Drive

    Control Stepping motor drive .01.04 The stepping motor control unit has the following basic setting: Motor 1: 6 A, SIN 4 Motor 2: 6 A, SIN 4 Current reduction 30%, coupling of motor 1 and motor 2 The settings are loaded. Software number: 79-001 358-91/002 Please refer to chapter 14.02.05 Stepping motor drive errors for the LED status indicators.

  • Page 125: Can Nodes A10, A11, A12

    Control X2, X3, X4 (Control of motor 1 to 3) Signal Signal 1 ....Pulse + 9 ......Pulse - 2 ....Direction + 10 ......Direction - 3 ....Gate/enable + 11 ......Gate/enable - 4 ....Current control + 12 ......
  • Page 126 Control X300 (Inputs) Signal Signal Signal ..........3 ......IN1 21 ....GND 39 ...... 24 V 4 ......IN2 22 ....GND 40 ...... 24 V 5 ......IN3 23 ....GND 41 ...... 24 V 6 ......IN4 24 ....

  • Page 127: Explanation Of Error Messages

    Control Explanation of error messages General errors .02.01 Display Description ERROR: 3 Error in allocating the EMS memory ERROR: 4 C167 is not reacting ERROR: 5 Boot file (c167boot.bin) cannot be opened ERROR: 6 Error in flash-programming ERROR: 7 Error when opening a file ERROR: 8 Battery ERROR: 9...
  • Page 128 Control Display Description ERROR: 214 No carriage start NIS ERROR: 215 Ramp not completed ERROR: 216 Material does not reach the clamp ERROR: 217 Needle thread malfunction ERROR: 241 Sewing motor error, (#Sewing motor error) see chapter 14.02.04 Sewing motor errors ERROR: 242 Remove material ERROR: 281...

  • Page 129: Can Errors

    Control Display Description ERROR: 401 Text file cannot be opened ERROR: 402 Error in read text file ERROR: 403 Error when assigning memory space for the texts ERROR: 501 Error when opening the file "pikto.hex" or "vorlagen.hex" ERROR: 502 No ACK from control panel CAN errors .02.02 Error byte...

  • Page 130: Sewing Motor Errors

    Control Sewing motor errors .02.04 Display Description Transmission error Serial interface time-out Checksum error in received data Tme-out command (48) Time-out slave expired (command string incomplete) (49) Incorrect command code (50) Framing or parity error (51) Incorrect checksum (52) Wrong date for queries (53) No parameter can be programmed (motor running) (54)

  • Page 131: Stepping Motor Drive Errors

    Control Stepping motor drive errors .02.05 It is possible to switch the stepping motor control unit to error mode if problems occur with the stepping motor drive during operation. The error message is indicated by LEDs on the stepping motor control unit. Description H 9 (red) Excessive end phase temperature...

  • Page 132: List Of Inputs And Outputs

    Control List of inputs and outputs CAN node 1 .03.01 Output Description Function Comment OUT1 Thread trimming on Valve OUT2 Positioning tube vacuum on Valve OUT3 Table vacuum on Valve OUT4 Workholder bar down Valve OUT5 Workholder bar up Valve OUT6 Work surface forwards Valve...

  • Page 133: Can Node 2

    Control CAN node 2 .03.02 Output Description Function Comment OUT1 Trimmer on Contactor OUT2 Wiper 2 off Valve OUT3 Wiper 1 off Valve OUT4 bobres Reset for bobbin thread monitor Dig. signal (active low) OUT5 Material take-over 1 closed Valve OUT6 Material take-over 2 closed Valve...

  • Page 134: Can Node 3

    Control CAN node 3 .03.03 Output Description Function Comment OUT1 Y27U1 Positioning tube cylinder 1 down (vertical) Impulse valve OUT2 Y27U2 Positioning tube cylinder 1 up (vertical) Impulse valve OUT3 Y28U1 Positioning tube cylinder 2 down Impulse valve (vertical) OUT4 Y28U2 Positioning tube cylinder 2 up Impulse valve...

  • Page 135: Special Outputs

    Control Special outputs .03.04 Description Function Comment Positioning tube down Positioning tube up Positioning tube in the middle, vertical Infeed table back Infeed table forwards Infeed table special position Positioning tube back Positioning tube forwards Positioning tube in the middle, horizontal Workholder bar down, depressurised Workholder bar down, pressurised Workholder bar up...

  • Page 136: Pneumatic Circuit Diagram

    91-744 699-95 Pneumatic Circuit Diagram Part 1 Version 14.06.06 Pneumatic Circuit Diagram The pneumatic diagram is drawn in the machine's home position. The power (air and electricity) is connected. The components are in a fixed state.
  • Page 137 Pneumatic Circuit Diagram 91-744 699-95 Version 14.06.06 Part 2...
  • Page 138 91-744 699-95 Pneumatic Circuit Diagram Part 3 Version 14.06.06...
  • Page 139 Pneumatic Circuit Diagram 91-744 699-95 Version 14.06.06 Part 4...
  • Page 140 91-744 699-95 Pneumatic Circuit Diagram Part 5 Version 14.06.06...
  • Page 141 Pneumatic Circuit Diagram 91-744 699-95 Version 14.06.06 Part 6...
  • Page 142 91-744 699-95 Pneumatic Circuit Diagram Part 7 Version 14.06.06...

  • Page 143: Circuit Diagrams

    Circuit Diagrams Circuit Diagrams Reference list for the circuit diagrams CAN 1 S200 =>1 CAN 2 S200 =>2 CAN 3 S200 =>3 Control device BS3 Sewing motor control MMC 1001 Needle thread monitor evaluation Needle thread monitor optics Control panel BDF-P1 Laser optics Bobbin thread monitor evaluation Bobbin thread monitor optics...
  • Page 144 Circuit diagrams B34U2 A12 CAN3 E34U2 Turn-up at front A12 CAN3 Spreader back A12 CAN3 Workholder bar table position Capacitor for trimming motor M5 A10 CAN1 Workholder bar up A10 CAN1 Work surface forwards A10 CAN1 Clamp feed unit to the right E10A A10 CAN1 Clamp feed unit in the middle...
  • Page 145 Circuit diagrams A30 LED => F4-6,3 A A30 LED => F5-0,5 A A30 LED => F2-0,5 A A31 LED Pulse power supply +24V / 5A / 125 VA A40 LED Axis 1 ready A40 LED Axis 2 ready A40 LED Axis 3 ready A40 LED Axis 1 excess current...
  • Page 146 Circuit diagrams X208 CAN bus X301 X-axis / motor SM 1 (M2) X302 Y-axis / motor SM 2 (M3) X303 B-axis / motor SM 3 (M4) option X400 Main drive on sewing motor M1 X401 Thread monitor Position sensor Interface Mains 230V AC Sewing motor M1 Secondary transformer...
  • Page 147 Circuit diagrams X111 A10 CAN1 Thread trimming on X112 A10 CAN1 Positioning tube vacuum on X113 A10 CAN1 Table vacuum on X114 A10 CAN1 Workholder bar down X115 A10 CAN1 Workholder bar up X116 A10 CAN1 Work surface forwards X117 A10 CAN1 Top clamp closed X118...
  • Page 148 Circuit Diagrams A10 CAN1 Top clamp closed A10 CAN1 Disengage bottom clamp A10 CAN1 Clamp coupling on A10 CAN1 Clamp feed unit to the right A10 CAN1 Clamp feed unit to the left A10 CAN1 Stacker table up A10 CAN1 Needle thread tension closed A10 CAN1 Wiper 3 off...
  • Page 149 Circuit Diagram Overview 91-191 499-95 Version 04.09.15 Part 1 3P / 230V...
  • Page 150 Circuit Diagram Overview 91-191 499-95 Version 07.02.12 Part 2 3P / 400V...
  • Page 151 91-191 499-95 Circuit Diagram Overview Part 3 Version 07.02.12...
  • Page 152 Circuit Diagram Overview 91-191 499-95 Version 07.02.12 Part 4...
  • Page 153 91-191 499-95 Circuit Diagram Overview Part 5 Version 07.02.12...
  • Page 154 Circuit Diagram Overview 91-191 499-95 Version 07.02.12 Part 6...
  • Page 155 91-191 499-95 Circuit Diagram Overview Part 7 Version 07.02.12...
  • Page 156 Circuit Diagram Overview 91-191 499-95 Version 07.02.12 Part 8...
  • Page 157 91-191 499-95 Circuit Diagram Overview Part 9 Version 07.02.12 (BDF P1)
  • Page 158 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.

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