Related Manuals for Pfaff PicoDrive P40PD
Summary of Contents for Pfaff PicoDrive P40PD
- Page 1 Instruction Manual PicoDrive P40,41,42,43,44PD Quick Part 2 Control panel Pico Top Instruction manual 08.2008 296-12-18 xxx/xxx...
- Page 2 The reprinting, copying or translation of PFAFF Manuals, whether in whole or in part, is only permitted with our previous authorization and with written reference to the source. PFAFF Industrie Maschinen AG Postfach 3020 D-67653 Kaiserslautern Königstr. 154 D-67655 Kaiserslautern...
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Page 3: Table Of Contents
Table of Contents Part 2 Chp. Contents Page Description of the PicoDrive drive system 7.1 - 7.8 Motor QE3760/QE5540 Control unit P4xPD Speed control unit SCU2 External PicoTop control panel Using the drive Application 8.1 - 8.18 Displays on the PicoTop control panel Sewing programs Sewing with an external PicoTop control panel Sewing with a sewing program based on a program example... -
Page 4: Description Of The Picodrive Drive System 7.1
Description of the PicoDrive drive system The PicoDrive drive system is an electronically commutated, brushless DC motor. The drive system comprises the following main assemblies: Fig. 7.1 Fig. 7.2 Fig. 7.3 Fig. 7.4 Motor QE3760 or QE5540 (Fig. 7.1) with an integrated opto-electronic angular rotation sensor for commutation and positioning. -
Page 5: Control Unit P4Xpd
7.2 Control unit P4xPD Fig. 7.5 Fig. 7.6 The control system casing is suspended from below and screwed to the table top with four screws which are included with delivery. The mains connection is single-phase via the three-conductor cable exiting from the back by means of a locally used plug with earthing contact. -
Page 6: Speed Control Unit Scu2
Speed control unit SCU2 The SCU2 is secured beneath the machine table using the bracket included and is mechanically connected to the machine treadle by means of a pitman rod. The SCU2 is connected electrically via the nine-connector coupling to the X3 connector on the back of the control unit. -
Page 7: External Picotop Control Panel
External PicoTop control panel Fig. 7.14 The PicoTop control panel (Fig. 7.14) has the following components a single line display with an 8-digit LCD matrix 4 setting ranges: A+ / A-, B+ / B-, C+ / C-, D+ / D- (when TE on) the T11 key (PM) for choosing the mode "manual sewing"... - Page 8 Function of the T11 key for choosing modes T11 (PM) unlit, manual sewing T11 (PM) lit, programmed sewing Function of the PM key in "Manual sewing" mode (Fig. 7.15) T11 key (PM) unlit, T10 key (TE) lit. Paging key TE key (Enter mode) PM key (Program mode)
- Page 9 Setting for T9 key (paging) is on mode 3 (Fig. 7.17): used to select front and end backtack stitches for the selected program: Paging key TE key (Enter mode) PM key (Program mode) Fig. 7.17 A+ / A- Set stitch number A front backtack forward B+ / B- Set stitch number B front backtack backward C+ / C-...
- Page 10 Setting for T9 key (paging) is on mode 1 (Fig. 7.19): used to select the display program number, display seam section number and the seam section stitches: Paging key TE key (Enter mode) PM key (Program mode) Fig. 7.19 A+ / A- Set the program number B+ / B- Set the seam section number...
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Page 11: Using The Drive
The following applies: For the P45PD drive system Parameter <799> to 1 = machine class 1 for: 1 = PFAFF machine class 1163 2 = PFAFF machine class 1180 3 = PFAFF machine class 1122 4 = PFAFF machine class 591... -
Page 12: Application 8.1
Application The PicoDrive drive system can only be operated with an external PicoTop control panel! Switching on The on/off switch (mains switch) S1 is located on the front of the control unit. When switched on, the S1 switch lights up if there is mains voltage. 8.1 Displays on the PicoTop control panel After switching on the control unit, the control field name (Fig. - Page 13 Then the current machine class (Fig. 8.3) is displayed for approx. 3 sec. Fig. 8.3 Depending on the setting, manual mode (PM off) will then display the set backtack stitch numbers for the front and end backstitch (Fig. 8.4), the set maximum speed (Fig. 8.5) or the parameter menu (Fig. 8.6). Fig.
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Page 14: Sewing Programs
Sewing programs a) Number of sewing programs: b) Seam sections per sewing program: c) Stitch number per seam section: max. 250 d) Assignment of sewing functions to the seam section (see also Chp. 7.7): - T1 front backtack (on / off) - T2 end backtack (on / off) - T3... -
Page 15: Sewing With An External Picotop Control Panel
8.3 Sewing with an external PicoTop control panel Sewing without a sewing program (manual sewing) Precondition: Key 11 (P/M) is unlit Shown on the display (Fig.8.8) target stitches for front backtack target stitches for end backtack Fig. 8.8 The target stitch numbers for the front and end backtacks can only be set when the machine is at standstill: for front backtack with key A+ or B+ or key A - or B-,... -
Page 16: Sewing With A Sewing Program Based On A Program Example
Sewing with a sewing program based on a program example: 3 programs that are linked to each other with the following functions Program 1, with constant speed of 1000 revolutions, 3 seam sections, 5 stitches per seam section and linked with program 2, Program 2, with constant speed of 1500 revolutions, 5 seam sections, 7 stitches per seam section and linked with program 3, Program 3, with constant speed of 1800 revolutions, 4 seam sections, 10 stitches per seam section... - Page 17 8.4.2 In program 1: Entering the program speed you want Precondition: Program 1 has been preselected as described under 1.2 to 1.3! To enter the desired program speed in "Program 1" press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig.
- Page 18 8.4.3 In program 1: Entering the desired number of seam sections Precondition: Program 1 has been preselected as described under 1.2 to 1.3! To enter the desired program speed in "Program 1" press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig.
- Page 19 8.4.4 In program 1: Entering the desired backtack stitches for front and end backtacks Precondition: Program 1 has been preselected as described under 1.2 to 1.3! To enter the desired backtack stitches for front and end backtacks in "Program 1" press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig.
- Page 20 8.4.5 In program 1: Entering the desired special functions for the intended seam sections Precondition: Program 1 has been preselected as described under 1.2 to 1.3! To enter the desired special functions in "Program 1" press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig.
- Page 21 8.4.6 Linking program 1 with program 2 and program 2 with program 3: Press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig. 8.6 appears Program number Seam section number Number of stitches (1-250) for seam section 1 Fig.
- Page 22 Press the paging key until the display Fig.8.8 appears Program number Seam section number Number of stitches (1-250) for seam section 1 Fig. 8.8 Set program number "2" with the A+ / A- keys, 6.10 Press the TE key, (LED off), values are accepted! 6.11 Press the TE key, (LED on), entry mode 6.12 Press the paging key until the display Fig.
- Page 23 8.4.7 Linking program 3 with program 1: To ensure that the machine starts again with program 1 at the end of program 3, you have to link program 3 with program 1! Press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig.
- Page 24 8.4.8 Entering thread trimming in program 3, at the end of seam section 3: In order for thread trimming to be carried out at the end of "Program 3" and "Seam section 3" proceed as follows: Press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig.
- Page 25 8.4.9 Preparing program 1: In order for the program start to begin with "Program 1" and "Seam section1" proceed as follows after programming: Press the PM key, (LED on) and press the TE key, (LED on) Press the paging key until the display Fig. 8.14 appears Program number Seam section number Number of stitches (1-250)
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Page 26: Special Darning Program
Special darning program The special darning program is activated when parameter <313> is set to 1 (Fig. 8.1) In this special program, only seam sections 1 and 2 are effective, consequently seam section 1 is sewn forwards and seam section 2 is sewn backwards. There are up to 99 repetitions (darning cycles) available. - Page 27 Press the TE key (LED on) Using the D+ / D- keys set parameter <313> to value 1 (Fig. 8.11) Press the paging key until display Fig. 8.2 appears Darning program speed Number of darning cycles Fig. 8.2 Use the A+ / A- keys to set the desired constant programmed speed Use the D+ / D- keys to set the desired number of darning cycles Note: A setting of "8 darning cycles"...
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Page 28: Error Messages (Troubleshooting)
8.6 Error messages (troubleshooting) The drive control system carries out cyclical checks of its own functional capacity and the functional capacity of the entire drive system. Malfunctions are shown via the external control panel display (Fig. 8.1), e.g.: Fig. 8.1 Summary of error numbers: Error No. - Page 29 Error No. Cause Remedy Power electronics shut-down Remove cause during operation because: a) Overcurrent or short circuit in motor b) Overvoltage, mains voltage > 300V Motor overloaded when braking c) Undervoltage Machine blocked, no increment Remove cause from sychronizer at maximum motor current.
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Page 30: Programming Level A (Operator Level)
Parameter programming Programming level A (operator level) Control parameters that directly affect the sewing process are programmed at this level. These are the parameters for the following functions: Light barrier compensation stitches <111> Darning program <313> Backtack (decorative backtack on/off) <523>... -
Page 31: Programming Level "B" (Mechanic Level)
Programming level "b" (mechanic level) The control parameters which have to be altered or adjusted only exceptionally rarely or only for commissioning the drive system are programmed at this level. Switching programming level "b" on - Press the T/E key, (LED on). - Press the paging key until display Fig. -
Page 32: Programming Level "C" (Special Level)
- Press keys A+ / A- and B+ / B- until the desired parameter is displayed. - Keys D+ or D- are used to enter the desired parameter value. Switching programming level "b" off - Press the T/E key, LED off; sewing is possible again. Programming level "c"... - Page 33 - Use the D+ or D- keys to enter parameter value "11", Fig. 9.5 - "c" = programming level "c" then appears, Fig. 9.5 Parameter number "D" key Parameter value "11" Paging key TE key, (LED on) PM key, (LED off) Fig.
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Page 34: Resetting
Resetting (RESET) a) Resetting parameter values - ParReset "1" All parameter values which have been altered from their status on delivery (standard value) will be reset by this procedure to their standard value (default value) again. Exceptions: Parameters that are marked with a " * " (such as e.g. B. 700, 799, 800) remain unaltered! See parameter list in Part 3 Regarding these parameters, the values programmed by the user remain even after implementing this RESET. - Page 35 Then the display (Fig. 9.8) changes back to the previously selected work mode. Fig. 9.8 b) Reset all seam data - SewReset "2" All seam data which have been programmed by the user are deleted! Expiry of the parameter value reset - SewReset "2": Switch off mains switch Press keys A+ and D+ simultaneously and hold pressed Switch on mains switch...
- Page 36 If RESET is executed, the display shows this reset version for approx . 1 sec! (Fig. 9.10)! Fig. 9.10 If the RESET is not carried out, the display shows this display for approx. 1 sec! (Fig. 9.11) Fig. 9.11 Then the display (Fig. 9.12) changes back to the previously selected work mode. Fig.
- Page 37 c) Reset all values - ResetAll "3" Attention: All values are reset to their default values; a so-called cold start is carried out! All parameter values, including those marked with a " * " are reset to their default values! All seam data that have been programmed by the user are deleted! Expiry of the parameter value reset - ResetAll "3": Switch off mains switch...
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Page 38: Start Inhibitor Device (Error 9)
Then the display (Fig. 9.15) changes back to the previously selected work mode. Fig. 9.15 Start inhibitor device (Error 9) Input E5 of the control unit is intended as a start inhibitor device for the machine. The input mode of operation can be selected with parameter <665>. Parameter <665>... -
Page 39: Treadle (Speed Control Unit)
Treadle (speed control unit) Treadle stages: Treadle fully back (initiate seam end) Treadle slightly back (lift presser foot) Zero position (no treadle operation) Treadle slightly forwards (lower presser foot) Treadle further forwards (minimum speed parameter 606 ) 2D to 23D other speed stages (depending on parameter 608) Treadle fully forwards (maximum speed) The course of speed (treadle stages 1D ... -
Page 40: Checking The Direction Of Rotation And Reference Position Of The Needle Bar (Needle Position Np0)
10. Commissioning If the PicoDrive has been stored at temperatures <+5°C, it must be brought up to an operating temperature between +5°C to +45°C before commissioning. There must be absolutely no moisture! Before you can work with the machine, carry out the following: a) Check the direction of rotation and the reference position of the needle bar b) Check the needle positions c) Check the maximum speed... -
Page 41: Teach Process For The Gear Ratio
10.2 Teach process for the gear ratio This is required if the motor drives the machine via a V belt (Parameter <802> = 1), or when there is an increase or reduction in ratio of motor to machine (unequal 1:1). Hardware prerequisite: Synchroniser PD3 or another sensor, that delivers precisely one impulse per revolution. -
Page 42: Checking Needle Positions Np1/Np2
10.3 Checking needle positions NP1/NP2 NP1 - needle down (<702>) NP2 - thread lever up (<703>) a) Switch on programming level "b" (mechanic level) (see Chp. 9.2 Programming level "b") b) Call up parameter <702> c) Press treadle forwards Response: Machine starts up and positions according to <702> d) Is the needle position correct? If yes, then continue with g) If no, then correct position by :... -
Page 43: Hardware Test
10.6 Hardware test The hardware test is a test program that makes it possible with the aid of the PicoTop control panel to check different drive components (of the control unit) and the machine installation. Switching on the "Hardware test" test program Procedure: Switch on programming level "c". - Page 44 The output mode is selected using keys A+ / A- (Fig. 10.3) Outputs: Output Output No. Fig. 10.3 The output is selected using keys C+ / C- The output displayed is switched on using key D+ The output displayed is switched off using key D- (or by changing menu) Output 1: Presser foot is cycled Output 2:...
- Page 45 The treadle test mode is selected using keys A+ / A- (Fig. 10.4) Testing treadle stages (speed control unit stages): Treadle (speed control unit) Example: Displays the fourth speed stage Fig. 10.4 By pressing the treadle forwards (on the speed control unit), the active treadle stages are displayed, treadle stages from -2, -1 to 0, +1 and from 1D to 24D are possible, depending on the setting for parameter <608>...
- Page 46 The synchroniser test mode is selected using keys A+ / A- (Fig. 10.5) Synchroniser in the motor: Position Relative position of the motor in relation to the logical zero marks Fig. 10.5 By turning the handwheel, the relative position of the motor in relation to the logical zero marks is shown on the display.
- Page 47 The external synchroniser test mode is selected using keys A+ / A- (Fig. 10.6) External synchroniser in the sewing head: Up position of the needle bar Down position of the needle bar Fig. 10.6 By turning the handwheel, the up position or the down position of the motor is shown on the display.
- Page 48 PFAFF Industrie Maschinen AG Postfach 3020 D-67653 Kaiserslautern Königstr. 154 D-67655 Kaiserslautern Telefon: (0631) 200-0 Telefax: (0631) 17202 E-Mail: info@pfaff-industrial.com...