Page 1
-1/1306
3108
INSTRUCTION MANUAL
-1/1310
with BDF S3
This instruction manual applies to machines
from serial number 2 774 709, software version
0394/008 (3108-1/1310) and
0408/008 (3108-1/1306) onwards.
296-12-19 165/002
Betriebsanleitung engl. 03.11
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
Contents
Contents .................................................................................... Chapter - Page
1
Safety .................................................................................................................................... 6
1.01 Directives ............................................................................................................................... 6
1.02 General notes on safety ......................................................................................................... 6
1.03 Safety symbols ......................................................................................................................7
1.04 Important notes for the user .................................................................................................. 7
1.05 Notes for operating and technical staff .................................................................................. 8
1.05.01 Operating staff ....................................................................................................................... 8
1.05.02 Technical staff ........................................................................................................................ 8
1.06 Danger warnings .................................................................................................................... 9
2 Proper use........................................................................................................................... 10
3 Specifi cations ......................................................................................................................11
4 Disposal of Machine .......................................................................................................... 12
5 Transportation, packing and storage ................................................................................ 13
5.01 Transportation to customer‘s premises ............................................................................... 13
5.02 Transportation inside the customer‘s premises ................................................................... 13
5.03 Disposal of packing materials ..............................................................................................13
5.04 Storage ................................................................................................................................ 13
6 Explanation of symbols ..................................................................................................... 14
7 Controls .............................................................................................................................. 15
7.01 On/off switch ....................................................................................................................... 15
7.02 Foot switch .......................................................................................................................... 15
7.03 Control panel ........................................................................................................................ 16
7.03.01 Screen displays .................................................................................................................... 16
7.03.02 Display symbols ................................................................................................................... 17
7.03.03 Function keys ....................................................................................................................... 17
8 Mounting and commissioning the machine .................................................................... 19
8.01 Mounting ............................................................................................................................. 19
8.02 Mounting the spool holder ................................................................................................... 20
8.03 Commissioning .................................................................................................................... 20
8.04 Switching the machine on/off ..............................................................................................21
8.05 Check/adjust zero points ...................................................................................................... 22
8.06 Adjusting the potentiometer for speed reduction ................................................................ 23
9 Preparation ........................................................................................................................ 24
9.01 Inserting the needle ............................................................................................................. 24
9.02 Winding the bobbin thread, regulating the winder tension .................................................. 25
9.03 Changing the bobbin / adjusting the bobbin thread tension ................................................ 26
9.04 Threading needle thread/adjusting needle thread tension ..............................................................27
Page 4
Contents
Contents .................................................................................... Chapter - Page
9
.05 Setting the lever pressure .................................................................................................... 28
9.06 Selecting a seam program ...................................................................................................29
9.06.01 Selecting and changing the seam pattern ............................................................................ 29
9.06.02 Selecting a program station. ................................................................................................ 30
9.06.03 Selecting a sequence ........................................................................................................... 30
9.07 Adjusting the size of the sewing area .................................................................................. 31
9.08 Setting up the bobbin thread counter .................................................................................. 32
9.09 Resetting the piece counter ................................................................................................. 32
9.10 Shifting the seam pattern ..................................................................................................... 33
9.11 Inserting and removing the SD-memory card ...................................................................... 34
10 Sewing ................................................................................................................................ 35
10.01 Operating cycle .................................................................................................................. 35
10.02 Display options..................................................................................................................... 35
10.03 Sewing in the "Direct program selection" mode .................................................................. 35
10.04 Sewing in the "Program stations" mode ...............................................................................35
10.05 Sewing in the "Sequences mode". ....................................................................................... 36
10.05.01 Interrupting a sequence .....................................................................................................36
10.06 Error messages .................................................................................................................... 36
11 Input .................................................................................................................................... 37
11 .01 Reserving program stations .................................................................................................37
11 .02 Sequences ........................................................................................................................... 38
11 .02.01 Entering sequences ............................................................................................................. 38
11 .02.02 Checking the sequence contents ........................................................................................ 38
11 .02.03 Deleting sequences ............................................................................................................39
11 .02.04 Combining sequences .........................................................................................................39
11 .03 Parameter input ................................................................................................................... 40
11 .04 Access codes .......................................................................................................................41
11 .04.01 Entering the access code .................................................................................................... 41
11 .04.02 Changing the access code ................................................................................................... 41
11 .04.03 Granting access rights ......................................................................................................... 42
11 .05 Program Management .........................................................................................................43
11 .05.01 Calling up the program management .................................................................................. 43
11 .05.02 Display of the data in the machine memory ........................................................................ 44
11 .05.03 Display of the data on the SD-memory card ........................................................................ 45
11 .05.04 Copying data onto the SD-memory card.............................................................................. 46
11 .05.05 Copying data into the machine memory .............................................................................. 47
11 .05.06 Deleting data in the machine memory ................................................................................. 48
11 .05.07 Deleting data from the SD-memory card ............................................................................. 49
11 .05.08 Formatting the SD-memory card ......................................................................................... 50
12 Care and maintenance ....................................................................................................... 51
12.01 Servicing and maintenance intervals ................................................................................... 51
Page 5
Contents
Contents .................................................................................... Chapter - Page
.02 Cleaning the machine .......................................................................................................... 51
12
12.03 Lubricating ........................................................................................................................... 52
12.04 Lubricate clamp drive ........................................................................................................... 53
12.05 Cleaning the blower air fi lter ................................................................................................ 54
12.06 Checking/regulating the air pressure ...................................................................................55
12.07 Emptying/cleaning the water bowl of the air fi lter/regulator ................................................ 55
13 Adjustment ......................................................................................................................... 56
13.01 Notes on adjustment ...........................................................................................................56
13.02 Tools, gauges and other accessories for adjusting .............................................................56
13.03 Abbreviations ....................................................................................................................... 56
13.04 Explanation of the symbols .................................................................................................. 56
13.05 Adjusting the sewing head ..................................................................................................57
13.05.01 Basic position of the balance wheel (adjustment aid) .......................................................... 57
13.05.02 Preliminary adjustment of the needle height ....................................................................... 58
13.05.03 Needle rise, hook clearance and needle height .................................................................. 59
13.05.04 Reversing point of hopping foot ........................................................................................... 60
13.05.05 Hopping foot lift ................................................................................................................... 61
13.05.06 Adjusting hopping foot pressure .......................................................................................... 62
13.05.07 Adjusting hopping foot height .............................................................................................. 63
13.05.08 Regulating the level of the hopping foot .............................................................................. 64
13.05.09 Bobbin winder ...................................................................................................................... 65
13.05.10 Thread check spring and thread regulator ............................................................................ 66
13.05.11 Lubrication ........................................................................................................................... 67
13.05.12 Basic position of the thread trimmer ...................................................................................68
13.05.13 Control cam to roller lever clearance (resting position) ........................................................ 69
13.05.14 Adjusting the control cam .................................................................................................... 70
13.05.15 Knife pressure ...................................................................................................................... 71
13.05.16 Manual cutting test .............................................................................................................. 72
13.05.17 Aligning the clamp drive ....................................................................................................... 73
13.05.18 Adjusting belt tensions .........................................................................................................74
13.06 Parameter list ....................................................................................................................... 75
13.07 Internet update of the machine software ............................................................................ 79
13.07.01 Update with null modem cable ............................................................................................79
13.07.02 Update with SD-card ............................................................................................................ 80
13.08 Error message explanations ................................................................................................. 82
13.08.01 General errors ...................................................................................................................... 82
13.08.02 Error in production mode ..................................................................................................... 82
13.08.03 Error during output switching ..............................................................................................83
13.08.04 Error in production mode ..................................................................................................... 83
13.08.05 Sewing motor errors ............................................................................................................ 84
13.08.06 OTE-errors ............................................................................................................................ 85
13.08.07 Stitch generation errors .......................................................................................................86
14 Circuit diagrams ................................................................................................................. 87
Page 6
Safety
1 Safety
1
1.02 General notes on safety
.01 Directives
This machine was built in accordance with the European regulations stated in the Conformi-
ty and Manufacturer’s Declaration.
In addition to this Instruction Manual, also observe all generally accepted, statutory and oth-
er regulations and legal requirements - also those of the country in which the machine will
be operated - and all valid environmental protection regulations!
Applicable local regulations of the social insurance society for occupational accidents or oth-
er supervisory organizations are to be strictly adhered to!
● This machine must only be operated by adequately trained operators and only after hav-
ing completely read and understood the Instruction Manual!
● All Notes on Safety and Instruction Manuals of the motor manufacturer are to be read be-
fore operating the machine!
● The Danger and Safety Instructions on the machine itself are to be followed!
● This machine must only be used for the purpose for which it is intended and must not be
operated without its safety devices. All applicable safety regulations must be observed.
● When leaving the machine unattended and during maintenance work, the machine must
be disconnected from the power supply by operating the main switch or by removing the
plug from the mains!
● Daily maintenance w
● When carr
disconnected from the pneumatic supply network! The only exceptions to this are adjust-
ment work and functional tests carried out by appropriately trained personnel!
● Repair work and special maintenance work must only be carried out by specialists or ap-
propriately trained personnel!
● Work on electrical equipment must only be carried out by appropriately trained specialist
personnel!
● 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.
● Modifi cations and alterations to the machine must only be carried out pursuant to all rele-
vant safety regulations!
● Only spare parts which have been approved by us are to be used for repairs! We express-
ly point out that any replacement parts or accessories not supplied by us have not been
tested and approved by us. The installation and/or use of any such products may result in
negative changes to the constructional characteristics of the machine. We are not liable
for any damage which may be caused by non-original parts.
ying out servicing or repair work on pneumatic devices, the machine must be
ork must only be car
ried out by appropriately trained personnel!
6
Page 7
Safety
1.03 Safety symbols
Danger!
Special points to observe.
Danger of injury to operating or technical staff!
Caution
Do not operate without fi nger guard and safety devic-
es.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.
I
1.04 Important notes for the user
● This instruction manual belongs to the equipment of the machine and must be available
to the operating staff at all times.
● This instruction manual must be read before the machine is operated for the fi rst time.
● Both operating and technical staff must be instructed on the safety devices of the ma-
chine and on safe working methods.
● It is the duty of the user to operate the machine in perfect running order only.
● The user must ensure that none of the safety devices are removed nor put out of work-
ing order.
● The user must ensure that only authorized persons operate and work on the machine.
For further information please refer to your PFAFF agency.
7
Page 8
Safety
1.05 Notes for operating and technical staff
1
.05.01 Operating staff
Operating staff are the persons responsible for setting up, operating and cleaning the ma-
chine and for eliminating any malfunctioning in the sewing area.
The operating staff is obliged to observe the following points:
● The notes on safety in this instruction manual must always be observed!
● Any working methods, which adversely affect the safety of the machine,
must be avoided!
● Loose-fi tting clothing should be avoided. No jewellery, such as chains and rings, should
be worn!
● Ensure that only authorised persons enter the danger area of the machine!
● Any changes occurring on the machine, which may affect its safety, must be reported to
the user immediately.
1.05.02 Technical staff
Technical staff are persons who have been trained in electrical engineering/electronics and
mechanical engineering. They are responsible for lubricating, servicing, repairing and adjust-
ing the machine.
The technical staff is obliged to observe the following points:
● The notes on safety in this instruction manual must always be observed!
● Before carrying out any adjustment or repair work the main switch must be switched off
and measures taken to prevent it from being switched on again!
● Never work on parts or equipment still connected to the power supply! Exceptions are
only permissible in accordance with the regulations EN 50110.
● All safety covers must be replaced after the completion of maintenance or repair work!
8
Page 9
Safety
1.06 Danger warnings
A working area of 1 m must be kept free both in front of and behind the
machine, so that easy access is possible at all times.
Never put your hands in the sewing area during sewing!
Danger of injury by the needle!
Never leave objects on the table while adjusting the machine settings! Objects
can become trapped or be slung away! Danger of injury by hurled objects!
3
Fig. 1 - 01
2
Do not operate the machine without the protective covers 1 and 2!
Danger of crushing between moving parts of the pneumatic and/or transport
devices.
1
Do not operate the machine without take-up lever guard 3!
Danger of injury by the movement of the take-up lever!
9
Page 10
Proper use
2 Proper use
The machines 3108-1/1306 and 3108-1/1310 are small area backtack automats for the
production of backtack and assembly seams in the shoe, leather, plastic, and automotive
industry.
Any and all uses of this machine which have not been approved of by the
manufacturer are considered to be inappropriate! The manufacturer cannot
be held liable for any damage caused by the inappropriate use of the machine!
The appropriate use of the machine means that all operational, adjustment,
maintenance and repair measures required by the manufacturer are to be ob-
served!
10
Page 11
Specifi cation
3 Specifi cations▲
Max. sewing speed:................................................................................................2800 s.p.m.
Max. stitch length: .................................................................................................. 0,1 - 12 mm
Stitch type: ..........................................................................................................301 (lockstitch)
Needle system: ..........................................................................................................134-35 KK
Needle size .................................................................................................................. 80 – 160
Operating voltage: .........................................................................230 V ± 10%, 50/60 Hz, A/C
Power requirement: ........................................................................................................2.2 kW
Leakage current ........................................................................................................... < 5 mA
Control range:
3108-1/1306 .......................................................................................................... 130 x 60 mm
3108-1/1310 ........................................................................................................ 130 x 100 mm
Storage capacity:: ..............................................................................................25.000 stitches
◆
Min. working pressure: ............................................................................. min. 4,5 - max. 6 bar
Air consumption: ..............................................................................................approx. 15l/cycle
Max. hopping foot lift: .......................................................................................................9 mm
Max. through-passage under clamp: ..............................................................................20 mm
Machine dimensions:
Length: ........................................................................................................... approx. 1035 mm
Width: .............................................................................................................. approx. 800 mm
Height: ........................................................................................................... approx. 1180 mm
Table height: ..................................................................................................................840 mm
Net weight: ......................................................................................................................150 kg
Ambient temperature
85% rel. humidity (condensation not permitted): ...................................................... 5 – 40° C
Noise data
Emission sound pressure level at the workplace
at a sewing speed of 3000 spm ........................................................................ LpA < 81 dB(A)
(Noise measurement in acc. with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)
■
▲
Subject to alteration
◆
Due to the use of network fi lters there is a nominal leakage current of < 5 mA.
■
KpA = 2,5 dB
11
Page 12
Disposal of Machine
4 Disposal of Machine
● Proper disposal of the machine is the responsibility of the customer.
● The materials used for the machine are steel, aluminium, brass and various plastic
materials. The electrical equipment comprises plastic materials and copper.
● The machine is to be disposed of according to the locally valid pollution control
regulations; if necessary, a specialist ist to be commissioned.
Care must be taken that parts soiled with lubricants are disposed of separately
according to the locally valid pollution control regulations!
12
Page 13
Transportation, packing and storage
5 Transportation, packing and storage
5
.01 Transportation to customer‘s premises
The machines are delivered completely packed.
5.02 Transportation inside the customer‘s premises
The manufacturer cannot be made liable for transportation inside the customer‘s premises
nor to other operating locations. It must be ensured that the machines are only transported
in an upright position.
5.03 Disposal of packing materials
The packing materials of this machine comprise paper, cardboard and VCE fi bre. Proper
disposal of the packing material is the responsibility of the customer.
5.04 Storage
If the machine is not in use, it can be stored as it is for a period of up to six months, but It
should be protected against dust and moisture.
If the machine is stored for longer periods, the individual parts, especially the surfaces of
moving parts, must be protected against corrosion, e.g. by a fi lm of oil.
13
Page 14
Explanation of symbols
6 Explanation of symbols
In this instruction manual, work to be carried out or important information is accentuated by
symbols. These symbols have the following meanings:
Note, information
Cleaning, care
Lubrication
Maintenance, repairs, adjustment, service work
(only to be carried out by technical staff)
14
Page 15
Control elements
7 Controls
7
.01 On/off switch
● By turning on/off switch 1, the power
supply to the machine is switched on or
off.
1
Fig. 7 - 01
7.02 Foot switch
1
● Foot switches 1 and 2 have
the following functions:
Foot switch 1:
+1 = left clamp up/down
Foot switch 2:
+1 = right clamp up/down
2
+2 = sewing start
Fig. 7 - 02
15
Page 16
Control elements
7.03 Control panel
The control panel is used to select seam programs, call up machine functions, change
parameters, control the different operating modes, as well as for reading error signals and
service settings.
1
2
3
Fig. 7 - 04
The control panel consists of display screen 1 with the function keys described below. The
display 1 consists of a two-row alphanumerical LCD display with 16 symbols per row. The
function keys 2 are located below and to the right of the display screen. The status of the
function keys and the machine operating modes are shown with LEDs in the corresponding
keys. Every time the function keys 2 are operated, a key tone sounds as confi rmation of the
input. If the input required is invalid, e.g. because the max. permissible value for the
parameter input has been reached, a double tone is audible. An SD-card reader for data
transfer is integrated.
7.03.01 Screen displays
Depending on the operating mode, on the screen 1 information is shown about the machine
status, program selection, sequence program progress, input parameters, as well as error signals (also see Chapter 11 Input).
● Depending on the operating mode, relevant data is displayed in combination with the ap-
propriate symbol or text, and can be altered directly.
● When the parameters are entered, the number of the parameter selected is shown with
the corresponding parameter value, see Chapter 11 .03 Parameter input.
16
● If faults occur in the sewing operation, a corresponding error signal appears in the display,
see Chapter 13.08 Error messages on the display.
Page 17
Control elements
7.03.02 Display symbols
Program number
Speed
X Size factor X-direction (crosswise) in %
Y Size factor Y-direction (lengthwise) in %
Bobbin thread counter / piece counter
Enter
Machine memory
SD-memory card
7.03.03 Function keys
The functions keys described below are used essentially to switch machine functions on and
off. When the function is switched on, the diode in the key is illuminated.
If a corresponding value has to be fi xed for the activated function, this can be carried out
with the corresponding +/- keys 3.
By pressing and holding the corresponding +/- key, fi rstly the numerical value displayed above it is altered slowly. If the +/- key is pressed longer, the numerical value changes more
quickly. The respective +/- keys shown opposite are described below.
Menü
This function is used in the respective operating mode to scroll within the existing menus.
Wind
The bobbin thread winding function is called up, see Chapter 9.03 Winding the bobbin
thread.
Basic position
Work clamp and needle are positioned in the basic position and , if necessary, the thread
trimming function is activated.
Tacting backwards
Each time the key is pressed, the selected seam program is sewn stitch by stitch in reverse,
and the coordinates for each stitch are shown on the control panel.
17
Page 18
Control elements
Tacting forwards
Each time the key is pressed, the selected seam program is sewn forwards stitch by stitch,
and the coordinates for each stitch are shown on the control panel.
Program stations
to
to
The function keys P1 to P8 are used to enter and select seam programs, see Chapter
9.06.02 Selecting the program station.
Direct program selection
This function is used to select a seam pattern. After selection, speed, stitch length and size
can be altered, see Chapter 9.06.01 Selecting and altering the seam pattern.
Sequences
The function keys C1 to C3 are used to enter and select sequences, see Chapter 9.06.03
Selecting a sequence.
TE
In the sewing mode, this key is used to change to the input mode. In the input mode this
key is used to acknowledge the input of program stations and sequences, and to change
into the sewing mode.
18
Page 19
Mounting and commissioning the machine
8 Mounting and commissioning the machine
After unpacking the machine, check it for any transport damage. In case of damage, inform
the shipping company and the responsible PFAFF dealer.
The machine must only be mounted and commissioned by qualifi ed personnel!
All relevant safety regulations are to be observed!
8.01 Mounting
At the machine’s location, there must be a stable and horizontal surface as well as suitable
electricity and compressed air supplies (see chapter 3 Specifi cations).
2
1
2
Fig. 8 - 01
● Lift the machine with a forklift from the shipping pallet.
● Level the machine just above the ground, and adjust the feet accordingly.
● The table height can be adjusted at crank 1 after loosening screws 2.
19
Page 20
Mounting and commissioning the machine
8.02 Mounting the spool holder
● Mount the spool holder according to
Fig. 8.02.
Fig. 8 - 02
8.03 Commissioning
● Before commissioning the machine, clean it thoroughly and lubricate it, or pour in oil,
see Chapter 12 Care and Maintenance!
● The machine, in particular the electric wires and pneumatic connection tubes, must be
examined for any damage.
● Have skilled personnel check if the machine can be operated with the available mains
voltage.
Do not operate the machine if there is any discrepancy.
20
The machine may only be connected to an earthed socket!
● Connect machine to the compressed air system.
The manometer on the air fi lter/lubricator unit must display a pressure of 6 bar.
If necessary, set to the correct value (see chapter 12.05 Checking / regulating air
compression).
Page 21
Mounting and commissioning the machine
8.04 Switching the machine on/off
2
1
3
Fig. 8 - 04
● Check air pressure on pressure gauge 1 and, if necessary, adjust air pressure with
adjusting knob 2.
● Turn main switch 3 to position "I"
HOME
MOVE CARRIAGE
● The machine will drive into home position after the controls have been booted.
In programs with obstacles, the prompt "HOME MOVE CARRIAGESDSq, and the clamp
will have to be moved to the home position by hand (= needle in the rear left corner of
the clamp).
● After shifting the clamp manually, press the "Basic position" button.
Fig. 8 - 05
HOME
PUSH HOME KEY
● Carry out a test run, see Chapter 10 Sewing.
At fi rst commissioning of the machine, the zero points and
the potentiometer for motor speed reduction must be checked and set
(see chapter 8.05 and 8.06 ).
● To switch off the machine, turn main switch 3 to position "0".
21
Page 22
Mounting and commissioning the machine
8.05 Check/adjust zero points
1
2
3
Fig. 8 - 09
Before commissioning the machine, or after changing the controller or one of
the initiators of the clamp drive, it is necessary to set the zero points.
● Unscrew material presser foot.
● Insert adjustment pin 1 into the needle bar and secure using screw 2.
● Screw on clamp setting gauge 3 (Order No. 95-295 500-05).
● Call up input mode (LED lights up).
● Call up parameter '608' by pressing the relevant +/- button.
● Enter the access code if available - see chapter 11 .04.01 Input access code.
22
NO VAL
608
● Confi rm the code input with the relevant +/- button.
Page 23
Mounting and commissioning the machine
NO SM1 SM2
608 0 0
● Turn the handwheel to check whether adjustment pin 1 can be inserted into the
adjustment hole on gauge 3.
● Where required, adjust the position of the clamp by changing the SM1 + SM2
accordingly.
● Release screw 2 and remove adjustment pin 1.
● Unscrew setting gauge 3.
● Finish input by pressing the button TE.
8.06 Adjusting the potentiometer for speed reduction
NO MIN
209 314 285
● Switch machine on.
NO MAX
210 314 373
● Set lowest lift "0" on the setting wheel.
● Call up parameter "209" and press button "D+" to store the lower value.
● Set highest lift "9" on the setting wheel.
● Call up parameter "210" and press button "D+" to store the upper value.
23
Page 24
Setting up
9 Preparation
9.01 Inserting the needle
All regulations and instructions in this Instruction Manual are to be observed!
Special attention is to be paid to the safety regulations!
All preparation work is only to be carried out by appropriately trained personnel!
Only use needles from the sys-
tem intended for the machine,
see Chapter 3 Specifi cations.
1
2
Fig. 9 - 01
● Switch on the machine.
● Call up the threading aid function.
Machine moves to thread-in position, sewing start is disengaged.
(when clamping with obstacles, the clamp must be pushed manually into thread-in posi-
tion).
● Loosen screw 1 and insert needle 2 as far as possible into the needle bar.
● Adjust needle 2 so that the long needle groove is pointing in the direction of the top
cover of the sewing head, and tighten screw 1.
24
● Move the machine to its basic position
Page 25
Setting up
9.02 Winding the bobbin thread, regulating the winder tension
1
4
3
2
5
6
Fig. 9 -02
● Draw the thread from the reel stand through guide hole 1 into the bobbin winder tension
unit 2 and then behind the thread clamp 3.
● Cut off the thread in thread clamp 3. The thread is retained.
● Place empty bobbin 4 on the bobbin winder spindle 5.
● To switch on the bobbin winder, push up lever 6.
The bobbin is wound during sewing.
● The bobbin winder stops automatically, when the bobbin 4 is fi lled suffi ciently.
● Remove full bobbin 4 and cut off the thread in thread clamp 3.
● The tension of the thread on bobbin 4 can be adjusted on the bobbin winder tension unit
2.
● The volume of thread on bobbin 4 can be adjusted with screw 7.
● If separate winding is required, proceed as follows:
7
● Call up bobbin winding function.
● Start the winding function using the treadle or the sewing start button.
25
Page 26
Setting up
9.03 Changing the bobbin / adjusting the bobbin thread tension
5 cm
2
1
3
Fig. 9 -03
● Call up the threading aid function.
Machine moves to thread-in position, sewing start is disengaged.
● Raise lever 1 and remove bobbin casing 2.
● Place the fi lled bobbin into the hook so that it turns in the direction of the arrow when
thread is pulled off.
● Close lever 1.
● Pass the thread through the slot under the spring according to Fig. 9 - 03a.
● Adjust the thread tension by turning screw 3.
Fig. 9 - 03a
● Move the machine to its basic position
26
Page 27
Setting up
9.04 Threading needle thread/adjusting needle thread tension
2
1
Fig. 9 - 04
● Switch on the machine.
● Call up the threading aid function.
Machine moves to thread-in position, sewing start is disengaged.
● Thread the machine as shown in Fig. 9 - 04.
● Regulate the needle-thread tension by turning milled screw 1.
Secondary tension is regulated by turning the knurled thumb screw.
● Move the machine to its basic position
27
Page 28
Setting up
9.05 Setting the lever pressure
1
Fig. 9 -05
● The lever pressure must be adjusted to the respective material to ensure perfect materi-
al feed.
● The max. lever pressure must not exceed 0.25 MPa.
● The lever pressure is adjusted at knob 1.
28
Page 29
Setting up
9.06 Selecting a seam program
After the machine has been switched on, it is in its basic position and offers various possibili-
ties for selecting seam programs.
- Direct selection of the seam pattern and its individual adaptation by changing the speed
and stitch length.
- Selection of the seam program via a program station. For this purpose a seam pattern with
its respective speed and corresponding size factors must have been stored previously.
- With the selection of a sequence several seam programs are sewn after each other. For
this purpose a sequence must have been compiled beforehand from individual seam pro
grams (program stations).
9.06.01 Selecting and changing the seam pattern
● Switch on programme selection (LED lights up)
5 2700 3,0mm
● Select the desired seam pattern with the corresponding +/- key.
● Select the desired speed with the corresponding +/- key.
● Select the desired stitch length with the corresponding +/- key.
● To conclude the input, press the TE key or operate the pedal forwards (machine changes
to the sewing mode).
29
Page 30
Setting up
9.06.02 Selecting a program station.
● With the machine in its basic position, select the desired program station, e.g. P3.
5 2700 3,0mm
Only those program stations can be selected, which have been reserved previ-
ously with a seam pattern with its respective speed and size factors, see Chapter 11 .01 Reserving program stations.
Speed and size factors cannot be changed directly in a seam program selected
via a program station.
9.06.03 Selecting a sequence
● With the machine in its basic position, select the desired sequence, e.g. C2.
A 3 - 3 - 3 - 3 - 3 - 3 - 8
8 - 8 - 8 - 4 - 4
IThe next seam program waiting to be sewn is depicted by the relevant fl ashing
entry.
Sequences can only be called up if they have been created beforehand (see
Chapter 11 .02.01 Enter sequences).
30
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Setting up
9.07 Adjusting the size of the sewing area
1
Y
X
Fig. 9 - 07
A comparison between the sewing area size entered and the actual sewing area size of the
work clamp ensures that seam programs, which are not within the sewing area size, cannot
be sewn.
If the actual and the entered sewing area size do not concur with each other,
severe damage can be caused to the machine!
● Measure the sewing area size of work clamp 1.
● With the machine in its basic position, select the input mode. (LED is illuminated).
● Call up parameters "201 - 204" in sequence by pressing the relevant +/- button.
● Enter the access code if available - see chapter 11 .04.01 Input access code.
● Enter the measured value via the relevant parameter (in 1/10 mm)
NO VAL
201 -650
Parameter 201 = Min. X-Coordinate (-650 bis 0)
202 = Max. X-Coordinate (0 bis 650)
203 = Min. C-Koordinate (-1000 bis 0)
204 = Max. C-Koordinate (-1000 bis 0)
● Finish the parameter input and switch to sewing mode (home position of the machine).
31
Page 32
Setting up
9.08 Setting up the bobbin thread counter
● With the machine in its basic position, select the input mode.
● With the corresponding +/- key select parameter "004".
● If required, enter the access code, see Chapter 11 .04.01 Entering the access code.
No VAL
004 ON 5000
● With the corresponding +/- key switch on the bobbin thread counter.
● With the corresponding +/- key enter the number of stitches to be sewn.
● Conclude the input by pressing the TE key. (Machine changes to the sewing mode).
9.09 Resetting the piece counter
In the sewing mode (basic position of the machine) the piece counter or the bobbin thread
counter can be displayed by pressing the menu key. (When the bobbin thread counter is
switched off, the piece counter is displayed - Selection under parameter 004) .
5 SET 0
32
The piece counter counts from 0 onwards and differs from the bobbin thread counter in the
display through the upwards pointing arrow.
● Reset the piece counter with the corresponding +/- keys.
Page 33
Setting up
9.10 Shifting the seam pattern
To adapt the seam patterns to formed workpiece holders, selected seam patterns can be
shifted.
● From the basic position of the machine select the desired program station, e.g. P1.
● Tact through the seam pattern, e.g. forwards.
The actual coordinates are shown together with the shift values for each stitch.
X: Y:
-300 - +0 -200 +0
● With the corresponding +/- keys it is possible to enter a shift value for the entire seam
pattern in X- or Y-direction at each seam pattern coordinate.
The seam pattern shift is allocated to the respective actual program station and
is deleted when the program number is changed.
33
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Setting up
9.11 Inserting and removing the SD-memory card
Inserting the SD-memory card
● Open cover 1.
1
● Insert SD-memory card 2 into the card
slot with the label at the front.
● Close cover 1 again.
2
Use only memory cards
2 GB
max.
Removing the SD-memory card
● Open cover 1.
● Press the edge of the SD-memory card 2
lightly – the SD-card is ejected.
formatted FAT 16
Fig. 9 - 08
3
By moving slide 3 it is possible to activate (position "LOCK") or deactivate
the write protection function of the SD-memory card. To store, process or
delete data on the SD-memory card, the write protection function must be
deactivated.
● Close cover 1 again.
34
Page 35
Sewing
10 Sewing
The machine must be installed, connected and set up as described in Chapter 8
Installation and Commissioning.
The machine must not be operated without the safety devices 1 to 5, see Chapter 1.06 Danger warnings! Danger of injury!
10.01 Operating cycle
● Carry out all steps in accordance with Chapter 9 Setting up.
● Place the material properly under the work clamp.
● Lower the work clamp and start the sewing cycle, see Chapter 7.02 Pedal.
10.02 Display options
By pressing the button "Menu", the operator can switch between four different displays
while sewing.
5 2700 3,0mm
Program number
Program number
Speed
5 SET 5
Stitch length
Piece counter
Program number
Program number
10.03 Sewing in the "Direct program selection" mode
In this function, a seam pattern is selected. After selection, the speed and stitch length can
be altered, see Chapter 9.06.01 Selecting and changing the seam pattern.
X Y
5 2700 100 100
Speed
5 SET 4955
Enlargement factor
Thread counter
10.04 Sewing in the "Program stations" mode
Program stations can be selected, which have been reserved beforehand with a seam pattern with relevant speed and size factors, see Chapter 11 .01 Reserving program stations.
35
Page 36
Sewing
10.05 Sewing in the "Sequences mode".
10.05.01 Interrupting a sequence
Sequences, which have been created beforehand, can be called up with the function keys
C1 to C3 (see Chap. 11 .02.01 Entering sequences)
If an interruption occurs during a sequence cycle (e.g. broken thread), it is possible to
continue at the same sequence point after the error has been eliminated.
The procedure is as follows:
A 3 - 3 - 3 - 3 - 3 - 3 - 8
8 - 8 - 8 - 4 - 4
● The activated sequence point fl ashes.
● Select the sequence A, B or C by pressing the left +/- key.
● Press the corresponding +/- key to move to the sequence point to be repeated.
● Conclude input by pressing the TE key.
10.06 Error messages
When an error occurs, the text "ERROR" appears on the display together with an error
code and short instructions. In addition the diode in the memory card slot lights up red
(see arrow). An explanation of the error codes can be found in the Chapter 13.08 Error
message explanations.
ERROR: 210
RESET
36
● Correct the error.
● Acknowledge the correction of the error by pressing the corresponding +/- key or by
switching the machine off and on.
● The diode in the memory card slot (see arrow) turns yellow again
Page 37
Input
11 Input
After the machine has been switched on, it is in the input mode. The LED in the "TE" key is
illuminated. The input mode is used to reserve program stations, to enter sequences and to
change machine parameters. In addition information and input possibilities for the service
area are available in this mode.
11 .01 Reserving program stations
to
to
The station keys P1 to P8 are used to enter and select seam programs. A complete seam
program is confi gured from the following parameter:
- seam pattern
- speed
- size factor in X-direction
- size factor in Y-direction
● Call up the input mode by pressing the TE key (LED is illuminated).
● Press a station key to call up the direct seam pattern selection function.
X Y
5 2700 90 110
X
Y
● With the corresponding plus/minus key select the desired seam pattern, e.g. 5.
The seam patterns are stored in the machine under program numbers, see Chapter
11 .05 Summary of the seam patterns.
● Select the desired speed with the corresponding +/- key.
● Enter the desired size factor (in %) (X-direction) with the corresponding +/- key.
● Enter the desired size factor (in %) (Y-direction) with the corresponding +/- key.
The enlargement of the seam pattern is limited by the size of the machine’s
sewing area.
● Conclude the input by pressing the TE key. (The machine changes to the sewing mode).
37
Page 38
Input
11 .02 Sequences
.02.01 Entering sequences
11
The sequence program keys C1 to C3 are used to enter and select sequence programs. The
to
sequence programs are put together from seam programs, which have been deposited under the station keys P1 to P8.
A sequence can consist of up to 3 segments (A, B + C). In each segment up to
14 entries can be made.
● Call up the input mode by pressing the TE key (LED is illuminated).
● In the input mode, select the desired sequence program key, e.g. C2.
● Enter the desired seam programs in any order by using the station keys, e.g. P3 six times ,
P8 four times,
2x
P4 twice
Press the TE key input twice (machine changes to the sewing mode).
A 3 - 3 - 3 - 3 - 3 - 3 - 8
8 - 8 - 8 - 4 - 4
The station keys for selection must have been reserved beforehand, see
Chapter 11 .01 Reserving program stations.
In the "Input" mode it is possible to scroll between the sequence zones
A, B and C by pressing the Menu key.
38
11 .02.02 Checking the sequence contents
● With the machine in its basic position, select the desired sequence, e.g. C2.
● The activated sequence point fl ashes.
● Press the corresponding +/- key to move to the sequence point to be checked (e.g. 8).
Page 39
Input
A 3 - 3 - 3 - 3 - 3 - 3 - 8
8 - 8 - 8 - 4 - 4
● Press the TE key (LED is not illuminated).
● The parameters, such as number of the seam pattern, speed and size factors of the fl as-
hing sequence entry are shown if the Menu key is pressed.
2x
● Quit the check mode by pressing the Menu key twice.
11 .02.03 Deleting sequences
● Call up the Input mode by pressing the TE key (LED is illuminated).
to
to
● Call up the sequence to be changed by pressing the C1, C2 or C3 keys.
Deleting individual entries
● Press a +/- key to set the cursor beneath the entry to be deleted and delete the entry by
pressing the reverse tacting key twice.
Inserting individual entries
● Press a +/- key to set the cursor beneath the position for the insertion.
● Insert the desired entry by pressing the corresponding station key.
Deleting a complete sequence
● Press a +/- key to set the cursor at the beginning of the sequence. Press the reverse
tacting key as often as necessary to delete all entries on the display.
2x
● Press the TE input key twice (machine changes to the sewing mode).
11
.02.04 Combining sequences
Several sequences can be combined to one seam program. To carry out the adjustment,
enter the corresponding value for parameter 005 (see Chapter 13.08 List of parameters).
39
Page 40
Input
11 .03 Parameter input
● Press button TE (LED lights up.
No VAL
001 2700
● With the corresponding +/- key select the desired parameter, e.g. 016 key tone ON/ OFF
No VAL
016 ON
● With the corresponding +/- key activate key tone.
● Conclude the input by pressing the TE key. (The machine changes to the sewing mode).
There is a list explaining all the parameters in Chapter 11 .06 List of parame-
ters.
40
Page 41
Input
11 .04 Access codes
The selection of seam patterns, the reservation of the program stations, the input of
sequences and the selection of individual parameter levels can be locked with a 4-fi gure
access code. The access code can be changed as desired. The factory set access code
is "3108".
11 .04.01 Entering the access code
If, in the input mode, a function is selected, which has an access code, the demand for
entering the access code appears on the display.
PINCODE:
3 1 0 8
● Enter the access code with the corresponding +/- keys.
● Conclude the input by pressing the TE key (machine changes to the sewing mode).
Once the access code has been entered, all functions with access protection
are freely accessible, until the machine is switched off.
11 .04.02 Changing the access code
● In the input mode, select parameter "811"
● Enter the access code, see Chapter 11 .04.01 Entering the access code
No VAL
811 3108
● Change the access code with the corresponding +/- keys.
● Conclude the input by pressing the TE key (machine changes to the sewing mode).
41
Page 42
Input
11 .04.03 Granting access rights
● In the input mode select the corresponding parameter ("801" to "806"), see
Chapter 13.06 List of parameters.
● If required, enter the access code, see Chapter 11 .04.01 Entering access codes.
No VAL
801 OFF
● With the corresponding +/- key approve (on) or lock (OFF) access..
● Conclude the input by pressing the TE key (machine changes to the sewing mode).
42
Page 43
Input
11 .05 Program Management
IIn the program management the programs fi led in the machine memory or on connected
SD-memory cards are displayed and can be deleted or copied. Commercially available
SD-memory cards with a storage capacity of max. 2 GB can be inserted in the control
panel. The data is stored in machine-relevant sub-directories. The way to insert or remove the
SD-memory card is described in Chapter 9.11
● The programs 0 – 99 are stored in the fi les 0 – 99 and
● the machine data in the fi le MD.
Should the SD-memory cards need to be formatted by the PC, they must be formatted
in the format “FAT16”. Alternatively the SD-memory cards can also be formatted on the
corresponding machine with the formatting function, see Chapter 11 .05.08 Formatting the
SD-memory card.
11 .05.01 Calling up the program management
● Switch on the machine.
● Call up the program management
DIR
After the program management has been called up, the fi rst menu item appears (display of
data in the machine memory).
Confi rm the selection of the menu item with the "Enter" function by pressing the right plus
key. In this example the contents of the machine memory are then displayed.
It is possible to scroll through the other menu points by pressing the left +/- key (see follow-
ing chapters).
The following menu items are available in the program management:
● Display data in the machine memory
● Display data on the connected SD-memory card
● Copy data to the SD-memory card
● Copy data to the machine memory (from the SD-memory card)
● Delete data in the machine memory
● Delete data on SD-memory card
● Format SD-memory card
43
Page 44
Input
11 .05.02 Display of the data in the machine memory
● Call up the program management, see Chapter 11 .05.01 Calling up the program
management.
DIR
● Press the left +/- keys until the corresponding menu item appears.
● Confi rm the selection of the menu item with the "Enter" function by pressing the right
plus key.
DIR
01 02 40 42 END
● By pressing the right +/- keys it is possible to scroll through the display of the machine
memory.
● When the left +/- keys are pressed, the other menu items of the program management
are called up.
44
Page 45
Input
11 .05.03 Display of the data on the SD-memory card
● Call up the program management, see Chapter 11 .05.01 Calling up the program
management.
DIR
● Press the left +/- keys until the corresponding menu item appears.
● Confi rm the selection of the menu item with the "Enter" function by pressing the right
plus key.
DIR
01 02 40 END
● By pressing the right +/- keys it is possible to scroll through the display of the
SD-memory card.
● When the left +/- keys are pressed, the other menu items of the program management
are called up.
45
Page 46
Input
11 .05.04 Copying data onto the SD-memory card
● Call up the program management, see Chapter 11 .05.01 Calling up the program
management.
COPY
● Press the left +/- keys until the corresponding menu item appears.
● Confi rm the selection of the menu item with the "Enter" function by pressing the right
plus key.
COPY 01 02
● Press the corresponding +/- keys to select the data to be copied from the
machine memory onto the SD-memory card:
MD = machine parameters
0 - 99 = programs
ALL = all programs
● The copying process is started with the "Enter" function by pressing the right plus key.
If the data for copying already exists, a safety enquiry appears before overwriting the data. Press the right plus key to confi rm the copying process. The copying process can be stopped by pressing the right minus key.
● When the left +/- keys are pressed, the other menu items of the program management
are called up.
46
Page 47
Input
11 .05.05 Copying data into the machine memory
● Call up the program management, see Chapter 11 .05.01 Calling up the program
management.
COPY
● Press the left +/- keys until the corresponding menu item appears.
● Confi rm the selection of the menu item with the "Enter" function by pressing the right
plus key.
COPY 01 02
● Press the corresponding +/- keys to select the data to be copied from the
SD-memory card into the machine memory:
MD = machine parameters
0 - 99 = programs
ALL = all programs
● The copying process is started with the "Enter" function by pressing the right plus key.
If the data for copying already exists, a safety enquiry appears before overwriting the data. Press the right plus key to confi rm the copying process. The copying process can be stopped by pressing the right minus key.
● When the left +/- keys are pressed, the other menu items of the program management
are called up.
47
Page 48
Input
11 .05.06 Deleting data in the machine memory
● Call up the program management, see Chapter 11 .05.01 Calling up the program
management.
DEL
● Press the left +/- keys until the corresponding menu item appears.
● Confi rm the selection of the menu item with the "Enter" function by pressing the right
plus key.
DEL 01
● Press the corresponding +/- keys to select the data to be deleted from the
machine memory:
0 - 99 = programs
ALL = all programs
Machine data cannot be deleted.
● The deleting process is started with the "Enter" function by pressing the right plus key.
Before the data is deleted, a safety enquiry ensues.
Press the right plus key to confi rm the deleting process.
The deleting process can be stopped by pressing the right minus key.
● When the left +/- keys are pressed, the other menu items of the program management
are called up
48
Page 49
Input
11 .05.07 Deleting data from the SD-memory card
● Call up the program management, see Chapter 11 .05.01 Calling up the program
management.
DEL
● Press the left +/- keys until the corresponding menu item appears.
● Confi rm the selection of the menu item with the "Enter" function by pressing the right
plus key.
DEL ALL
● Press the corresponding +/- keys to select the data to be deleted from the SD-memory
card:
MD = machine parameters
0 - 99 = programs
ALL = all programs
● The deleting process is started with the "Enter" function by pressing the right plus key.
Before the data is deleted, a safety enquiry ensues.
Press the right plus key to confi rm the deleting process.
The deleting process can be stopped by pressing the right minus key.
● When the left +/- keys are pressed, the other menu items of the program management
are called up
49
Page 50
Input
11 .05.08 Formatting the SD-memory card
● Call up the program management, see Chapter 11 .05.01 Calling up the program
management.
FORMAT
● Press the left +/- keys until the corresponding menu item appears.
● The formatting process is started with the "Enter" function by pressing the right plus key.
Before formatting begins, a safety enquiry ensues.
Press the right plus key to confi rm the formatting process.
The formatting process can be stopped by pressing the right minus key.
● When the left +/- keys are pressed, the other menu items of the program management
are called up
50
Page 51
Care and maintenance
12 Care and maintenance
12
.01 Servicing and maintenance intervals
Clean the entire machine ..................................................................................once a week
Clean the hook compartment ...............................Daily, several times if in continuous use
Check the oil level ........................................................... Daily, before starting the machine
Check/adjust the air pressure ......................................... Daily, before starting the machine
Clean the fi lter of the air fi lter/lubricator ........................................................... As required
These maintenance intervals are calculated for the average running time of a
single shift operation. If the machine is operated more than this, shorter inter-
vals are recommended.
12.02 Cleaning the machine
The cleaning cycle required for the machine depends on following factors:
● Single or several shift operation
● Amount of dust resulting from the workpiece
It is therefore only possible to stipulate the best possible cleaning instructions for each
individual case.
To avoid breakdowns, the following cleaning work is recommended for single shift operation:
● Clean hook compartment and needle area of sewing head several times daily.
● Clean the entire machine at least once a week.
To do so:
● Switch on the machine.
● Call up the threading aid function. Sewing start is disengaged.
● Clean the machine.
● Move the machine to its basic position.
51
Page 52
Care and maintenance
12.03 Lubricating
2
1
Fig. 12 - 03
Before commissioning the machine, fi ll in oil through hole 1 until the oil level
indicator 2 is at the "MAX" marking.
Check the oil level daily before starting the machine!
The level of the oil in indicator 2 must not sink below the "MIN" marking and
not exceed the "MAX" marking.
If required, fi ll oil into the tank through hole 1.
Only use oil with a medium viscosity of 22.0 mm²/s at 40° C and a density
of 0.865 g/cm³ at 15°C!
We recommend PFAFF sewing-machine oil, part No. 280-1-120 144.
52
Page 53
Care and maintenance
12.04 Lubricate clamp drive
1
1
Fig. 12 - 04
Switch off the machine and take measures to prevent it being switched on
again!
Only use Isofl ex Topas L32 high-performance grease, part no. 280-1-120 210.
● Unscrew the cover of the jig drive.
● With the appropriate lubricating nipple 1, using a grease gun, lubricate the guide units
every 3 months for single shift operation, and once a month for double shift operation.
● Screw cover back on.
53
Page 54
Care and maintenance
12.05 Cleaning the blower air fi lter
● Remove cover 1.
● Take out fi lter element and clean with
compressed air.
● Insert the clean fi lter element and
replace cover 1.
Fig. 12 - 05
54
Page 55
Care and maintenance
12.06 Checking/regulating the air pressure
● Check the air pressure on gauge 1 every
2
time before operation.
● Gauge 1 must show a pressure of 6 bar.
● Regulate this pressure if required.
● To do so, pull knob 2 up and turn it accor-
dingly.
1
Fig. 12 - 06
12.07 Emptying/cleaning the water bowl of the air fi lter/regulator
Switch off the machine.
Disconnect the air hose at the
air fi lter/regulating unit.
Emptying the water bowl
● Water bowl 1 empties itself automatically
when the air hose is disconnected from
the air fi lter/regulator.
Cleaning the fi lter
● Unscrew water bowl 1 and take out fi l-
2
ter 2.
● Clean the fi lter with compressed air
or with isopropyl-alcohol, part number
1
Fig. 12 - 07
95-665735-91.
● Screw in fi lter 2 and screw on water
bowl 1.
55
Page 56
Adjustment
13 Adjustment
13.01 Notes on adjustment
Please observe all notes from Chapter 1 Safety of the instruction manual!
In particular care must be taken to see that all protective devices are refi tted
properly after adjustment, see Chapter 1.06 Danger warnings of the instruc-
tion manual!
If not otherwise stated, the machine must be disconnected from the electrical
power supply. Danger of injury due to unintentional starting of the machine!
All following adjustments are based on a fully assembled machine and may only be carried
out by expert 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 which have to be completely adjusted. If only specifi c individual work steps are
carried out, both the preceding and following chapters must be observed.
Screws, nuts indicated in brackets ( ) are fastenings for machine parts, which must be
loosened before adjustment and tightened again afterwards.
13.02 Tools, gauges and other accessories for adjusting
● Screwdrivers with blade width from 2 to 10 mm
● Spanners (wrenches) with jaw width from 7 to 14 mm
● 1 set Allen keys from 1.5 to 6 mm
● 1 clamp adjusting gauge Order No. 95-295 500-05
● Metal rule (part No. 08-880 218-00)
● Sewing thread and test materials
13.03 Abbreviations
t.d.c. = top dead centre
b.d.c. = bottom dead centre
13.04 Explanation of the symbols
In this adjustment manual, symbols emphasize operations to be carried out or important in-
formation. The symbols used have the following meaning:
Note, information
56
Service, repair, adjustment, maintenance
(work to be carried out by qualifi ed staff only)
Page 57
Adjustment
13.05 Adjusting the sewing head
13
.05.01 Basic position of the balance wheel (adjustment aid)
Requirement
When the needle bar is positioned at t.d.c., the marking "0" on the scale should be level
with the top edge of the belt guard (see arrow).
Fig. 13 - 01
2
1
2
Adjust the scale dial 1 (four screws 2) in accordance with the requirement.
57
Page 58
Adjustment
13.05.02 Preliminary adjustment of the needle height
Requirement
When the needle bar is positioned at t.d.c. (balance wheel position 0°), the clearance
between the needle point and the cover plate 6 should be 27 mm.
5
4
27 mm
1
3
2
Fig. 13- 02
● Unscrew clamp 1, plate 2 and hopping foot 3.
● Without turning it, re-position needle bar 4 (screw 5) in accordance with the
requirement.
6
58
Page 59
Adjustment
13.05.03 Needle rise, hook clearance and needle height
Requirement
In needle bar position, 2.0 mm after b.d.c. (balance wheel position 202°):
1. The hook point 5 should be positioned at "needle centre" with a hook-to-needle clearance of 0.05 – 0.10 mm.
2. The top of the needle eye should be positioned 0.8 mm below hook point 5.
4
0,05 - 0,10 mm
2
5
1
2
Fig. 13 - 03
● Maschine mittels Handrad in Schlingenhubstellung bringen.
● Adjust hook 1 (screws 2) in accordance with requirement 1.
● Bring oil distributor ring 3 (screw 4) into contact with hook 1.
3
5
0,8 mm
● Without turning it, re-position the needle bar in accordance with the requirement 2.
59
Page 60
Adjustment
13.05.04 Reversing point of hopping foot
Requirement
When the needle bar is in b.d.c. hopping foot 3 should have reached its bottom point of
reversal.
3
Fig. 13 - 04
● Turn crank 1 ( screws 2 ) according to requirement.
2
1
60
Page 61
Adjustment
13.05.05 Hopping foot lift
Requirement
The hopping foot should
1. make no movement when setting wheel 5 is set to "0",
2. rise 5 mm when setting wheel 5 is set to "5".
5
1
2
3
4
Fig. 13 - 05
● Turn crank 1 (screw 2) according to requirement 1
● Adjust crank 3 (screw 4) according to requirement 2.
61
Page 62
Adjustment
13.05.06 Adjusting hopping foot pressure
Requirement
The hopping foot pressure should be adjusted so that the hopping foot movement is also
ensured at top speed.
2
1
62
Fig. 13 - 06
● Turn knurled nut 1 (lock nut 2) according to the requirement.
The hopping foot height must be readjusted (see Chapter 13.05.07) after
changing the hopping foot pressure.
Page 63
Adjustment
13.05.07 Adjusting hopping foot height
Requirement
When at its lowest point of reversal, hopping foot 3 should be positioned
above cover plate 4 at a distance corresponding to the material thickness.
1
2
4
Fig. 13 - 07
● Turn knurled thumb screw 1 (lock nut 2) according to the requirement.
3
63
Page 64
Adjustment
13.05.08 Regulating the level of the hopping foot
Requirement
1. When executing programmed level regulation, the second foot height should be ad-
justed so that hopping foot 5 is positioned above cover plate 6 at a distance corre-
sponding to the sewing material thickness.
2. When the needle bar is in b.d.c. and level regulation is raised to maximum, the needle
bar must not contact with hopping foot 5..
2
1
64
6
5
Fig. 13 - 08
● Turn screw 1 (lock nut 2) according to the requirement.
Page 65
Adjustment
13.05.09 Bobbin winder
Requirement
1. When the bobbin winder is engaged, the winding spindle must be driven reliably.
When it is disengaged, friction wheel 3 should not be touching drive wheel 1.
2. When it is switched off, the bobbin winder must click securely into its end position
(knife raised).
1
2
Fig. 13 - 09
● Adjust drive wheel 1 (screw 2) in accordance with the requirement.
3
65
Page 66
Adjustment
13.05.10 Thread check spring and thread regulator
Requirement
1. The movement of thread regulator 3 must be completed when the needle point enters
the material.
2. When the thread loop is at its largest while being passed around the hook, the check
thread spring 3 should rise slightly from the rest 1.
6
5
4
2
1
3
Fig. 13 - 10
● Position rest 1 (screw 2) in accordance with requirement 1.
● Turn sleeve 4 (screw 2) to adjust the tension of thread check spring 3.
● Position thread regulator 5 (screw 6) in accordance with requirement 2.
For technical reasons it may be necessary to deviate from the indicated spring
stroke or spring tension.
Move thread regulator 5 (screw 6) towards ("+") (= more thread) or ("-") (= less
thread).
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Adjustment
13.05.11 Lubrication
Requirement
After a running time of 10 seconds a thin fi lm of oil should be visible on paper strip 1
when this is held over the hook.
+
-
2
2
1
Fig. 13 - 11
● Check that the machine is fi lled with oil and that the oil lines are free of air.
● Call up bobbin winding function.
● Use the pedal function to run the machine 2 - 3 minutes.
● With the machine running, hold paper strip 1 against the hook and check the requirement.
● If necessary, regulate amount of oil with screw 2.
Do not reach into the hook area while the machine is running!
Danger of injury from rotating hook tipsreifen!
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Adjustment
13.05.12 Basic position of the thread trimmer
Requirement
1. When the thread trimmer is in its resting position (cylinder extended), the point of
thread catcher 6 should be fl ush with the cutting edge of knife 7 (see arrow).
2. The roller lever 3 should have a clearance of 1 mm to the connecting piece.
1 mm
1
5
2
4
3
Fig. 13 - 12
● Adjust thread trimmer 1 (screws 2) in accordance with requirement 1.
2
6
7
68
● Adjust roller lever 3 (only screw 4) in accordance with requirement 2.
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Adjustment
13.05.13 Control cam to roller lever clearance (resting position)
Requirement
When the thread trimmer is in its resting position (balance wheel position 270°) there
should be a clearance of 0.1 mm between the roller lever 5 and the outside edge of control cam 1.
2
5
4
3
1
0,1 mm
Fig. 13 - 13
● Adjust control cam 1 (screw 2) together with retaining collar 3 (screw 4) in accordance
with the requirement.
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Adjustment
13.05.14 Adjusting the control cam
Requirement
When the take-up lever is at the top of its stroke (balance wheel position 70°), the cutting
operation should just have been completed.
70
1
2
Fig. 13 - 14
● Adjust control cam 1 (screw 2) in accordance with the requirement.
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Adjustment
13.05.15 Knife pressure
Requirement
The thread should be cut reliably at all times.
+
-
Fig. 13 - 15
● Increase ("+") or reduce ("-") the knife pressure accordingly with screw 1.
1
71
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Adjustment
13.05.16 Manual cutting test
Requirement
Both the needle and the bobbin thread should be cut neatly.
1
Fig. 13 - 16
● Bring thread catcher 1 by hand to its front position.
● Take a double thread and place it into the catcher slot.
● Carry out a manual cutting test.
● If the thread is not cut in accordance with the requirement, adjust the knife pressure as
described in Chapter 13.05.15 Knife pressure.
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Adjustment
13.05.17 Aligning the clamp drive
Requirement
The clamp should be parallel to the table plate both in "X" and in "Y" direction.
3
1
2
1
Fig. 13 - 17
● Turn adjusting nut 1 (lock nut 2 and lock nut 3) according to the requirement.
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Adjustment
13.05.18 Adjusting belt tensions
Requirement
The belt tensions should be tested and adjusted using a measuring device.
The clamp drive belt tensions should be tested with a measured value of
300 - 400 Nm..
2
1
Fig. 13 - 18
● Adjust clamp drive belt tensions using screws 1 (screws 2) in accordance with the re-
quirement.
The measuring device is available under Order No 99-137 171-91.
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Adjustment
13.06 Parameter list
Group
0
Parameter
Description
001 Maximum speed 500 - 2800 2800
002 Sewing stitch speed 1 -5 1: 500
003 Clamp type
0 - split,
1 - single
004 Bobbin thread counter,
Preset value
005 Sequence combination
This parameter is used to combine several
sequences with each other.
0 = no combination
1 = C1 with C2
2 = C2 with C3
3 = C1 with C3
4 = C1 with C2 and C3
Setting range
0 - 1 0
ON - OFF
1 -9999
0 - 4 0
Set value
2: 900
3: 1500
4: 2000
5: 2500
OFF
1000
006 Reversing after thread trimming ON - OFF ON
007 Starting point = scale reference point ON - OFF OFF
009 Drive to start position via zero position after se-
quencing
010 Drive to start position via zero position after
number of programs Number1 - 100
011 Pedal mode,
0 = Level mode,
1 = FlipFlop mode
012 Needle or balance wheel position
in degrees (0 - 360)
015 Reduced current for stepping motors ON - OFF ON
016 Key tone ON - OFF ON
027 Basic position / loading point = zero point ON - OFF OFF
028 Number of slow starting stitches 1 - 9 2
ON - OFF OFF
ON - OFF OFF
0 - 1 0
--
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Adjustment
0
100
200
Group
Parameter
Description
029 Auto. clamp opening after program end off ON - OFF OFF
030 Continuous start, test function ON - OFF OFF
031 0 = material thickness < = 4.5 mm,
1 = material thickness > = 4.5 mm
101 Software version main processor
102 Software version sewing drive unit
103 Software version control panel
201 Min. X-coordinate -650 - 0 -650
202 Max X-coordinate 0 - 650 650
203 Min. Y-coordinate -1000 - 0 -1000
204 Max. Y-coordinate -1000 - 0 0
205 Increment correction X -30 - +30 0
206 Increment correction Y -30 - +30 0
207 0 = Foot jumper not attached,
1 = Foot jumper attached (lift monitoring active)
2 = Foot jumper not attached (lift monitoring active)
Setting range
0 - 1 0
0 - 2
Set value
1
300
500
208 Thread wedeler attached ON - OFF OFF
209 Min. Jumper foot lift (potentiometer value) - 0
210 Max. Jumper foot lift (potentiometer value) - 1023
301 NIS 0 - 255 78
302 Thread lever t.d.c. 0 - 255 61
303 Thread trimming position on 0 - 255 180
hread trimming position of
304
305 Thread clamp position closed, during sewing 0 - 255 71
306 Thread clamp position open, during sewing 0 - 255 235
307 Reverse rotation position 0 - 255 20
308 Stop position 0 - 255 71
309 Thread tension during thread trimming 0 - 255 0
T
310 Thread-in position 0 - 255 40
501 Reduced speed (set value x 100) 1 - 28 15
f 0 - 255 245
76
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Adjustment
500
600
Group
Parameter
Description
502 Trimming speed (set value x 100) 5 - 25 2
503 Speed during bobbin winding 2 - 28 15
505 Time for wiper [in 10ms] 1 - 50 30
601
602
603
Display inputs
With this function the digital inputs can be checked. "IN" shows the input numbers (1 - 16). Under
"VAL" the respective switch status is displayed.
IN VAL
1 SMREF1
2 SMREF2
3 IN1, programmable input 1
4 IN1, programmable input 2
5 Treadle switch
6 - 16 free
Display special inputs
IN VAL
PED Pedal (speed control unit –1,0,+1,+2)
Connect outputs
With this function the outlets can be connected.
"OUT" shows the outlet selected (1-16). Under
"VAL" the selected output is set (S) with the
plus/minus key (+), and reset (R) with the
plus/minus key. Interlocks are checked. Non-assigned outlets are not connected.
Setting range
Set value
OUT VAL
1 S/R
2 S/R
3 S/R clamp 1 closed
4 S/R Thread wedeler on (optional)
5 S/R
6 S/R clamp 1 open
7 S/R clamp 2 open
8 S/R thread trimming on
9 S/R Thread tension open
10 S/R Secondary thread tension open
(Progr. output 4)
11 S/R Foot open
12 S/R Thread clamp closed
13 S/R clamp 2 closed
14 S/R 2nd level jumper foot on
(Progr. output 3)
15 S/R Progr. output 1
16 S/R Progr. output 2
77
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Adjustment
Group
600
800
Parameter
Description
604 Move stepping motors
(SM1 = X-axis, SM2 = Y-axis)
605 Turn sewing motor 200 - 2800 200
606 Thread trimming sequence
607 Cold start (RESET)
608 Setting zero points
801 Right of access function group 000 ON - OFF ON
802 Right of access function group 100 ON - OFF ON
803 Right of access function group 200 ON - OFF OFF
804 Right of access function group 300 ON - OFF OFF
806 Right of access function group 500 ON - OFF OFF
805 Right of access function group 600 ON - OFF OFF
808 Right of access function group 700 ON - OFF OFF
809 Right of access function group 800 ON - OFF OFF
Setting range
Set value
810 Right of access to keys
P, P1 - P8, C1 – C3
811 Access code 0 - 9999 3108
ON - OFF ON
78
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Adjustment
13.07 Internet update of the machine software
The machine software can be updated with PFAFF fl ash programming. For this purpose
the PFP boot program (from version 3.25 on) and the appropriate control software for
the machine type must be installed on a PC. The transfer of the data to the machine can
be carried out with a null modem cable (part no. 91-291 998-91) or with an SD-card.
The SD-card must be formatted in the FAT16 format and must not exceed a capacity of
2 GBytes.
The PFP boot program and the control software of the machine type can
be downloaded from the PFAFF-homepage using the following path:
www.pfaff-industrial.com/pfaff/de/service/downloads
13.07.01 Update with null modem cable
● After downloading the PFP tool and the control software, open the PFP program.
● Select the machine type and under control unit P320.
● The software version is displayed under report.
3108
P320
Ausgewählt:
Maschinentyp: 3108
Steuerung: P320
Softwareversion:
79-0011-0394/006
● Switch off the machine.
● Connect the PC (serial interface or appropriate USB-adapter) and the machine control unit
(RS232). To do so disconnect the plug of the control panel.
While the machine software is being updated, no setting up, maintenance or
adjustment work may be carried out on the machine!
● Switch on the machine, keeping the boot key 1 pressed.
● Press the "OK" button.
T
he software update is carried out, the update progress is shown on the bar display of
the PFP boot program.
● During the updating process the machine must not be switched off.
● When the update has been completed, switch off the machine and end the PFP boot
program.
● End the connection between the PC and the machine control unit and reconnect the
control panel to the machine control unit.
79
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Adjustment
● Switch on the machine
● A plausibility control is carried out and, if necessary, a cold start.
More information and assi-
stance is at your disposal in the
fi le "PFPHILFE.TXT", which can
be called up from the PFP boot
program by pressing the "help"
button.
1
Fig. 13 - 46
13.07.02 Update with SD-card
● After downloading the PFP tool and the control software, open the PFP program.
● Select the machine type and under control unit SD-CARD.
● The software version is displayed under report.
3108
SD-CARD
Ausgewählt:
Maschinentyp: 3108
Steuerung: P320
Softwareversion:
79-0011-0394/006
80
● Under programming copy the software to the drive with the SD-card.
Page 81
Adjustment
● With the machine switched off insert the SD-card into the control panel.
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!
Fig. 13 - 46
● Switch on the machine, keeping the boot
key 1 pressed.
● Press the "TE" key.
The software update is carried out. Duri-
ng the updating process the diode in the
memory card slot fl ashes.
● During the updating process the machine
must not be switched off.
1
More information and assistance is at your disposal in the fi le "PFPHILFE.TXT",
which can be called up from the PFP boot program by pressing the "help"
button.
● When the update has been completed,
switch off the machine and remove the
SD-card.
● Switch on the machine
● A plausibility control is carried out and, if
necessary, a cold start.
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Adjustment
13.08 Error message explanations
13
.08.01 General errors
Display Description Response
ERROR: 1 STACK_OVERFLOW processor error Troubleshoot
ERROR: 2 STACK_UNDERFLOW processor error Troubleshoot
ERROR: 3 UNDEF_OPCODE processor error Troubleshoot
ERROR: 4 PROTECTION_FAULT processor error Troubleshoot
ERROR: 5 ILLEGAL_WORD_OPERAND processor error Troubleshoot
ERROR: 6 ILLEGAL_INSTRUCTION processor error Troubleshoot
ERROR: 7 ILLEGAL_BUS_ACCESS processor error Troubleshoot
ERROR: 8 NMI processor error Troubleshoot
ERROR: 15 Checksum error in power failure backup data Troubleshoot
ERROR: 30
(OTE-error)
ERROR: 31
(sewing motor error)
ERROR: 50 Incorrect control panel Switch off
ERROR: 51 Incorrect machine class in OTE
ERROR: 52 Incorrect main drive software Switch off
ERROR: 53 Mains monitor (Bangalore) has triggered Switch off
ERROR: 101 Mains voltage Switch off
ERROR: 102 Mains part overload Troubleshoot
ERROR: 103 24V too low Troubleshoot
OTE error Troubleshoot
Sewing motor error Troubleshoot
Switch off
(ILLEGAL IDENTITY)
82
13.08.02 Error in production mode
Display Description Response
ERROR: 201
(sewing motor error)
ERROR: 202 Image too large Troubleshoot
ERROR: 203 Sewing motor data transfer overload Troubleshoot
ERROR: 204
(#error No.)
ERROR: 205 Movement locked (needle position) Troubleshoot
ERROR: 206 No NIS Troubleshoot
Sewing motor error Troubleshoot
Tacting locked: 1 – open clamp,
2 – needle position, 3 - needle range
Troubleshoot
Page 83
Adjustment
Display Description Response
ERROR: 207 Ramp not completed Troubleshoot
ERROR: 208 Zero point not found Troubleshoot
ERROR: 209 Sewing locked (clamp open) Troubleshoot
ERROR: 210 Bobbin thread fault Troubleshoot
ERROR: 211 Stich zu groß Troubleshoot
ERROR: 212 Speicherüberlauf Troubleshoot
ERROR: 213
(#Konv.Fehler)
Konvertierungsfehler Troubleshoot
13.08.03 Error during output switching
Display Description Response
ERROR: 301 Clamp1 open locked (needle position) Troubleshoot
ERROR: 302 Clamp2 open locked (needle position) Troubleshoot
ERROR: 303 Foot open locked (needle position) Troubleshoot
ERROR: 305 Clamp2 closed locked (clamp 1 is open with
split clamp)
ERROR: 306 Clamp1 closed locked (clamp 2 is closed
with split clamp)
Troubleshoot
Troubleshoot
13.08.04 Error in production mode
Display Description Response
ERROR: 401
(sewing motor error)
ERROR: 402 Sewing motor data transfer overload Troubleshoot
ERROR: 403 Program station not programmed Troubleshoot
ERROR: 404 Program locked Troubleshoot
ERROR: 405 No program Troubleshoot
ERROR: 406 No NIS Troubleshoot
ERROR: 407 Zero points invalid Troubleshoot
ERROR: 408 Machine not in basic position Troubleshoot
ERROR: 409 Zero point not found Troubleshoot
ERROR: 410 Memory overrun when writing to internal
ERROR: 411 No program number free Troubleshoot
ERROR: 412 Generate memory overrun with stitch data Troubleshoot
ERROR: 413
(#conv.error)
ERROR: 414 File in CMOS RAM could not be opened or
Sewing motor error Troubleshoot
memory
Conversion error Troubleshoot
read error
Troubleshoot
83
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Adjustment
Display Description Response
ERROR: 415 File on SD card could not be opened
ERROR: 416
(sub-error)
ERROR: 417 No piercing point for bobbin winding found Troubleshoot
ERROR: 418 1. Piercing point for bobbin winding is out-
ERROR: 422 Incorrect version of machine data Troubleshoot
ERROR: 423 Potentiometer jumper foot not confi gured Troubleshoot
SD card reader error
1: No SD card inserted
2: Incorrect SD card (does not fi t 3108)
3: SD card not correctly inserted
4: SD card write-protected
5: Data error on SD card
6: Formatting failed
7: File does not fi t 3108
8: Incorrect fi le size
9: Transfer error
10: File could not be deleted
11 : OTE not inserted
side sewing range
Troubleshoot
Troubleshoot
13.08.05 Sewing motor errors
Display Description
1 Timeout
2 Position not reached
33 Parameter value invalid (ED)
35 Communication error
36 Init. not ready
37 Command overrun (ED)
64 Mains off during initialisation (ED)
65 Excess current directly after mains on
66 Short circuit
67 Mains off
68 Excess current during operation
70 Motor blocked
71 No incremental plug
74 Incremental encoder missing for transmission/reduction (ED)
173 Motor blocked in 1st stitch (ED)
175 Internal starting error
222 Dead man monitoring
84
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Adjustment
13.08.06 OTE-errors
Anzeige Beschreibung
1 Read error
2 Write error
3 Full EEPROM
4 No EEPROM
5 Invalid size
6 Invalid address
7 Address overfl ow
8 Checksum falled
9 Serialnr. changed
85
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Adjustment
13.08.07 Stitch generation errors
Display Description
1 Incorrect machine code
2 'Clamp form' section or
'obstacle' section missing or at incorrect position
3 Increment too large
4 Program end without thread trimming
5 Impermissible stitch length entry
6 Incorrect element in geometr. data set
7 Rapid motion although machine is sewing
8 Impermissible stitch length entry
9 Impermissible stitch length entry
10 Circle support point = circle end point
11 Division by zero
12 Impermissible stitch length entry
13 No coord. section before curve support point
14 Sewing fi eld limit exceeded
15 Curve without end point
16 MFktBuffer overrun
17 Sewing command in loading point program
18 Incorrect curve support point
19 Incorrect curve support point
20 Incorrect curve support point
21 Incorrect curve support point
22 Stitch length not initialised
23 Loading point program not completed
24 Stitch width command in loading point program
25 Impermissible value for stitch section
26 Trimming command, although thread trimmed
27 Sewing command, although machine is sewing
28 Trimming command in sewing off range
29 Sewing off command, although thread trimmed
30 Trimming command directly after sewing command
31 Front backtack too long
86
Page 87
Reference list
14 Stromlaufpläne
14 Circuit diagrams
Reference list for circuit diagrams 91-191 543-95
A1 Quick P 320ED control device
A2 P1 control panel (BDF S3 option)
A14 OTE sewing head detection
B31 Initiator (X-axis)
B32 Initiator (Y-axis)
H1 Sewing lamp
M1 Sewing motor
M2 SM1 stepping motor (X-axis moving conjointly)
M3 SM2 stepping motor (Y-axis stationary)
Q1 Main switch
S1 Treadle nominal value transmitter
S35 Foot switch
X1 Mains plug
X1A P1 control panel (BDF S3 option)
X1B OTE (cable)
X3 Incremental encoder (sewing motor)
X4A M2 stepping motor
X4B M3 stepping motor
X5 Inputs
X8 Sewing motor
X11A CAN interface
X11B Foot pedal nominal value transmitter
X13 Outputs
X30 Programmable outputs 1+2
X35 S35 foot switch
X53 Y 3
X56 Y 6
X57 Y 7
X58 Y 8
X59 Y 9
X60 Y 10
X61 Y 11
X62 Y 12
X63 Y 13
X64 Y 14
X65 Y 15
X100 X-Y drive central plug
87
Page 88
Y1 Clamp open
Y3 Clamp 1 closed left
Y4 Fadenklemme (Option)
Y6 Clamp
Y7 Clamp
Y8 Thread trimmer on
Y9 Thread tension up
Y10 Secondary thread tension closed (programmable output 4)
Y11 Foot up
Y12 Thread clamp closed
Y13 Clamp 2 closed right
Y14 Hopping foot level on (programmable output 3)
Y15 Turning cam (programmable output 1)
Y16 Free (programmable output 2)
1 open left
2 open right
Reference list
88
Page 89
Circuit diagrams Version 10.02.11 91-191 543-95 Part 1
89
Page 90
91-191 543-95 Part 2 Version 15.03.10 Circuit diagrams
90
Page 91
Circuit diagrams Version 15.03.10 91-191 543-95 Part 3
91
Page 92
91-191 543-95 Part 4 Version 10.02.11 Circuit diagrams
92
Page 93
Note
Page 94
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
© PFAFF Industriesysteme und Maschinen AG 2009, PFAFF is the exclusive trademark of VSM Group AB.PFAFF Industriesysteme und Maschinen AG is an authorized licensee of the PFAFF trademark.
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