Pfaff P45 PD 2-L Instruction Manual

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PicoDrive

P45 PD

EcoDrive

P74 ED-L

INSTRUCTION MANUAL

This Instruction Manual is valid for drives

from the following software version on:

P45 PD2-L # 4_045_05

P74 ED-L

# 1_074_06

296-12-19 160/002

Betriebsanleitung engl. 04.11

Industrial

-L

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Page 1 ® Industrial PicoDrive P45 PD EcoDrive P74 ED-L INSTRUCTION MANUAL This Instruction Manual is valid for drives from the following software version on: P45 PD2-L # 4_045_05 P74 ED-L # 1_074_06 296-12-19 160/002 Betriebsanleitung engl. 04.11...
Page 2 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. PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern...
Page 3: Table Of Contents
Index Contents ..................Page Safety ............................ 5 Directives ..........................5 General notes on safety ......................5 Safety and work symbols ....................... 6 Important notes for the user ....................6 Operating and technical staff ....................7 .05.01 Operating staff ........................7 .05.02 Technical staff ........................
Page 4 Index Contents ..................Page .02.04 Altering the number of bartacks ..................24 .02.05 Special functions ........................25 Error messages ........................26 .03.01 Description of the error messages ..................26 .03.02 Error messages for sewing head recognition unit (only on EcoDrive P74 ED-L) ....27 Bobbin thread monitor ......................
Page 5: Safety
Safety Safety Directives This sewing machine drive was built in accordance with the European regulations stated in the Conformity and Manufacturer’s Declaration. In addition to this Instruction Manual, please also observe all generally accepted, statutory and other regulations and legal requirements – also those of the country of operation – and all valid environmental protection regulations! The applicable local regulations of the social in- surance society for occupational accidents or other supervisory organisations must also be strictly adhered to!
Page 6: Safety And Work Symbols
Safety ● Work is not permitted on parts and equipment which are connected to the power supply! Exceptions to this are contained in the regulations EN 50110. ● Repair work and special maintenance work must only be carried out by specialists or appropriately trained personnel! ●...
Page 7: Operating And Technical Staff
Safety Operating and technical staff Operating staff .05.01 Operating staff are the persons responsible for setting up, operating and cleaning the machi- ne and for eliminating any malfunctions in the sewing area. The operating staff is obliged to observe the following points: ●...
Page 8: Notes On Danger
Safety Notes on danger Only operate the sewing machine drive with a protective earth conductor con- nected to a functioning protective system in accordance with all local regulati- ons and directives! Danger of electric shocks! Do not disconnect the protective earth conductor! Do not neutralize the protection by using extension lines without a protective earth conductor! Danger of electric shocks!
Page 9: Proper Use
Proper use Proper use The sewing machine drives P45 PD2-L and P74 ED-L are not machines which are ready for use. They are intended for installation in machines for the sewing thread processing industry, which are operated in clean, dry rooms. Any and all uses of this machine, e.g.
Page 10: Specifi Cations
Speciﬁ cations ▲ Speciﬁ cations Rated values Voltage: .......................230 V, single-phase Frequency: ........................50/60 Hz Current for drive: .......................5.0 A Current for control unit: .....................0.6 A Power output: .........................550 W Speed: ........................4000 min Torque: ...........................1.2 Nm Moment of inertia of motor (without belt pulley): .............1.0 kgcm2 Operating mode: ............S5 (40% rel.
Page 11: Disposal
Disposal Disposal ● Proper disposal of the sewing machine drive is the responsibility of the customer. ● The materials used for the sewing machine drive are steel, aluminium, brass and various plastic materials. The electrical equipment comprises plastic materials and copper. ●...
Page 12: Transportation Packing And Storage
Transportation packing and storage Transportation packing and storage The sewing machine drive can be transported and stored at temperatures in the range from -25 to +55 ° C. For a period of less than 24 hours temperatures up to +70° C are permitted. Transportation to the customer’s premises The sewing machine drives are delivered completely packed.
Page 13: Control Elements
Control elements Control elements Main switch ● Turn main switch 1 to switch the power supply of the sewing machine drive on or off. Fig. 6 - 01 Control panel The control panel is used to display and call up the machine functions for setting up and for sewing operation, for entering parameter values and for reading error messages and service settings.
Page 14: Selection Keys
Control elements Selection keys .02.01 The functions of the selections keys 2 are described in detail below: Scrolling ● This selection key is used to change between the different menus shown on the display. The selection of the menu and the setting values shown depend on the selection of the operating mode, also see Chapter 9.01 Manual sewing or Chapter 9.02 Programmed sewing.
Page 15: Function Keys
Control elements Function keys .02.02 The function keys 3 described below generally have two basic functions: ● To switch the sewing function on or off (LED in the "TE/Input" key is off) An activated function is always shown by the corresponding illuminated LED. ●...
Page 16 Control elements Sewing with light barrier / D+ ● If the "TE / Input key" is switched off, the sewing with light barrier functions is switched on or off. When sewing with light barrier, the number of stitches entered corresponds to the light barrier compensation stitches.
Page 17: Installation And Commissioning
Installation and commissioning Installation and commissioning Only operate the sewing machine drive with a protective earth conductor connected to a functioning protective system in accordance with all local regulations and directives! Danger of electric shocks! Do not disconnect the protective earth conductor! Protection is neutralized by the use of extension lines without a protective earth conductor! Danger of electric shocks! Before connecting the sewing drive make sure that the mains voltage is within...
Page 18: Sewing
Sewing Sewing In the sewing mode all settings, which are relevant for the sewing operation, are shown on the display. Functions can be switched on or off by pressing a key, set values for the most important parameters can be altered directly. The "PM"...
Page 19: Switching The Sewing Functions On / Off
Sewing Switching the sewing functions on / off .01.01 ● When the "TE / input" selection key is switched off, the sewing functions for manual sewing can be switched on or off. If a function is activated, the LED in the corresponding key is illuminated: Foot position raised after sewing Start tacks on/off...
Page 20: Selecting The Parameter Input
Sewing Selecting the parameter input .01.03 ● Call up the display diagram for the parameters (if necessary, press the key several times). ● Switch on the "TE / input" function (LED is illuminated). 111a The ﬁ rst parameter with the corresponding set value is shown on the display. The parameter selection and the alteration of the value can be carried out as follows: Selecting the hundred ﬁ...
Page 21: Programmed Sewing
Sewing Programmed sewing ● Switch on the machine. ● Select programmed sewing (LED in the selection key is illuminated) by pressing the "PM" key. ● By pressing the "scroll" key it is possible to choose one of the following display diagrams: Seam program number, seam segment number and number of seam segment stitches...
Page 22: Switching The Sewing Functions On / Off
Sewing Switching the sewing functions on / off .02.01 When the "TE / input" selection key is switched off, the sewing functions for the current seam sector can be switched on or off. If a function is activated, the LED in the corresponding key is illuminated: Foot position raised after sewing Start tacks on/off...
Page 23: Selecting The Speed, Next Program And Number Of Seam Segments
Sewing Selecting the speed, next program and number of seam segments .02.03 ● Call up the display diagram for the speed, the next program and the number of seam segments (if necessary, press key several times). ● Switch on the "TE / input" function (LED is illuminated). 1000 0 5 The corresponding set values are shown on the display and can be altered as follows: Alter the speed (A+)
Page 24: Altering The Number Of Bartacks
Sewing Altering the number of bartacks .02.04 ● Call up the display diagram for the start and end bartacks (if necessary, press key several times). ● Switch on the "TE / input" function (LED is illuminated). 3 3 3 3 The number of bartack stitches are shown on the display, which can be altered as follows when the machine has stopped: Increase the number of...
Page 25: Special Functions
Sewing Special functions .02.05 ● Call up the display diagram for the special functions (if necessary, press key several times). ● Switch on the "TE / input" function (LED is illuminated). 1 1 I I 00 The special functions together with the corresponding seam program and seam segment are shown on the display: Select the seam Stop at seam end on/off (C+)
Page 26: Error Messages
Sewing Error messages When an error occurs, the text "Err:" appears on the display together with an error code, as shown in the example below. An error message can be caused by incorrect settings, defec- tive elements or overload conditions. Err: ●...
Page 27: Error Messages For Sewing Head Recognition Unit (Only On Ecodrive P74 Ed-L)
Sewing E r r o r- Cause Remedy code Err: 71 Incremental transmitter of motor Check plug of incremental transmitter not connected Err: 73 Faulty running of motor (set rotati- Check machine for binding on speed not reached) Err: 74 No synchronisation impulse from Check transmitter sewing head...
Page 28: Bobbin Thread Monitor
Sewing Bobbin thread monitor The adjustment of the bobbin thread monitor is carried out with parameters "660", "727" and "760" (760 only on P74 ED-L), see Chapter 9.03 Parameter input. ● Switch on the machine. ● Call up the display diagram for the parameters (if necessary, press key several times). ●...
Page 29 Sewing RM: 987 ● Reset the stitch counter by operating the "F1-key". The number of remaining stitches till bobbin change appears on the display. Depending on the drive unit and parameter setting, the following message appears on the display after the number of remaining stitches have been sewn: Bobbin The machine positions and the LED in the function key "F1"...
Page 30: Input
Input Input Seam programming The display diagrams shown below serve as an example for the corresponding input possibilities. The set values described on the machine may differ from these. ● Switch on the machine. ● Select programmed sewing function by pressing the "PM" key (LED on the selection key is illuminated).
Page 31: Selecting The Seam Program Number And Seam Segment
Input Seam program number, seam segment and special function 1 1 I I 00 ● The set values can be adjusted in each case by pressing the corresponding function keys. Selecting the seam program number and seam segment .01.01 ● Switch on the machine. ●...
Page 32: Entering The Speed, Next Program And Number Of Seam Segments
Input Entering the speed, next program and number of seam segments .01.02 ● Switch on the machine. ● Select programmed sewing function by pressing the "PM" key (LED on the selection key is illuminated). ● Switch on the "TE / input" function (LED is illuminated). ●...
Page 33: Entering Bartack Stitches
Input Entering bartack stitches .01.03 ● Switch on the machine. ● Select programmed sewing function by pressing the "PM" key (LED on the selection key is illuminated). ● Switch on the "TE / input" function (LED is illuminated). ● Press the selection key until the display for entering the bartack stitches appears on the screen.
Page 34: Entering Special Functions
Input Entering special functions .01.04 ● Switch on the machine. ● Select programmed sewing function by pressing the "PM" key (LED on the selection key is illuminated). ● Switch on the "TE / input" function (LED is illuminated). ● Press the selection key until the display for entering special functions appears on the screen.
Page 35 Input Switching the feed changeover function on/off (I = on; 0 = off) If the function is switched on, the feed unit is switched at the end of the selected seam segment. Switching the manual seam segment on/off (I = on; 0 = off) If the function is switched on, the selected seam segment is sewn without stitch coun- ting.
Page 36: Entering The Seam Segment Stitches
Input Entering the seam segment stitches .01.05 ● Switch on the machine. ● Select programmed sewing function by pressing the "PM" key (LED on the selection key is illuminated). ● Switch on the "TE / input" function (LED is illuminated). ●...
Page 37: Example Of How To Enter A Seam Program
Input Example of how to enter a seam program Seam segment 1 Seam segment 2 Seam segment 4 Program 1 Seam segment 3 Example: Attaching a label - Program number: 1 - Speed: 1500 min-1 - Seam segment 1 with 20 stitches, start bartack, programmed stop and raise sewing foot at end of seam - Seam segment 2 with 10 stitches, programmed stop and raise sewing foot at end of seam - Seam segment 3...
Page 38 Input 3 3 3 3 ● Select the desired number of stitches for each case with the corresponding function keys. Number of forward stitches for the start bartack (setting range A) Number of reverse stitches for the start bartack (setting range B) Number of reverse stitches for the end bartack (setting range C) Number of forward stitches for the end bartack (setting range D) ●...
Page 39 Input ● Using the corresponding function keys, call up seam segment "1". ● Enter the number of seam segment stitches ("20") for seam segment "1" with the corre- sponding function keys. ● Press the selection key until the display for entering the special functions appears on the screen.
Page 40 Input ● Switch the "TE / input" function on again (LED is illuminated). ● Press the selection key until the display for the seam program number appears on the screen together with the seam segment number and the number of seam segment stitches.
Page 41 Input ● Switch the "TE / input" function on again ((LED is illuminated) ● Press the selection key until the display for the seam program number appears on the screen together with the seam segment number and the number of seam segment stitches.
Page 42 Input ● Switch the "TE / input" function on again ((LED is illuminated). ● Press the selection key until the display for the seam program number appears on the screen together with the seam segment number and the number of seam segment stit- ches.
Page 43: Parameter Input
Input Parameter input Example of how to enter the parameters .03.01 ● Switch on the machine. ● Select the manual sewing mode by pressing the "PM" key (LED in the selection key is off). ● Switch on the "TE / input" function (LED is illuminated). ●...
Page 44: Selecting The User Level
Input Selecting the user level .03.02 ● Switch on the machine. ● Select the manual sewing mode by pressing the "PM" key (LED in the selection key is off). ● Switch on the "TE / input" function (LED is illuminated).. ●...
Page 45: List Of Parameters For Control Unit P45 Pd2-L
P45 PD2 Input List of parameters for control unit P45 PD2-L .03.03 Only appropriately trained personnel is authorized to alter the set values in the parameters of user level "B" and "C". Speed at seam start 300 - 2000 Speed at seam end 300 - 2000 Light barrier compensating stitches 1 - 30...
Page 46 Input P45 PD2 Function of "needle position change" key 1 - 6 1 = needle raised without trimming 2 = needle position change 3 = single stitch 4 = not allocated 5 = tack inversion 6 = tack suppression Function of F1 key on control panel 1 - 6 1 = needle up without trimming 2 = needle position change...
Page 47 P45 PD2 Input Actual speed value in display ON - OFF ON = on, OFF = off Minimum speed 120 - 800 ▲ Maximum speed 300 - 3000 Speed stage curve (pedal characteristic) 0 - 4 0 = 12 stages non-linear 1 = 12 stages linear 2 = 24 stages non-linear 3 = 24 stages linear...
Page 48 Input P45 PD2 Thread wiper ON - OFF ON = yes, OFF = no Thread tension release in conjunction with ON - OFF presser foot lift during intermediate stop, if parameter 636 is at ON ON = on, OFF = off 700* Needle position 0 0 - 255...
Page 49 P45 PD2 Input Acceleration ramp for sewing motor 0 - 50 1 = ﬂ at, 50 = steep Brake ramp for sewing motor 1 - 50 1 = ﬂ at, 50 = steep Bobbin monitoring effective ON - OFF ON = sewing motor stop and signal lamp on OFF = signal lamp on Start delay after lowering presser foot [ms]...
Page 50 Input P45 PD2 799* Selected machine class 1 - 2 2231, 2235, 2545/46 2335 800* Motor rotating direction when looking at V- 0 - 1 belt pulley 1= anti-clockwise, 0 = clockwise Reversing angle at end of seam 10 - 212 802* Speed reduction main drive 0 - 1...
Page 51 P45 PD2 Input Switchover of display on screen 0 - 4 >1 = diagnosis display 0 = standard display Hold-back time (premature electrical switch- 10 - 200 over) for feed adjustment when switching on [ms] Hold-back time (premature electrical switch- 10 - 200 over) for feed adjustment when switching off [ms]...
Page 52: List Of Parameters For Control Unit P74 Ed-L
Input P74 ED List of parameters for control unit P74 ED-L .03.04 Only appropriately trained personnel is authorized to alter the set values in the parameters of user level "B" and "C". Control panel key tone ON - OFF Speed at seam start 100 - 6400 Speed at seam start ON - OFF...
Page 53 P74 ED Input End tack ON - OFF (when parameter 523 is set at "1") ON = ornamental tack, OFF = standard tack Third seam section at start of decorative back- ON - OFF tack Function selection for knee switch 0 - 2 0 = Function off 1 = Stroke adjustment manual...
Page 54 Input P74 ED Selection of tack type 1 - 2 1 = programmable start tack as loose tack 2 = programmable start tack as ornamental tack No. of forward stitches for programmable start 1 - 9 tack No. of reverse stitches for programmable start 1 - 9 tack Speed of programmable start tack...
Page 55 P74 ED Input Speed at max. stroke adjustment 300 - 6400 1000 Delay time till speed release at end of stroke 0 - 2500 adjustment [ms] No. of stitches with stroke adjustment 0 - 250 Special function ON - OFF On = bartack with short stitch length, seam with long stitch length, control for stitch length without function...
Page 56 Input P74 ED Speed level curve (pedal characteristic ON - OFF ON = linear, OFF = non-linear Trimming speed 1 60 - 300 End recognition with light barrier ON - OFF ON = from bright to dark Off = from dark to bright Return after seam end ON - OFF ON = yes, OFF = no...
Page 57 P74 ED Input Start inhibitor when drive is running and ma- ON - OFF chine is tilted back ON = Error 92 appears on the display. After the machine has been set in an upright position, the drive must be switched off then on again. The start inhibitor function is then out of action.
Page 58 Input P74 ED 705* End of cutting signal (no. of degrees on balance wheel - 0°) 2235, 2542, 2545/46-900/81, 2595/96 0 - 255 2545-900/82 0 - 255 706* Start of cutting signal (no. of degrees on balance wheel - 173°) 2235, 2542, 2545/46-900/81, 2595/96 0 - 255 2545-900/82...
Page 59 P74 ED Input Thread tension control during stroke adjust- ON - OFF ment, ON = on, OFF = off Lifting delay for presser foot when pedal posi- 10 - 2000 tion is "-1" [ms] No. of stitches for stitch length "0" at begin- 0 - 20 ning of seam Stop time for ornamental tack [ms]...
Page 60 Input P74 ED Needle position 10 (bearing position) 0 - 255 Delay for feed adjustment on during 0 - 2000 trimming with shortened trim stitch [ms) Hardware test ON - OFF OFF = off, ON = on User level 0 - 20 0 = user level A 1 = mechanic level B 11 = service level C...
Page 61 P74 ED Input Proportional ampliﬁ cation of speed control of sewing motor 2235, 2542, 2545/46-900/81, 2545-900/82 3 - 24 2595/96 3 - 24 Integral ampliﬁ cation of speed control of sew- 10 - 80 ing motor Proportional ampliﬁ cation of positioning con- 1 - 30 troller (sewing motor) Differential ampliﬁ...
Page 62 Input P74 ED Switch off position for presser foot when 0 - 255 thread is clamped at beginning of seam Switch on position for thread clamp 2235, 2542, 2545/46-900/81, 2595/96 0 - 255 2545-900/82 0 - 255 Switch off position for thread clamp 2235, 2542, 2545/46-900/81, 2595/96 0 - 255 2545-900/82...
Page 63: Service Functions
Service functions Service functions Resetting the control unit Calling up the reset function .01.01 ● Switch off the machine. ● Press and hold the "start bartack" and "sewing with light barrier" function keys simultane- ously and switch on the machine. Continue pressing the function keys until the following display appears on the screen.
Page 64: Resetting The Set Parameter Values
Service functions Resetting the set parameter values .01.02 With this function all set values, with the exception of the specially marked parameters, are set back to their default value (status at time of delivery), see Chapter 9.03.03 List of parameters. ●...
Page 65: Deleting All Seam Programs
Service functions Deleting all seam programs .01.03 With this function all seam program inputs are deleted. ● Call up the reset function, see Chapter 10.01.01 Calling up the reset function. Danger of unintentional data loss! After operating the corresponding function key, the selected reset is carried out without further check.
Page 66: Cold Start
Service functions Cold start .01.04 With this function a cold start is carried out. All inputs are deleted and all set parameter values are set back to their default value (status at time of delivery), see Chapter 9.03.03 List of parameters. ●...
Page 67: Display Of Software Version And Current Machine Class For Picodrive P45 Pd2-L
Service functions Display of software version and current machine class for PicoDrive P45 PD2-L ● Switch off the machine. ● Hold the "scroll" key pressed down and switch on the machine. The current software version is displayed, until any key is pressed. 4_045_00 ●...
Page 68: Display Of Software Version For Ecodrive P74 Ed-L
Service functions Display of software version for EcoDrive P74 ED-L ● Switch on the machine. First the type of control panel is shown. Pico Top Then the type of control unit and the set machine class are shown. P74ED 1 Then the software version is shown for a short time.
Page 69: Hardware Test For The Picodrive P45 Pd2-L
Service functions Hardware test for the PicoDrive P45 PD2-L ● Switch on the machine. ● Select the manual sewing mode by pressing the "PM" key (LED in the selection key is off). ● Switch on the "TE / input" function (LED is illuminated). ●...
Page 70 Service functions ● Select the desired input with the corresponding function keys (setting range C). The switch status of the current input is shown in setting range D. Following inputs can be shown: In 1: E1 / TUM manual In 2: E2 / various functions, selection with parameter "446"...
Page 71 Service functions Ped: ● Operate the pedal. The activated pedal stages are shown in setting range D. ● Call up the test for the synchronizer in the motor with the corresponding function keys. Pos: 137 ● Turn the balance wheel and check the needle bar reference position (parameter "700"). ●...
Page 72: Hardware Test For The Ecodrive P74 Ed-L
Service functions Hardware test for the EcoDrive P74 ED-L ● Switch on the machine. ● Select the manual sewing mode by pressing the "PM" key (LED in the selection key is off). ● Switch on the "TE / input" function (LED is illuminated). ●...
Page 73 Service functions ● Select the desired input with the corresponding function keys (setting range C). The switch status of the current input is shown in setting range D. Following inputs can be shown: In 3: Slide sensor In 6: Stop / start inhibitor In 7: Stroke lift adjustment In 8:...
Page 74 Service functions ● Select the test mode for the pedal with the corresponding function keys. Ped: ● Operate the pedal. The activated pedal stages are shown in setting range D. ● Call up the test for the synchronizer in the motor with the corresponding function keys. Pos: 137 ●...
Page 75 Service functions ● With the corresponding function keys, call up the display for testing the LEDs on the key panel of the sewing machine head. The corresponding number of the pressed key appears on the display. If no key panel is connected, the message "Err"...
Page 76 PFAFF Industriesysteme und Maschinen AG Hans-Geiger-Str. 12 - IG Nord D-67661 Kaiserslautern Phone: +49 - 6301 3205 - 0 Fax: +49 - 6301 3205 1386 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 Printed in Germany...

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