With the puller the workpiece is fed continously, which makes it possible to sew to a great
extent without shifting and puckering. The puller’s linear motor enables an individual
clearance space between the needle plate and the puller roller.
All adjustments, such as e.g. puller feed stroke, puller roller clearance etc. are carried out by
altering the parameter values, see Chapter 2.03.03 Selecting and altering parameters.
Any use of these machines which is not approved by the manufacturer shall be
considered as improper use! The manufacturer shall not be liable for any dam-
age arising out of improper use! Proper use shall also be considered to include
compliance with the operation, adjustment, service and repair measures speci-
fied by the manufacturer!
● With the adapter 1 which belongs to the
accessories, standard presser feed can
also be used
(Ordering number 91-154 790-22).
● Mount adapter 1 as shown in Fig. 1-01.
● Loosen screw 2 and push puller arm 3
back.
● Screw the presser foot onto adapter 1.
● Adjust puller arm 3 so that there is a
clearance of approx. 1 mm between the
2
puller roller and the presser foot.
● Tighten screw 2.
3
1 mm
Fig. 1 - 01
When using the adapter, the
height of the puller roller must
be adjusted as described in
Chapter 2.02.
4
1
2Controls
2.01Puller functions
1
2
Fig. 2 - 01
Controls
Engaging/disengaging the puller
● Raise the puller drive unit 1 until it locks
into place and swing puller arm 2 back as
far as possible. To engage the puller,
follow the instructions in the reverse
order.
Switching the puller on/off
● The puller is automatically switched on or
off when the puller unit is engaged or
disengaged.
Setting the puller feed motion
● The feed motion of the puller is set by
means of parameters (see Chap. 1.06
Parameter settings and the Motor
Instruction Manual)
2.02Aligning the puller
2
3
1
Fig. 2 - 02
Puller crosswise to sewing direction
● Loosen screw 1.
● Align puller 2 to the seam.
● Tighten screw 1.
Height of the puller roller
● Loosen screw 3
● Align puller 2, so that there is a clearance
of approx. 0.3 mm between the puller
roller 4 and the cloth plate.
● Tighten screw 3.
4
5
Controls
2.03Control panel
The control panel consists of display 1 and the function keys described below. Display 1
consists of a two-row, alpha-numerical display with 16 symbols per row. The texts 3 show
the respective status of the function keys and the operating modes of the machine.
During the power-on phase the control panel automatically switches on all LCD segments
and the horn. The number of the version of the installed software then appears on the
display, until the higher-ranking control unit sends commands to the control panel.
2.03.01Screen displays
12
3
Speed
4000 PUL 30%
2.0mm
4
● Activated functions are displayed with a triangular marking 2 below or next to the
respective function key.
● In the sewing mode all relevant sewing data is displayed and these can be changed
directly, depending on the status of the machine, see also Chapter 5 Sewing.
● During the parameter input the selected parameter number with the corresponding value
is displayed, see Chapter 2.02.03 Selecting/changing parameters.
2.03.02Function keys
The function keys described below are used basically to switch machine functions on and
off.
If a corresponding value has to be set for the activated function, this is carried out with the
corresponding +/- key. By pressing and holding the corresponding +/- key, the appropriate
numerical value 4 is changed slowly to begin with. If the corresponding +/- key is held down
longer, the values change more quickly.
Start backtacks
If this key is pressed, the backtacks at the beginning of the seam (start backtacks) are
switched on or off. The number of forward stitches (A) or reverse stitches (B) for the start
backtacks can be changed by pressing the +/- key underneath. To convert from double
backtack to single backtack set the corresponding number of stitches at zero.
6
Controls
End backtacks
● If this key is pressed, the backtacks at the end of the seam (end backtacks) are switched
on or off. The number of reverse stitches (C) or forward stitches (D) can be changed by
pressing the +/- key underneath. To convert from double backtack to single backtack set
the corresponding number of stitches at zero.
Needle position
● If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the needle positions at t.d.c. after sewing stops.
Foot position after stop
● If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the presser foot is raised after sewing stops.
Foot position after trimming
● If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the presser foot is raised after thread trimming.
Thread trimmer
● If this key is pressed the thread trimming function is switched on or off.
Speed (only in programmed sewing)
● If this key is pressed the corresponding function is switched on or off. In the seam
program the speed is not dependent on the pedal. When the function is switched on, the
speed cannot be adjusted by pedal. Sewing can only be carried out at the set maximum
speed.
● If the function is switched off, the speed up to maximum speed is adjusted by the pedal.
Reverse sewing
● If this key is pressed the corresponding function is switched on or off. When the function
is switched during programmed sewing, the corresponding seam section is sewn in
reverse.
Manual seam (only in programmed sewing)
● If this key is pressed the machine switches to manual sewing. When the function is
switched on, the move to the next seam section is not carried out by stitch counting or
sensor, but manually with the use of the pedal (position "-2").
Stop
● If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the machine stops automatically at the end of a seam section.
Sensor
● In manual sewing the number of compensating stitches from the point where the
photocell is light to the end of the seam can be set under parameter 111, and in
programmed sewing directly.
7
Controls
Stitch counting
● If this key is pressed the corresponding function is switched on or off. When the function
is switched on, the machine moves to the next seam section after sewing the number of
stitches entered.
TE/Speed
● In the programmed sewing mode, the number of stitches is entered by stitching them off.
● If this key is pressed once, the machine changes to parameter input.
● If this key is pressed twice (within 5 seconds) the machine changes to stitch input.
Scrolling
● If this key is pressed in the programmed sewing mode, the machine scrolls through the
input menus on the display.
PM
● If this key is pressed the programmed sewing function is switched on or off. When the
function is switched on, the letters "PM" appear on the display of the control panel. The
parameters related to the program are shown in the alpha-numerical part of the display.
F1
No function assigned
F2
No function assigned
F3
No function assigned
F4
No function assigned
8
2.03.03Selecting and altering parameters
● Switch on the machine.
● Press the TE/Speed key to call up the parameter input function.
TE
NoVAL
A101OFF
No
● By pressing the corresponding +/- key select the desired parameter group, e.g. "600".
TE
No
A600
Controls
● By pressing the corresponding +/- key select the desired parameter, e.g. "660" for the
No
bobbin thread monitoring function.
TE
NoVAL
A6601
● By pressing the corresponding +/- key set the desired value for the parameter selected,
VAL
e.g. "2" for the "bobbin rest thread counter on" function.
TE
NoVAL
A6602
● Press the TE/Speed key to take over the value and change to the sewing mode.
9
Controls
2.03.04Selecting the user level
● Switch on the machine.
● Press the TE/Speed key to call up the parameter input function.
TE
No
A101
No
● By pressing the corresponding +/- key select the parameter group "700".
TE
No
A7980
● By pressing the corresponding +/- key select the parameter "798".
No
TE
NoVAL
7981
B
VAL
● By pressing the corresponding +/- key select the desired user level:
"0" = operator level A
"1" = technician level B
"11" = service level C
The respective level is displayed on the screen. (see arrow)
● Press the TE/Speed key to take over the value and change to the sewing mode.
10
3Commissioning
3.01Basic position of the machine drive
● Switch on the machine.
Speed
4000 PUL 30%
2.0mm
● Press the TE/Speed key to call up the parameter input function.
● Select the technician level B (value "1") with parameter "798", see Chapter 2.03.04
Selecting the user level.
Commissioning
TE
NoVAL
7981
B
No
● By pressing the corresponding +/- key select the parameter group "700".
TE
No
7000
B
B
● Sew a stitch by operating the pedal.
● Turn the balance wheel in the direction of sewing until the needle point is level with the
top edge of the needle plate.
● Press the TE/Speed key to take over the setting and to conclude the input.
11
Commissioning
3.02Testing the function of the start inhibitor
● Switch the machine on at the main switch and tilt back the sewing head.
The error message "9" must appear on the control panel.
● If the message does not appear, check the setting of the safety switch
(in the machine instruction manual).
● Set the sewing head upright again and acknowledge the error message by pressing the
TE/Speed key. The machine is ready for operation again.
ERROR
9
PRESS TE/SPEED
12
4Setting up
.01Entering the puller feed stroke (stitch length)
4
● Switch on the machine.
Speed
4000 PUL 30%
2.0mm
● Enter the feed stroke by pressing the corresponding +/- key.
The puller feed stroke setting must match the stitch length setting of the basic
machine!
Setting up
4.02Setting the puller pressure
Speed
4000 PUL 30%
● Switch on the machine.
● Set the desired puller pressure by pressing the corresponding +/- key.
The value for the current puller pressure (in %) can be read on the display.
2.0mm
13
Setting up
4.03Entering the maximum speed
4.04Entering the start and end backtacks
● Switch on the machine.
Speed
4000 PUL 30%
2.0mm
● Enter the maximum speed by pressing the corresponding +/- key.
The max. speed is limited with parameter 607.
2 x
● Switch on the machine.
● Press the TE/Speedkey twice to select the input menu for start and end backtacks.
PM
A B C D
33
● By pressing the corresponding +/- key select the desired value for the number of forward
A
stitches (A) of the start backtack.
● By pressing the corresponding +/- key select the desired value for the number of reverse
B
stitches (B) of the start backtack.
● By pressing the corresponding +/- key select the desired value for the number of reverse
C
stitches (C) of the end backtack.
33
14
● By pressing the corresponding +/- key select the desired value for the number of forward
D
stitches (D) of the end backtack.
In the programmed sewing mode it is possible to call up the input menu for
start and end backtacks by pressing the scroll key, see Chapter 5.02
Programmed sewing.
Setting up
4.05Setting the stitch counting function for the bobbin thread control
● Switch on the machine.
● Press the TE/Speed key to call up the parameter input function.
TE
NoVAL
A
101ON
● By pressing the corresponding +/- key select the parameter "760".No
TE
NoVAL
7605
A
VAL
● Press the corresponding +/- key to set the number of remaining stitches, which can still
be sewn after recognition by the bobbin thread control function.
The selected value is multiplied by 10* or 200** and the result is the number of stitches.
Example display 5 x 200** = 1000 stitches. The setting depends among other things on
the thread strength.
● If the TE/Speed key is pressed, the value is taken over and the machine changes into the
sewing mode.
The bobbin thread rest counter can only be used, if parameter "660" is set at
value "1" or "2".
* If for parameter 660 the value is "1", the multiplier is 10
** If for parameter 660 the value is "2", the multiplier is 200
15
Sewing
5Sewing
5.01Manual sewing
In the sewing mode all relevant adjustments for the sewing operation are shown on the
display and can be altered directly. Functions can be switched on and off by pressing the
key.
In this mode a difference is made between manual sewing and programmed sewing. To
change from manual to programmed sewing, press the PM key. In programmed sewing the
text "PM" appears on the display.
After the machine has been switched on, the maximum speed, the puller feed stroke and
the puller pressure can be adjusted with the corresponding +/- keys.
Speed
4000 PUL 30%
2.0mm
Further functions in manual sewing, also see Chapter 2.02.02Function keys:
Start backtacks on/offPresser foot raised at end of seam on/off
End backtacks on/offThread trimming on/off
Needle position raised on/offSensor on/off
Presser foot raised on/off
On the basic machine the stitch length is adjusted with the balance wheel.
The stitch length for the puller is adjusted on the control panel
16
.02Programmed sewing
5
In the programmed sewing mode 99 programs, each with 9 seam sections and 999 stitches,
can be programmed.
The fixed programs are used for the quick and easy production of seams with different
numbers of stitches. The pedal setting „0“ is used to switch to the next seam section.
After the machine has been switched on and the programmed sewing mode has been
selected with the PM key, the display appears for selecting the program number, seam
section and number of stitches.
Sewing
PM
current
11 13
program number
current seam segment
number of stitches
With the scroll key other menus can be selected for entering the values for start and end
backtacks and the maximum speed in the corresponding seam section.
PM
speed
in current
seam segment
100050
program number
of linked program
number
of seam segments
Further functions in programmed sewing, also see Chapter 2.02.02 Function keys:
Start backtacks on/offSeam section speed on/off
End backtacks on/offReverse sewing direction on/off
Needle position raised on/offManual sewing on/off
Presser foot raised on/offStop on/off
Presser foot raised afterSensor on/off
thread trimming on/off
Thread trimming on/offStitch count on/off
17
Sewing
.03Error messages
5
If a fault occurs, the text "ERROR" appears on the display, together with an error code and
short instructions. An error message is caused by incorrect settings, faulty elements or
seam programs as well as by overload conditions.
ERROR
9
PRESS TE/SPEED
● Correct the error.
● Acknowledge error correction by pressing the TE/Speedkey.
18
6Parameter Settings
Parameter Settings
Group
Parameter
Description
2252Puller roller clearanceB, C5 - 20030
for start backtack ca. 4 mm
254Puller roller clearance after trimming ca. 7mmB, C10 - 25550
3302Holding power of puller roller when risingB, C50 - 200140
To update the machine software carry out the following steps:
While the machine software is being updated, no setting up, maintenance or
adjustment work may be carried out on the machine!
● Switch off the machine.
● Connect the PC (serial interface or appropriate USB-adapter) and the machine control unit
(RS232).
● Switch on the PC and start the PFP boot program.
● Select the machine type.
● Press the „programming“ button.
● An auxiliary program (Quickloader) is started.
● Switch on the machine within 60 seconds.
● The software update is carried out, the updating status is shown on the bar display.
● After the update has been completed, the message "Software updated successfully
completed" appears.
Software-Update
If this message does not appear, the entire procedure must be repeated!
The operational reliability of the machine is not restored until the programming
has been carried out successfully and without errors.
● Switch off the machine, end the quickloader and PFP-boot program.
● End the connection between the PC and the machine control unit.
● Switch on the machine.
A plausibility control is carried out and, if necessary, a cold start.
More information and assistance is at your disposal in the file „PFPHILFE.TXT“,
which can be called up from the PFP boot program by pressing the „help“
button.
21
Reset / Cold start
8Reset / Cold start
After selecting the reset menu, by pressing the corresponding key it is possible to delete
seam parameters, to delete seam programs or to carry out a cold start.
A
● Press and hold "+" on keys A and D and switch on the machine.
SelectReset
123
A
B
1 = Resetting the seam parameters
● Press "+" on key A.
All seam parameters are deleted, "MASTER-RESET 1" is displayed for a short time on the
screen.
2 = Resetting the seam programs
● Press "+" on key B.
All seam programs are deleted, "MASTER-RESET 2" is displayed for a short time on the
screen.
D
D
22
3 = Cold start
● Press "+" on key D.
The values of the machine control unit are set back to their basic values, except the value
for the machine class. "COLD START" is displayed for a short time on the screen.
After a cold start, all programmed values are reset to their state at the time of
delivery. For this reason, after a cold start, the parameters 799, 800 and 700
must be checked and reset if necessary.
9Partslist
16
Partslist
2
1
14
6
7
Item No
1 - 1595-774 673-71/895
191-262 916-91
291-262 983-75/699
3 - 491-262 920-91
391-262 921-05
411-330 277-15 (2x)
591-262 919-05 (2x)
671-520 000-70
711-130 179-15 (4x)
895-774 647-05
Part No.
5
4
3
8
13
10
11
12
15
9
Item NoPart No.
991-262 860-92
1091-262 865-92 (2x)
1116-409 981-05
1295-774 686-91
1371-120 006-33
1495-784 321-91
1595-774 630-05 (10 mm wide)
1691-292 276-91
23
Circuit diagrams
10Circuit diagrams
10.01Reference lists for the circuit diagrams of the 1180 and 3701 series
(Connection diagram 91-191 504-95)
A1Controller Quick P350 ED
A2S2 control panel
A14Sewing head recognition unit (OTE)
H1Sewing lamp
H10LED Stitch counter
M1Sewing motor
M2Linear motor lift puller
M3Stepping motor roller presser
Q1Main switch
S1Pedal set value transmitter
S3Puller release
S6Start inhibitor E6 (stop)
S41Manual backtacking key
S42Needle position change key (threading key)
S43Single stitch switch
S60Edge guide key (optional)
X0PC-interface (RS 232)
X1Motor
X2Incremental transmitter
X3Speed control unit
X4/AM3 stepping motor puller roller
X5Outputs-Inputs
X6Bobbin thread monitor (optional)
X7Light barrier (optional)
X8M2 linear motor lift puller
X13S3 puller release
X16S6 start inhibitor E6 (stop)
X23Y23-900/.. Thread trimmer
X24Y24-910/.. Automatic foot lift
X25Y25-911/.. Backtacking/condensed stitches
X40Keyboard S41-S43 + H11
X50A14 sewing head recognition unit (OTE)
X60S60 + Y60 Edge guide (optional)
Y2-900/..Thread trimmer
Y4-910/..Automatic presser foot lift
Y5-911/Backtacking / condensed stitches
Y60Edge guide (optional
24
91-191 504-95
Page 1Version 03.07.06
Circuit diagrams
25
Circuit diagrams
Version 03.07.06
91-191 504-95
Page 2
26
91-191 504-95
Page 3Version 03.07.06
Circuit diagrams
27
Circuit diagrams
10.02Reference lists for the circuit diagrams of the 5483
(Connection diagram 91-191 504-95)
A1Controller Quick P350 ED
A2Control panel BDF S2
A14Sewing head recognition unit (OTE)
H1Sewing lamp
H10LED Stitch counter
M1Sewing motor
M2Linear motor lift puller
M3Stepping motor roller presser
Q1Main switch
S1Pedal set value transmitter
S3Puller release
S41Manual backtacking key
S42Needle position change key (threading key)
S43Single stitch switch
S60Edge guide key (optional)
X0PC-interface (RS 232)
X1Motor
X2Incremental transmitter
X2.1Inkrementalgeber Adapter
X2.2Synchronisator Adapter
X3Speed control unit
X4A2 control panel BDF S2
X4/AM3 stepping motor puller roller
X5Outputs-Inputs
X6Bobbin thread monitor (optional)
X7Light barrier (optional)
X8M2 linear motor lift puller
X13S3 puller release
X23Y23-900/.. Thread trimmer
X24Y24-910/.. Automatic foot lift
X25Y25-911/.. Backtacking/condensed stitches
X40Keyboard S41-S43 + H11
X50A14 sewing head recognition unit (OTE)
X60S60 + Y60 Edge guide (optional)
28
Y2-900/..Thread trimmer
Y4-910/..Automatic presser foot lift
Y5-911/Backtacking / condensed stitches
Y60Edge guide (optional
91-191 503-95
Page 1Version 30.06.06
Circuit diagrams
29
Circuit diagrams
Version 30.06.06
91-191 503-95
Page 2
30
91-191 503-95
Page 3Version 30.06.06
Circuit diagrams
31
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 ser vice: +49 - 175/2243-101
Application consultance: +49 - 175/2243-102
Spare-parts hotline: +49 - 175/2243-103
Printed in Germany
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