Pfaff 2481-980/30 PLUSLINE, PLUSLINE 2483-3/03-980 Series Adjustment Manual

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2481
ADJUSTMENT MANUAL
-3/01-980/30
This instruction manual applies to machines from the serial number 2 809 573 and software version 0307/010 onwards.
296-12-19 273/002 Adjustment manual in English 05.16
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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
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Table of Contents
Contents ..................................................................................Page
15 Adjustment ........................................................................................................................... 5
15.01 Notes on adjustment ............................................................................................................. 5
15.02 Tools, gauges and other accessories .................................................................................... 5
15.03 Abbreviations ......................................................................................................................... 5
15.04 Explanation of symbols .......................................................................................................... 5
15.05 Checking and adjustment aid ................................................................................................. 6
15.06 Adjusting basic machine ........................................................................................................ 7
15.06.01 Machine drive home position ................................................................................................ 7
15.06.02 Pre-calibrating the needle height ........................................................................................... 8
15.06.03 Bottom transporter zero position ........................................................................................... 9
15.06.04 Needle transport zero position ............................................................................................. 10
15.06.05 Bottom transporter sliding movement ................................................................................. 11
15.06.06 Needle transport sliding motion ........................................................................................... 12
15.06.07 Bottom transporter lifting movement .................................................................................. 13
15.06.08 Bottom transporter height / position in stitch platen cutout ................................................ 14
15.06.09 Needle in needle hole centre ............................................................................................... 15
15.06.10 Hook shaft bearing and spur gear clearance ........................................................................ 16
15.06.11 Hook lubrication .................................................................................................................. 17
15.06.12 Needle bar rise, hook-to-needle clearance, needle height and bobbin case position finger 18
15.06.13 Thread check spring and slack thread regulator .................................................................. 20
15.06.14 Passage under sewing foot ................................................................................................. 21
15.06.15 Adjusting the feed regulator zero position ........................................................................... 22
15.06.16 Stitch length adjustment forwards and backwards ............................................................. 23
15.06.17 Bobbin winder ...................................................................................................................... 24
15.06.18 Mechanical stitch length limitation ...................................................................................... 25
15.06.19 Sewing foot pressure .......................................................................................................... 26
15.07 Adjusting thread trimmer -900/24 ........................................................................................ 27
15.07.01 Pre-calibrating solenoid setting / control cam ...................................................................... 27
15.07.02 Aligning thread catcher laterally ........................................................................................... 28
15.07.03 Knife position ....................................................................................................................... 29
15.07.04 Front turning point of thread catcher ................................................................................... 30
15.07.05 Manual cutting control ......................................................................................................... 31
15.07.06 Needle thread tension release ............................................................................................. 32
15.07.07 Re-calibrating control cam ................................................................................................... 33
15.08 Aligning transmitted light transmitter .................................................................................. 34
15.09 Adjusting transmitted light sensors ..................................................................................... 35
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Table of Contents
Contents ..................................................................................Page
15.10 Functional check of bobbin thread monitor ......................................................................... 36
15.11 Adjusting electric edge guide .............................................................................................. 37
15.12 Parameter settings .............................................................................................................. 38
15.12.01 Overview of parameter functions ........................................................................................ 38
15.12.02 Example of a parameter entry ............................................................................................. 39
15.12.03 Selecting user level .............................................................................................................. 40
15.12.04 List of parameters ................................................................................................................ 41
15.13 Error messages and description .......................................................................................... 47
15.14 Sewing motor errors ............................................................................................................ 48
15.15 Service menu ....................................................................................................................... 49
15.16 Internet update of machine software .................................................................................. 50
16 Circuit Diagrams ................................................................................................................ 51
16.01 Block diagram of PFAFF 2481 with control unit P322 ED .................................................... 51
16.02 Circuit diagrams ................................................................................................................... 52
16.03 Plug connections ................................................................................................................. 57
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Adjustment
15 Adjustment
Observe and comply with all instructions in the operating manual’s chapter 1 Safety! In particular make sure that all safety covers are installed again correct-
ly after making adjustments, see chapter 1.06 Operating manual hazard infor­mation!
Unless otherwise stated, the machine must be disconnected from the power supply before all adjustment work! Risk of injury due to accidental machine start-up!
No screw clamp may be fastened to the needle bar with the PFAFF 2481-980/30!
This may damage the special needle bar coating.
15.01 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. Machine covers, which have to be re­moved and replaced to carry out checks and adjustments, are not mentioned in the text. The order of the following chapters corresponds to the most logical work sequence for ma­chines that have to be completely adjusted. Both the preceding and following chapters must be observed if only specific individual work steps are carried out. Screws and nuts indicated in brackets ( ) are fastenings for machine parts, which must be loosened before any adjust­ment and tightened again afterwards.
15.02 Tools, gauges and other accessories
O 1 set of screwdrivers with knife widths of 2 to 10 mm
O 1 set of wrenches with jaw widths from 7 to 14 mm
O 1 set of Allen keys of 1.5 to 6 mm
O 1 feed dog setting gauge (order no. 61-111 639-71)
O 1 setting gauge (order no. 61-111 639-73)
O 1 adjustment pin (5 mm diameter), order no. 13-033 346-05
O 1 metal ruler (order no. 08-880 218-00)
O Thread and testing material
15.03 Abbreviations
t.d.c. = top dead centre b.d.c. = bottom dead centre
15.04 Explanation of symbols
Activities to be performed or important information in this adjustment manual are empha­sised by symbols. The symbols used have the following meaning:
Note, information
Maintenance, repairs, adjustment, service work (only to be carried out by technical staff)
5
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Adjustment
15.05 Checking and adjustment aid
The adjustment pin 1 (order no. 13-033 346-05) and the adjustment gauge 3
(order no. 61-111 639-73) if necessary can be used to fix the required positions
during the adjustment.
1
3
4
2
5
Fig. 15 - 01
Needle bar positioned 1.8 mm after b.d.c.
O Turn the handwheel until the needle bar is approximately in the required position.
O Push the adjustment pin 1 into the hole.
O Move the handwheel gently back and forwards until the adjustment pin 1 engages in the
crank 2.
Needle bar positioned 0.6 mm after b.d.c.
O Move the needle bar approximately into the required position.
O Fit the adjustment gauge 3 to the studs 4 and 5 ensuring the right side (for a 30 mm or
36 mm needle bar stroke).
6
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Adjustment
15.06 Adjusting basic machine
15.06.01 Machine drive home position
This setting is only required if the toothed belt 2 has been dismantled.
Rule The markings 3 and 4 should be aligned if the needle bar is positioned 0.6 mm after b.d.c.
2
4
1
3
Fig. 15 - 02
O Move the needle bar to 0.6 mm after b.d.c.
O Turn the toothed belt wheel 1 according to the rule and slide on the toothed belt 2.
Make sure that the shaft flange, shock absorber and motor flange are in the
right position when installing the motor!
The second toothed belt wheel screw 1 is a balance cup screw
7
Page 8
Adjustment
15.06.02 Pre-calibrating the needle height
Rule
The marking on the needle bar 1 should be flush with the lower edge of the needle bar frame 3 when the needle bar is positioned 1.8 mm after b.d.c.
2
3
1
Fig. 15 - 03
O Move the needle bar to 1.8 mm after b.d.c. and fix with the adjustment pin, see chapter
15.05 Checking and adjustment aid.
O Adjust the needle bar 1 ( screw 2 ) without twisting according to the rule.
8
Page 9
Adjustment
15.06.03 Bottom transporter zero position
Rule
At stitch length regulation “0”
1. The marking on the toothed segment 1 should be in the centre of the shaft of the gear wheel 3,
2. The cranks 4 and 6 should be aligned and the bottom transporter should not move
when turning the handwheel.
6
4
0.0
5
2
1
2
3
Fig. 15 - 04
O Switch the machine on.
O Set the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
O Make sure that parameter 834 is set to “0”, see chapter 15.11 Parameter settings.
O Adjust the toothed segment 1 ( screws 2 ) without the gear wheel 3 according to rule 1.
O Turn the crank 4 ( screws 5 ) according to rule 2.
O Switch the machine off.
9
Page 10
Adjustment
15.06.04 Needle transport zero position
Rule
The needle bar should not move when turning the handwheel with stitch length regulation “0”.
2
1
10
0.0
Fig. 15 - 05
O Switch the machine on.
O Set the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
O Make sure that parameter 834 is set to “0”, see chapter 15.11 Parameter settings.
O Turn the crank 1 ( screw 2 ) according to the rule.
O Switch the machine off.
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Adjustment
15.06.05 Bottom transporter sliding movement
Rule
When the needle bar is positioned 0.6 mm after b.d.c., the bottom transporter should not move when the shaft 3 is rotated back and forth.
3
1
2
2
Fig. 15 - 06
O Move the needle bar to a position 0.6 mm after b.d.c.
O Turn the eccentric 1 ( screws 2 ), without moving it sideways according to the rule.
11
Page 12
Adjustment
15.06.06 Needle transport sliding motion
Rule
When the needle bar is positioned 0.6 mm after b.d.c., the needle should not move when the shaft 4 is rotated back and forth.
3
1
2
2
3
12
Fig. 15 - 07
O Move the needle bar to a position 0.6 mm after b.d.c.
O Turn the eccentric 1 ( screws 2 ) until the adjustment pin 3 engages according to the
rule.
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Adjustment
15.06.07 Bottom transporter lifting movement
Rule
When the needle bar is positioned 0.6 mm after b.d.c. and with stitch length regulation “0”,
1. the bottom transporter should be in its upper turning point and
2. the control cam 3 should abut the feed lifting eccentric 1.
0.0
3
4
2
1
Fig. 15 - 08
O Switch the machine on.
O Set the stitch length to “0” and move the needle bar to a position 0.6 mm after b.d.c.
O Turn the handwheel until the feed regulator motor responds.
O Turn the eccentric 1 ( screws 2 ) according to rule 1.
O Adjust the control cam 3 ( screws 4 ) according to rule 2 and switch off the machine.
13
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Adjustment
15.06.08 Bottom transporter height / position in stitch platen cutout
Rule
In its upper turning point and with stitch length regulation “0” the bottom transporter 1 should
1. be in the centre of the stitch platen cutout looking from the side and in the feeding di-
rection and
2. abut the feed dog setting gauge 2 along its entire length.
6
7
4
0.0
3
5
2
1
Fig. 15 - 09
O Turn on machine and set the stitch length to “0”.
O Turn the handwheel until the feed regulator motor responds.
O Move the bottom transporter 1 to its upper turning point.
O Raise the sewing foot, move the feed dog setting gauge 2 over the stitch platen cut-
out with the arrow in the sewing direction and the front edge flush with the stitch platen edge and lower the sewing foot.
O Adjust the bottom transporter carrier 3 ( screw 4 ) according to rule 1.
O Loosen the screws 5 and 6
O Adjust the bottom transporter carrier 3 and eccentric 7 according to rule 2.
O Tighten the screws 5 and 6
O Switch the machine off.
14
Page 15
Adjustment
15.06.09 Needle in needle hole centre
Rule
The needle should pierce the centre of the needle hole exactly.
3
0.0
1
2
Fig. 15 - 10
O Switch the machine on.
O Set the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
O Insert the needle into the needle hole by turning the handwheel.
O Adjust the needle bar frame 1 ( screws 2 and 3 ) according to the rule.
O Switch the machine off.
15
Page 16
Adjustment
15.06.10 Hook shaft bearing and spur gear clearance
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.
2. There should be minimal yet noticeable play between the plastic pinion 3 and the steel wheel 4. This play should be approximately the same for a 360° turn.
3. The steel wheel 4 should align with the plastic pinion 3.
Fig. 15 - 11
4
2
3
6
14.5 mm
1
16
O Align the hook shaft bearing 1 ( screw 2 ) according to rule 1.
O Set the steel wheel 4 with the eccentric bush of the hook shaft bearing 1 according to
rule 2 and tighten the screw 2.
O Adjust the plastic pinion 3 ( screws 6 ) according to rule 3 and tighten the screws 6.
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Adjustment
15.06.11 Hook lubrication
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.
1.5 mm
3
2
1
Fig. 15 - 12
The setting is only required if the wick is replaced.
Make sure that the new wick is impregnated with oil when replacing the wick.
O Adjust the centrifugal disc 1 ( screw 2 ) according to rule 1.
O Check rule 2 and adjust the centrifugal disc 1 if necessary.
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Adjustment
15.06.12 Needle bar rise, hook-to-needle clearance, needle height and bobbin case
position finger
Rule
When the needle is 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 fillet of the needle and
2. The upper edge of the eye of the needle should be 0.8 mm under the tip of the hook.
3. There should be a clearance of 0.5 mm between the lug of the bobbin case position finger 4 and the base of the stop groove.
0.05 - 0.1 mm
4
0.8 mm
1
0.5 mm
6
3
5
4
18
0.0
2
Fig. 15 - 13
O Switch the machine on.
O Set the stitch length to “0” using the control panel and turn the handwheel until the feed
regulator motor responds.
O Switch the machine off.
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Adjustment
O Use the adjustment pin to move the needle bar to 1.8 mm after b.d.c.
O Adjust the hook according to rule 1
O Tighten the screws 1.
O Adjust the needle bar 2 ( screw 3 ), without twisting according to rule 2.
O Align the bobbin case position finger 4 ( screw 5 ) according to rule 3.
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Adjustment
15.06.13 Thread check spring and slack thread regulator
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 maxi-
mum thread loop while passing the thread around the hook.
4
-
+
3
1
2
7 mm
20
Fig. 15 - 14
O Turn the thread tension 1 ( screw 2 ) according to rule 1.
O Adjust the slack thread regulator 3 ( screws 4 ) according to rule 2.
It may be necessary to deviate from the specified spring deflection for reasons
relating to the sewing technology.
Adjust the slack thread regulator 3 ( screw 4 ) by “ + “ (= more thread) or “ - “
(= less thread).
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Adjustment
15.06.14 Passage under sewing foot
Rule
1. When the automatic presser foot lift is activated, the clearance between the sewing
foot and needle plate should be should be 7 mm.
2. When the hand lever is raised, the clearance between the sewing foot and needle
plate should be should be 5 mm.
4
5
1
Fig. 15 - 15
5 mm
2
3
7 mm
O Adjust the solenoid 1 ( screw 2 ) according to rule 1.
O Raise the hand lever and place the adjustment gauge 3 (order no. 61-111 639-70) under
the sewing foot according to rule 2.
O Move the presser bar lifting lever 4 so that it touches the lift piece 5.
Make sure that the needle is positioned in the middle of the needle foot.
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Adjustment
15.06.15 Adjusting the feed regulator zero position
Rule
The needle should always puncture the material at the same position at maximum speed (4500 min-1) with stitch length regulation “0”.
834
Fig. 15 - 16
O Unthread the machine.
O Switch the machine on.
O Place the workpiece under the sewing foot.
O Sew with the machine at max. speed and check the rule.
(Workpiece must not move.)
O Change the value for parameter 834 within the permissible values according to the rule.
The permissible values for parameter 834 are “-1”, “0” or “1”.
0
22
If the feed regulator zero position cannot be set by selecting the permissi­ble values, the mechanical setting must be checked or corrected, see chapter
15.06.03 Bottom transporter zero position.
The zero position of the feed regulator is always identifiable in a range of 3 val-
ues. The middle value must be selected when making the adjustment.
O Switch the machine off.
Further information about selecting and changing parameters and explanations (functions) about the individual parameters can be found in chapter 15.11 Pa- rameter settings.
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Adjustment
15.06.16 Stitch length adjustment forwards and backwards
Rule
The stitch length selected on the control panel should not deviate from the actual stitch length when sewing forwards and backwards at a maximum speed of 400 min-1.
O Thread the machine.
O Switch the machine on.
O Select the stitch length to be used via the control panel.
O Limit the max. speed to 400 min
O Set the value for parameter 846 to 100.
O Place the workpiece under the sewing foot.
O Sew a seam with at least 20 stitches.
O Measure the length of the seam over 20 stitches and determine the actual stitch length.
O The value for parameter 846 must be corrected if the deviation over 20 stitches is great-
er than +/- 0.5 mm.
O Take the value for parameter 846 from the table or calculate it using the formula:
-1
via parameter 607.
Set stitch length
Actual stitch length
Stitch length 3.0 mm Stitch length 2.5 mm Stitch length 2.0 mm Stitch length 1.5 mm
58.5 102 48.5 103 38.5 104 28.5 105
59.0 102 49.0 102 39.0 103 29.0 103
59.5 101 49.5 101 39.5 101 29.5 102
60.0 100 50.0 100 40.0 100 30.0 100
60.5 99 50.5 99 40.5 99 30.5 98
61.0 98 51.0 98 41.0 97 31.0 97
61.5 98 51.5 97 41.5 96 31.5 95
62.0 97 52.0 96 42.0 95 32.0 94
62.5 96 52.5 95 42.5 94 32.5 92
63.0 95 53.0 94 43.0 93
63.5 94 53.5 93 43.5 92
64.0 94 54.0 93
64.5 93 54.5 92
65.0 92
20 stitches
Length over
Value for
846 / 847
parameters
20 stitches
Length over
Value for
846 / 847
parameters
20 stitches
Length over
Value for
846 / 847
parameters
20 stitches
Length over
Value for
846 / 847
parameters
O Select the determined value for parameter 846 and switch off the machine.
The stitch length adjustment backwards is performed under parameter “847
according to the work steps mentioned above; the key for reverse sewing must be pressed, see chapter 7.02 Keys on the machine head. Further information
about selecting and changing parameters and explanations (functions) about the individual parameters can be found in chapter 15.11 Parameter settings.
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Adjustment
15.06.17 Bobbin winder
Rule
1. When the bobbin winder is switched on, the drive wheel should be moved easily, whereas when the bobbin winder is switched off, the friction wheel 5 must not touch the drive wheel 1.
2. The bobbin winder should switch off automatically if the thread fill is approx. 1 mm
away from edge of the bobbin.
3. The eccentric stud 3 should be at the centre of the large bobbin chamber.
5
1
3
2
1 mm
4
3
81-043
24
Fig. 15 - 17
O Adjust the drive wheel 1 ( screw 2 ) according to rule 1.
O Place a bobbin on the bobbin winder, thread the bobbin and switch on the bobbin winder.
O Adjust the stud 3 ( screw 4 ) according to rule 2 and turn according to rule 3.
Page 25
Adjustment
15.06.18 Mechanical stitch length limitation
Rule
1. The feed dog must not strike against the needle plate cutout when sewing forwards
and backwards at max. stitch length.
2. The screws of the stops 1 (forward sewing) and 3 (reverse sewing) should each have a clearance of 0.3 mm to the corresponding cast edge.
2
1
0.3 mm
3
4
0.3 mm
Fig. 15 - 18
O Turn on the machine and adjust parameter 849 according to rule 1, see chapter 15.11
Parameter settings.
3.5
0.0
O Select the maximum stitch via the control panel.
O Turn the stop 1 ( screw 2 ) according to rule 2.
O Sew stitches with the key for reverse sewing 2 pressed, see chapter 7.02 Keys on the
machine head.
O Turn the stop 3 ( screw 4 ) according to rule 2.
O Switch the machine off.
25
Page 26
Adjustment
15.06.19 Sewing foot pressure
Rule
The material should be transported properly at all times; no pressure marks should appear
on the material.
1
+
-
26
Fig. 15 - 19
O Turn the screw 1 according to the rule.
Page 27
Adjustment
15.07 Adjusting thread trimmer -900/24
15.07.01 Pre-calibrating solenoid setting / control cam
Rule
1. When the solenoid 3 is completely extended, the roller lever 4 should be at the lowest
point of the control cam.
2. When the needle bar is positioned 1.8 mm after b.d.c. (needle rise position), the roller lever 4 should engage in the corresponding control cam cutout.
4
5
Fig. 15 - 20
4
6
2
1
3
O Move the solenoid carrier 1 ( screws 2 ) according to rule 1.
O Turn the control cam 5 ( screws 6 ) according to rule 2.
27
Page 28
Adjustment
15.07.02 Aligning thread catcher laterally
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.
5
2
1
6
6
3
5
28
Fig. 15 - 21
O Remove the knife 1 ( screw 2 ).
O Move the needle bar to b.d.c.
O Loosen the stop 3 ( screws 4 ).
O Manually position the thread catcher 5 in front of the needle.
O Align the thread catcher 5 ( screws 6 ) according to the rules.
The knife 1 remains dismantled and the stop 3 remains loosened for other set-
tings.
Page 29
Adjustment
15.07.03 Knife position
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 ).
3
4 mm
1
2
Fig. 15 - 22
O Move the needle bar to b.d.c.
O Slide the knife 1 under the locking tab and align according to rule 1.
O Gently tighten the screw 2.
O Manually adjust the thread catcher carrier 3 until the cutting tip in the thread catcher is
positioned just in front of the knife edge.
O Align the knife 1 according to rule 2 and tighten the screw 2.
1
29
Page 30
Adjustment
15.07.04 Front turning point of thread catcher
Rule
When the thread catcher 4 is in the front turning point, the tip of the thread catcher cutout should be 1 mm in front of the bobbin case position finger 5.
1
1
2
3
1 mm
Fig. 15 - 23
O Swivel the roller lever 1 to the lowest point of the control cam.
O Turn the lever 2 ( screws 3 ) according to the rule.
4
5
30
Page 31
Adjustment
15.07.05 Manual cutting control
Rule Two threads must be cut cleanly on both the left and right in the thread catcher cutout 1.
3
1
2
5
4
1
Fig. 15 - 24
O Manually move the thread catcher 1 to its front turning point.
O Pull a double-up length of thread and hook it in the thread catcher cutout.
O Carry out the cutting operation manually.
O If the threads are not cut according to the rule, align the thread catcher 1 (screws 2) to
the knife 3 accordingly.
O Move the stop 4 until it abuts the thread catcher 1 and tighten the screws 5.
O Chapter 15.07.02 Aligning thread catcher laterally, check and adjust if necessary.
31
Page 32
Adjustment
15.07.06 Needle thread tension release
Rule
1. The magnet lift should be 1.5 mm.
2. When the solenoid 5 is operated manually, there should be a clearance of at least
0.5 mm between the tension discs 6.
0.5 mm
6
5
4
3
Fig. 15 - 25
O Turn the disc 1 ( nuts 2 ) according to rule 1.
2
1
32
O Turn the screw 3 ( nut 4 ) according to rule 2.
Page 33
Adjustment
15.07.07 Re-calibrating control cam
Rule
When the thread lever is at t.d.c., the control cam 1 should have controlled the thread catcher 3.
3
1
Fig. 15 - 26
O Turn the control cam 1 ( screws 2 ) according to the rule.
2
33
Page 34
Adjustment
15.08 Aligning transmitted light transmitter
Rule
The receivers PS2 and PS1 should show the same value (same signal strength) when the
sewing material is in place.
2
12
97%
97%
Fig. 15 - 27
O Switch the machine on.
O Call up entry mode.
O Call up the service menu.
O Call up the sensor menu.
O Adjust the transmitted light transmitter 1 ( screw 2 ) according to the rule.
O Switch the machine off.
1
34
Page 35
Adjustment
15.09 Adjusting transmitted light sensors
Rule
The difference between one and more material layers should be reliably detected.
O Switch the machine on.
O Call up entry mode.
A 100
O Call up the menu to adjust the transmitted light sensors.
0 - 100 % 0 - 100 %20 %
O Start the adjustment without material.
100
96 - 96 % 52 %
O End the adjustment without material.
O Start the adjustment with material (e.g. cuff).
O Move the cuff back and forth under the sensors.
O End the adjustment with material.
O Adjust the transmission power if necessary.
O End the adjustment of the transmitted light sensors.
35
Page 36
Adjustment
15.10 Functional check of bobbin thread monitor
Rule
The value under “Rx” must switch between “ON” and “OFF” when the thread is drawn
off (perfect transmission of the bobbin thread sensor receiving signal).
12
97%
97%
36
Fig. 15 - 28
O Insert the bobbin into the bobbin case and insert the bobbin case into the hook.
O Switch the machine on.
O Call up entry mode.
O Call up the service menu.
O Call up the sensor menu.
O Remove the thread by hand and check the rule.
O Increase or reduce the transmission power (Tx) if necessary.
O Switch the machine off.
Page 37
Adjustment
15.11 Adjusting electric edge guide
Rule
The guide 3 should have a clearance of approx. 0.1 mm to the sewing foot 4 when se­lecting a 1.0 mm seam depth (via the control panel.
1
3
4
2
Fig. 15 - 29
O Switch the machine on.
O Set the edge guide position to 1.0 mm, see chapter 9.07 Entering edge guide position
in instruction manual
O Adjust the edge guide 1 ( screws 2 ) according to the rule.
O Switch the machine off.
0.1 mm
37
Page 38
Adjustment
15.12 Parameter settings
15.12.01 Overview of parameter functions
After switching on the machine, the input mode in which the individual parameters can be
called up directly is called up by pressing the corresponding function. All parameter groups
or also individual ones can be protected by a code against unauthorised access.
Select parameter
100 User level
200 Mechanic level
300 Sewing motor positions
400 Times
500 Counter and speeds
700 Sewing motor
800 Access rights
38
Page 39
Adjustment
15.12.02 Example of a parameter entry
O Switch the machine on.
O Call up entry mode.
A 100
O e.g. Call up parameter “660” (bobbin thread monitor)
A 660
A 660
100
1
1
O Switch on the bobbin thread monitor (value “1”).
O Conclude the parameter input.
39
Page 40
Adjustment
15.12.03 Selecting user level
O Switch the machine on.
O Call up entry mode.
A 100
O Call up parameter ‘798’.
A 798
100
0
O The user level is determined and displayed in front of the actual parameter by selecting
the corresponding value for parameter 798:
0” = User level A1” = Mechanic level B11” = Service level C
O Conclude the parameter input. The changed values are saved and the control unit switch-
es to sewing mode.
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Adjustment
15.12.04 List of parameters
Group
0 10 Bobbin thread monitor current level C 8 - 16 12
11 Bobbin thread monitor stitch counter C 0 - 255 32 (start value)
1 100 Control panel contrast [%] A 90 - 110 100
101 Control panel key response signal A 0 - 1 1 0=tone off / 1=tone on
102 Start backtack stitches forwards C 0 - 9 3
103 Start backtack stitches in reverse C 0 - 9 3
105 Start backtack speed B 100 - 1500 900
106 Start backtack speed: C OFF - ON OFF ON = pedal-controlled OFF = set with param. “105”
107 Pedal-controlled start backtack speed: C OFF - ON OFF ON = limited with parameter “105” OFF = limited with parameter “607”
Parameter
Description
User level
Setting
range
Set value
108 End backtack stitches in reverse C 0 - 9 3
109 End backtack stitches forwards C 0 - 9 3
110 End backtack speed B 100 - 1500 1000
111 Stitch count of bright light barrier A 1 - 255 6 to seam end in manual sewing
113 Start with light barrier B OFF - ON ON ON = only when light barrier is dark OFF = also when light barrier is bright
114 After light barrier or stitch counting: C OFF - ON OFF ON = stop OFF = autom. end backtacks and seam end
116 Soft starting stitches (soft start) A 0 - 10 1
117 Speed for soft starting stitches B 180 - 1200 400
148 Start backtacks A OFF - ON ON ON = double / OFF = single
149 End backtacks A OFF - ON ON ON = double / OFF = single
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Adjustment
Group
1 199 Speed for B 300 - 1500 1200
2 206 Seam interrupt with pedal -2 C OFF - ON OFF 220 Speed level 12 (poti-reserve) [min-1] A 300 - 5000 4500 221 Speed limit for seam programs [min-1] B 300 - 5000 4500 222 Speed constant for seam programs [min-1] B 300 - 5000 3000 298 Number of reduced stitches A 1 - 3 1 299 Edge guide position in A 10 - 185 185 “manual sewing” [1/10 mm] 3 323 Min. edge guide position [1/10 mm] B 10 - 50 10 325 Max. edge guide position [1/10 mm] B 165 - 185 185 347 Bobbin changer 0= OFF / 1= ON B OFF - ON 0 348 Bobbin changer (pick-up time in 10 ms) B 0 - 100 20 349 Bobbin changer (hold bobbin, activate in B 0 - 100 10 10 ms) 350 Bobbin changer (hold bobbin, deactivate in B 0 - 100 10 10 ms) 4 419 Bartacks: C OFF - ON ON ON = inverted OFF = suppressed 478 Corner stitch C OFF - ON ON ON = accurate OFF = quick (faster cycle time at the expense of accuracy) 492 Number of seam programs B 1 - 99 99 493 Number of seam sections per seam program B 1 - 15 25 494 Max. number of sequences B 1 - 15 3 495 Max. number of program entries in the sequence B 3 - 15 5 5 554 Presser foot after seam section C OFF - ON ON with pedal forwards: ON = raised / OFF = lowered 584 Interlock mechanism: C OFF - ON OFF ON = fourfold / OFF = normal 6 601 Cutting: B OFF - ON ON ON = on / OFF = off
602 ON = Cutting with pedal -1 C OFF - ON OFF OFF = Cutting with pedal -2
603 ON = Pedal stops after cutting C OFF - ON ON OFF = immediate start after seam end
Parameter
Description
light barrier compensation stitches [min-1]
User level
Setting
range
Set value
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Adjustment
Group
6 604 Cutting: C OFF - ON ON ON = forwards after semi end backtack OFF = in reverse too
605 Speed display: B OFF - ON OFF ON = on / OFF = off
606 Speed level 1 (min.) [min-1] B 30 - 550 180
607 Speed level 12 (max.) [min-1] B 300 - 5000 4500
609 Cutting speed [min-1] B 60 - 500 180
618 Reverse turning angle B OFF - ON OFF ON = on / OFF = off
624 Start inhibitor: ON = on / OFF = off C OFF - ON ON
642 Presser foot - time from switch-on C 10 - 50 50 to tension reduction (timing)
651 Automatic lowering of presser foot: C OFF - ON ON ON = on / OFF = off
Parameter
Description
User level
Setting
range
Set value
660 Bobbin thread monitor: A 0 - 2 1 0 = off, 1 = on 2 = bobbin thread reverse counter on
668 Thread wiper = 1, B 0 - 2 2 Thread clamp = 2, 0 = off
7 700 Logical zero mark [increments] B 0 - 127 0
702 Needle position (needle lowered) B 0 - 30 15
703 Needle position (take-up lever raised) B 100 - 127 113
705 Needle position (end of cutting signal) B 80 - 127 98
706 Needle position (start of cutting signal) B 40 - 80 68
707 Needle position B 40 - 80 70 (start thread tension release)
710 Needle position B 80 - 127 106 (needle raised without cutting)
715 Switch-on duration of thread wiper [ms] B 0 - 2550 120
718 Moment of standstill brake (rest brake) B 0 - 100 0
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Adjustment
Group
7 719 Sewing foot holding current B 0 - 50 40
720 Cutting holding current B 0 - 50 40
721 Feed converter holding current C 0 - 50 40
722 Acceleration ramp: C 1 - 50 50 1 = flat / 50 = steep
723 Brake ramp: C 4 - 50 50 1 = flat / 50 = steep
729 Start delay after B 0 - 2550 120 lowering the sewing foot [ms]
730 Lift delay B 0 - 2550 0 for sewing foot after seam end [ms]
731 Stitch count delay for end backtacks C 0 - 2550 70
732 Holdoff time for cutting C 0 - 2550 30 after simple end backtack [ms]
Parameter
Description
User level
Setting
range
Set value
733 Holdoff time from C 0 - 200 30 switch-on feed reverse to speed start [ms]
739 Holdoff time for speed C 0 - 2550 200 after start backtack or stitch condensation [ms]
740 Stitch count delay for end backtacks [ms] C 0 - 2550 60
760 Stitch count to bobbin thread monitor A 0 - 50000 1000 (machine stop in needle lowered position)
761 Extension of B 0 - 2550 0 thread tension release/ thread tensioning [ms]
791 Stitch count delay C 0 - 2550 30 for start backtacks [ms]
797 Hardware test: ON = on / OFF = off B OFF - ON OFF
798 User level: A 0 - 255 0 0 = User level A 1 = Mechanic level B 11 = Service level C
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Adjustment
Group
Parameter
Description
User level
Setting
range
Set value
7 799 Machine class: C 1 - 4 1 1 = 2481 (2 to 4 = other machine classes)
8 800 Rotating direction of motor C OFF - ON ON
801 Reverse turning angle C 5 - 106 16 (618 = ON)
831 Start delay for B 0 - 10 5 stepping motor 2 [increments]
832 Needle position (feed start) B 0 - 127 15
833 Needle position (feed end) B 0 - 127 67
834 Feed regulator balance B -5 - 5 0 [1 semi-step = 5/100mm]
835 Reduced single stitch [%] A 0 - 100 50
843 Distance sensor 1 to sensor 2 B 75 - 85 80 [1/10mm]
844 Distance sensor 1 to needle [2/10mm] B 80 - 300 200
845 Speed-controlled B 0 - 3 1 stitch length adjustment [% per 1000 min-1]
846 Feed regulator characteristic line adjustment A 80 - 110 for forward switch length [%]
847 Feed regulator characteristic line adjustment A 80 - 110 for reverse stitch length [%]
849 Maximum stitch length [1/10 mm] A 0 - 60 25
862 Current for stepping motor axis 1 C 16 - 63 32
863 Current for current reduction of C 8 - 63 32 stepping motor axis 1
864 Stepping motor axis 1 Standstill duration of edge guide (pause between 2 B 0 - 2500 20 movements in ms)
= factory set
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Adjustment
Group
8 880 Starting current main drive C 1 - 10 8
881 Filter parameter for position controller C 0 - 12 5
884 Proportional amplification C 1 - 50 25 of speed control (general)
885 Integral amplification C 0 - 50 35 of speed control
886 Proportional amplification C 1 - 50 30 of position controller
887 Differential amplification C 1 - 50 30 of position controller
889 Time for position control (0 = always) C 0 - 2550 200
890 Proportional amplification of C 1 - 50 25 higher ranking speed controller for standstill brake (rest brake)
891 Proportional amplification of C 1 - 50 20 subordinate speed controller for standstill brake (rest brake)
Parameter
Description
User level
Setting
range
Set value
9 901 Cutting release speed C 180 - 500 400
956 Current for stepping motor axis 2 B 30 - 63 56
957 Current for current reduction B 15 - 48 39 of stepping motor axis 2
958 Current reduction time B 0 - 2500 2000 stepping motor axis 2
978 Current reduction time stepping motor 2 C 0 - 99 0
979 Current reduction time stepping motor 1 C 0 - 99 0
985 Position for thread clamp on B 0 - 127 34
986 Position for thread clamp off B 0 - 127 103
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Adjustment
15.13 Error messages and description
Error Description
ERROR: 1 Pedal not at neutral position
ERROR: 3 SM 1 Edge guide (for reference)
ERROR: 4 SM 2 Feed regulator (for reference)
ERROR: 5 Control panel
ERROR: 6 OTE
ERROR: 7 Can node missing (if bobbin changer can node is missing)
ERROR: 8 Zig-zag sensor
ERROR: 9 Starting lock-out at standstill
ERROR: 10 Incorrect machine class
ERROR: 20 Incorrect software version on BDF - P1
ERROR: 27 SD card
ERROR: 40 Transmitted light sensors
ERROR: 45 Bobbin thread monitor
ERROR: 46 Bobbin changer if timeout
ERROR: 47 Bobbin changer empty (if magazine is empty)
ERROR: 48 Bobbin changer error with can node suberror
ERROR: 60 Power supply 24V too low
ERROR: 61 Power supply 24V too high
ERROR: 62 Short circuit 24 V
ERROR: 63 Overload on switch power supply
ERROR: 92 Start inhibitor when motor is running
ERROR: 97 SM 1
ERROR: 98 SM 2
ERROR: 100 Non-maskable interrupt
ERROR: 151 System
ERROR: 155 Sewing motor
ERROR: 156 Timeout communication
ERROR: 157 Stepping motor ramps
ERROR: 158 Stepping motor frequency
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Adjustment
15.14 Sewing motor errors
Error Description
ERROR: 34 Brake path too short
ERROR: 35 Communication
ERROR: 64 Mains monitor
ERROR: 65 Excess current directly after mains on
ERROR: 66 Short circuit
ERROR: 67 Mains off
ERROR: 68 Excess current during operation
ERROR: 69 No increments
ERROR: 70 Motor blocked
ERROR: 71 No incremental encoder connector
ERROR: 73 Faulty motor operation
ERROR: 75 Control locked
ERROR: 170 Transmission invalid
ERROR: 171 Zero mark invalid
ERROR: 173 Motor blocked in 1st stitch
ERROR: 175 Internal starting error
ERROR: 222 Dead man monitoring
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Adjustment
15.15 Service menu
Information about machine inputs and outputs as well as values for the two pedals and the
handwheel position are displayed in the service menu.
In addition, the functions shown below can be performed.
O Switch the machine on.
O Call up entry mode.
O Call up the service menu.
Description of the functions
Input mode
Quit the service menu and call up the input mode.
Sewing mode
Quit the service menu and call up the sewing mode.
Set/reset the outputs
Select the desired output using the arrow functions and set “Function 1” or reset “Function 2”.
Parameter reset All parameters are reset to the default values.
Program reset
All seam programs are reset to the default values.
Sensor menu
The sensors of the transmitted light transmitter and the bobbin thread monitor can be
adjusted after calling up this function.
Motors
The stepping motors for the band feed wheel as well as the sewing motor can be moved
after calling up these functions.
Control panel See chapter 9.12 Setting the control panel in the instruction manual.
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Adjustment
15.16 Internet update of machine software
The machine software can be updated using PFAFF flash-programming. The PFP-boot pro­gram as well as the corresponding control software for the machine type must be installed on a PC for this purpose. The PC and machine control unit must be connected to an appro­priate null modem cable (order no. 91-291 998-91) to transmit data to the machine.
The PFP-boot program and the control software for the machine type can be
downloaded from the PFAFF-homepage using the following path:
www.pfaff-industrial.de/pfaff/de/service/downloads
Proceed as follows to update the machine software:
No set-up, maintenance or adjustment work on the machine must be carried
out whilst updating the machine software!
O Switch the machine off.
O Establish a connection between the PC
(serial interface or corresponding USB
adapter) and the machine control unit (RS232) by loosening the control pan-
el connector. Switch on the PC and start
1
Fig. 15 - 30
O The machine must not be switched off during the update.
O Switch off the machine and end the PFP-boot program when the update is completed.
O Release the plug-in connection between the PC and machine control unit and plug the
control panel back into the machine control unit.
O Switch the machine on.
Perform a plausibility check and carry out a cold start if necessary.
the PFP-boot program.
O Select the machine type.
O Press the “Programming” button.
O Press and hold the boot key 1 and switch
on the machine.
O Press the “OK” button.
The software update is conducted and
the progress of the update can be deter-
mined from the bar graph display of the
PFP-boot program.
50
Further information and assistance can be found in the file “PFPHILFE.TXT”, which can be called up by pressing the “Help” button from the PFP-boot pro­gram.
Page 51
Circuit Diagrams
16 Circuit Diagrams
16.01 Block diagram of PFAFF 2481 with control unit P322 ED
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Circuit Diagrams
16.02 Circuit diagrams
Reference list for circuit diagrams 91-191 441-95
A1 Control device P322 ED
A2 Control panel BDF P1
A3 Incremental encoder ( included in M1 )
A4 Key field
A11 Transmitted light transmitter
A12 Transmitter light receiver
A13 Bobbin thread monitor
A14 Sewing head detection
S1 Nominal value transmitter
S10 Single stitch ( included in A4 )
S11 Hand operation front (bartack) ( included in A4 )
S12 Needle position ( included in A4 )
S13 Knee switch ( single stitch )
S14 Starting lock-out
S15 Knee switch 2
H1 Sewing lamp
H10 Bobbin thread alarm ( included in A4 )
Q1 Main switch
M1 Sewing motor
M10 Stepping motor (feed regulator)
M11 Stepping motor (edge guide)
B10 Forked light barrier ( included in M10 )
Y2 900 (Thread trimmer)
Y3 WI (Thread wiper device)
Y4 PFA (Presser foot)
Y8 FSL (Thread tension ventilation)
X40 Zig-zag sensor
X41 DLS - Transmitted light transmitter
X42 DLE - Transmitted light receiver
X43 UFW - Bobbin thread monitor
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Circuit Diagrams
91-191 441-95 Part 1 Version 01.05.15 Circuit diagram
P
RS232 – interface
Control panel BDF-P1
Power
CAN interface
Control device A1
Speed control unit
Speed control unit
Sewing lamp
Incremental encoder
Rotor position sensor
Sewing motor
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Circuit Diagrams
Circuit diagram Version 01.05.15 91-191 441-95 Part 2
Control device A1
Step motors
SM position
Forked light barrier
SM stitch setter SM straight edge
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Circuit Diagrams
91-191 441-95 Part 3 Version 01.05.15 Circuit diagram
Control device A1
Key
field
Thread
trimmer
wiper
thread
Optional:
foot
Presser
Outputs
Thread
tension
ventilation
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Circuit Diagrams
Circuit diagram Version 01.05.15 91-191 441-95 Part 4
Receiver sensor Transmitted light
Transmitter sensor Transmitted light
monitor Bobbin thread
Control device A1
Inputs
Key field
knee switch Second Optional:
(Knee switch) Single stitch
Start inhibitor
alarm Bobbin thread
Single stitch
change-over Needle position
Bartack
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Circuit Diagrams
16.03 Plug connections
CAN
Pin no. Comment Function Connector name Signal name
X11A.2 CAN CAN- CAN_HIGH CAN_TxD
X11A.3 CAN Gnd
X11A.7 CAN CAN+ CAN_LOW CAN_RxD
Nominal value transmitter
Pin no. Comment Function Connector name Signal name
X11B.4 Pedal +5V
X11B.5 Pedal +5V
X11B.6 Pedal Gnd
X11B.7 Pedal 2 Setpoint SW2 (analog)
X11B.8 Pedal 1 Setpoint SW1 (analog)
X11B.9 Pedal Gnd
Sensors
Pin no. Comment Function Connector name Signal name
X15.1 Sensors Power source UFW P7.3
X15.2 Sensors DLS external (LS2) P5.3 (analog)
X15.3 Sensors DLS internal (LS1) P5.6 (analog)
X15.4 Sensors Zig-zag sensor 2438 E9 E9/Port_E9
X15.5 Sensors Power source DLS A10/PortA10 O10
X15.6 Sensors +5V +5V
X15.7 Sensors UFW-Out UFW_MESS
X15.8 Sensors +24V +24V
X15.9 Sensors 0V 0V
RS232
Pin no. Comment Function Connector name Signal name
X1A.1 BDF-S2/T1 +24V +24V
X1A.2 BDF-S2/T1 RxD RxD
X1A.3 BDF-S2/T1 TxD TxD
X1A.4 BDF-S2/T1 +5V +5V
X1A.5 BDF-S2/T1 Gnd Gnd
X1A.6 BDF-S2/T1 -
X1A.7 BDF-S2/T1 RTS RTS
X1A.8 BDF-S2/T1 CTS CTS
X1A.9 BDF-S2/T1 Gnd Gnd
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Circuit Diagrams
OTE
Pin no. Comment Function Connector name Signal name
X1B.1 OTE Gnd
X1B.2 OTE SSI-Out ( TxD) SSOut
X1B.3 OTE SSI-Clock SSClk
X1B.4 OTE +24V
X1B.5 OTE +5V
X1B.6 OTE SSI-Strobe (Mode) SSStr
X1B.7 OTE SSI-In (RxD) SSIn
X1B.8 OTE (Light barrier 1) (LS1)
X1B.9 OTE
Incremental encoder
Pin no. Comment Function Connector name Signal name
X3.1 IncrEncod Track A 256Incr/rev. FA_MINI
X3.2 IncrEncod Track B 256Incr/rev. FB_MINI
X3.3 IncrEncod SyMa 360°/256
X3.4 IncrEncod Autodetect ADTC
X3.5 IncrEncod +5V
X3.6 IncrEncod +5V
X3.7 IncrEncod Gnd
X3.8 IncrEncod Ext. SyMa 180° EXTSM_MINI
X3.9 IncrEncod Gnd
Stepping motor 1 (edge guide)
Pin no. Comment Function Connector name Signal name
X4B.1 SM1/FSL Phase A.2 A11
X4B.2 SM1/FSL Phase A.1 A12
X4B.3 SM1 Phase B.2 A21
X4B.4 SM1 Phase B.1 A22
X4B.5 SM1
X4B.6 SM1
X4B.7 SM1 +5V (with 120R ?)
X4B.8 SM1 Reference SM1 SM_REF1 SM_REF1
X4B.9 SM1 Gnd
Stepping motor 2 (stitch length)
Pin no. Comment Function Connector name Signal name
X4A.1 SM2 Phase A.2 B11
X4A.2 SM2 Phase A.1 B12
X4A.3 SM2 Phase B.2 B21
X4A.4 SM2 Phase B.1 B22
X4A.5 SM2
X4A.6 SM2
X4A.7 SM2 +5V (with 120R ?)
X4A.8 SM2 Reference SM2 SM_REF2 SM_REF2
X4A.9 SM2 Gnd
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Circuit Diagrams
Outputs
Pin no. Comment Function Connector name Signal name
X13.01 PWM FSL-solenoid(Y8) A1 O1.1 X13.02 FSL-solenoid(Y8+) A1 O1.2 X13.03 PWM PFH-solenoid(Y4) A2 O2.1 X13.04 PFH-solenoid(Y4+) A2 O2.2 X13.05 WI-solenoid(Y3) A3 O3 X13.06 PWM SN-solenoid(Y2) A4 O4 X13.07 A5 O5 X13.08 RAFI-LED(H1) A6 O6 X13.09 A7 O7 X13.10 A8 O8 X13.11 A9 O9 X13.12 (from DX) Power source DLS A10/PortA10 O10 X13.13 A11 O11 X13.14 +24V +24V X13.15 +24V +24V X13.16 A14 O14 X13.17 A15 O15 X13.18 A16 O16 X13.19 SN-solenoid(Y2+) +24V +24V X13.20 WI-solenoid(Y3+) +24V +24V X13.21 +24V +24V X13.22 RAFI-LED(H1+) +24V +24V X13.23 +24V +24V X13.24 A13 O13 X13.25 A12 O12
Inputs
Pin no. Comment Function Connector name Signal name
X5.01 TUM switch-key(S1) E1 E7 X5.02 NPW switch-key(S2) E2 E8 X5.03 EST switch-key(S2) E3 E2 X5.04 ANLSP switch(S14) E4 E4 X5.05 EST knee switch(S13) E5 E5 X5.06 Knee switch 2 E15 E15 X5.07 E16 E16 X5.08 E14 E14 X5.09 (from DX) Zig-zag sensor 2438 E9 E9/Port_E9 X5.10 E10 E10 X5.11 E11 E11 X5.12 E12 E12 X5.13 E13 E13 X5.14 E6 E6 X5.15 E7 E1 X5.16 E8 E3 X5.17 S1-S2-S3(Gnd) 0V 0V X5.18 0V 0V X5.19 ANLSP switch(Gnd) 0V 0V X5.20 EST knee switch(Gnd) 0V 0V X5.21 0V 0V X5.22 0V 0V X5.23 +24V +24V X5.24 A16 Output_A16 X5.25 +24V +24V
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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. / Impreso en la R.F.A
© PFAFF is the exclusive trademark of VSM Group AB I PFAFF Industriesysteme und Maschinen GmbH is an authorised licensee of the PFAFF trademark.
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