Page 1
-20/02
3538
INSTRUCTION MANUAL
-30/02
This instruction manual applies to machines
from the following serial numbers onwards: 2 804 345
and software version 0437/001.
296-12-19 292/002
Instruction Manual engl. 10.15
Page 2
This instruction manual applies to all models and subclasses listed in Chapter 3
Technical Data.
The adjustment manual for the machine can be downloaded at no charge under
www.pfaff-industrial.de/de/service-support/downloads/technical.
As an alternative to the Internet download, the adjustment manual can also be
ordered under order no. 296-12-19 293/002.
Reprinting, reproduction and/or translation of PFAFF instruction 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
Page 3
Table of Contents
Contents ..................................................................................................Page
1 Safety .................................................................................................................................... 5
1.01 Directives ............................................................................................................................... 5
1.02 General safety instructions ....................................................................................................5
1.03 Safety symbols ...................................................................................................................... 6
1.04 Special points of attention for the owner-operator ................................................................6
1.05 Operating personnel and technical staff ................................................................................7
1.05.01 Operating personnel .............................................................................................................. 7
1.05.02 Technical staff ........................................................................................................................ 7
1.06 Danger warnings ....................................................................................................................8
2 Proper Use ............................................................................................................................9
3 Technical Data
................................................................................................................. 10
3.01 PFAFF 3538 ......................................................................................................................... 10
4 Disposal of the Machine .................................................................................................... 11
5 Transport, Packaging and Storage ...................................................................................12
5.01 Transport to the customer’s premises ................................................................................ 12
5.02 Transport within the customer’s premises .......................................................................... 12
5.03 Disposal of the packaging materials .................................................................................... 12
5.04 Storage ................................................................................................................................ 12
6 Work Symbols ....................................................................................................................13
7 Operating Controls ............................................................................................................14
7.01 Main switch ........................................................................................................................ 14
7.02 Light barrier ..........................................................................................................................14
7.03 Stop button .......................................................................................................................... 15
7.04 Control panel ........................................................................................................................16
7.04.01 Symbols on the display ........................................................................................................ 17
7.04.02 Plus/minus keys ................................................................................................................... 17
7.04.03 Function keys ....................................................................................................................... 18
8 Set-up and Initial Commissioning ....................................................................................20
8.01 Set-up .................................................................................................................................. 20
8.01.01 Aligning the machine .......................................................................................................... 20
8.01.02 Mounting the reel stand ...................................................................................................... 21
8.02 Connecting the plug-in connections and ground cable ........................................................22
8.03 Initial start-up ....................................................................................................................... 23
8.04 Switching the machine on/off ............................................................................................. 23
Page 4
Table of Contents
Contents ..................................................................................................Page
9 Set-up .................................................................................................................................. 24
9.01 Inserting the needle ............................................................................................................. 24
9.02 Threading the needle / adjusting the needle thread ............................................................ 25
10 Input .................................................................................................................................... 26
10.01 Sewing – automatic mode ...................................................................................................27
10.02 Sewing – Unit with cutter and rack ......................................................................................28
10.03 Input mode .......................................................................................................................... 29
10.04 Input mode ..........................................................................................................................31
10.09 Parameter list ....................................................................................................................... 32
10.10 Error messages .................................................................................................................... 36
11 Maintenance and Care .......................................................................................................38
11.01 Maintenance intervals .......................................................................................................... 38
11.02 Cleaning the machine .......................................................................................................... 38
11.03 Checking / topping up the oil level of the oil tank for the front parts ................................... 39
11.04 Checking / topping up the oil level of the gear mechanism ................................................. 40
11.05 Checking / setting the air pressure ......................................................................................41
11.06 Emptying / cleaning the maintenance unit’s water tank ...................................................... 41
12 Wearing Parts .....................................................................................................................42
Page 5
Safety
1 Safety
1
.01 Directives
The machine was built in compliance with the European regulations specifi ed in the declara-
tion of conformity and declaration of incorporation.
As a supplement to this instruction manual, please also observe the generally applicable, le-
gal and other regulations and legislation – also in the country of use – and the valid environ-
mental protection regulations! Always comply with the locally applicable regulations of the
professional associations and other supervisory authorities!
1.02 General safety instructions
The machine may only be operated after you have become acquainted with the associ-
ated instruction manual and only by operating personnel who have received appropriate
training!
Always read the safety instructions and the instruction manual of the motor manufactur-
er before starting up the machine!
Always follow the hazard and safety instructions attached to the machine!
The machine may only be operated for its intended purpose and only with the associated
safety covers, while adhering to all the relevant safety requirements.
The machine must always be disconnected from the power supply by pressing the main
switch or pulling out the mains plug when sewing tools are replaced (such as the needle,
sewing foot, needle plate, feed dog etc.) and when threading, leaving the workstation, or
performing maintenance!
The daily maintenance work may only be carried out by suitably qualifi ed personnel!
Repairs and special maintenance work may only be carried out by technical staff or peo-
ple with appropriate training!
Unless otherwise stated, the machine must be isolated from the power supply and pneu-
matic supplies before any servicing work or repairs are performed! The only permitted
exceptions are for adjustment work and functional tests by appropriately trained techni-
cal staff!
Work on electrical equipment may only be carried out by qualifi ed technical staff!
Work on parts and equipment under voltage is not permitted!
Exceptions are regulated by the EN 50110 standards.
Modifi cations and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
Only those replacement parts approved by us for usage may be used for repairs! We
warn you expressly that spare parts and accessories that are not supplied by us are also
not tested and approved by us.
Fitting or using these products may therefore have negative effects on features which
depend on the machine design. We are not liable for any damage caused by the use of
non-Pfaff parts.
5
Page 6
Safety
1.03 Safety symbols
Hazard point!
Special points of attention.
Risk of injury to operating personnel or technical staff!
Electric voltage!
Danger to operating personnel or technical staff.
Danger of hands being crushed!
Caution!
Do not operate without fi nger guard and safety covers!
Turn off the main switch before threading, changing the
bobbin or needle, cleaning etc!
I
1.04 Special points of attention for the owner-operator
This instruction manual is a part of the machine and must be made available to the oper-
ating personnel at all times. The instruction manual must have been read before the ini-
tial start-up.
The operating personnel and technical staff must be instructed about the machine’s safe-
ty covers and about safe working methods.
The owner-operator may only operate the machine in a fl awless condition.
The owner-operator must ensure that no safety covers are removed or disabled.
The owner-operator must ensure that only authorised persons work on the machine.
Additional information can be requested from the responsible sales centre.
6
Page 7
Safety
1.05 Operating personnel and technical staff
1
.05.01 Operating personnel
Operating personnel are persons responsible for equipping, operating and cleaning the ma-
chine and for fault clearance in the sewing area.
The operating personnel are obligated to comply with the following points:
The safety instructions provided in the instruction manual must be followed for all work!
Any work method jeopardising machine safety must be refrained from!
Tight-fi tting clothing must be worn. The wearing of jewellery such as chains and rings is
prohibited!
Care must be taken to ensure that no unauthorised persons are located in the machine’s
hazard zone!
Any changes occurring on the machine which impair its safety must be reported to the
owner-operator immediately!
1.05.02 Technical staff
Technical staff are persons with technical training in electricity/electronics and mechanics.
They are responsible for lubricating, servicing, repairing and adjusting the machine.
The technical staff are obligated to comply with the following points:
The safety instructions provided in the instruction manual must be followed for all work!
Turn off the main switch before starting any adjustment or repair work and secure it
against reactivation!
Working on live parts and equipment is prohibited!
Exceptions are regulated by the EN 50110 standards.
Unless otherwise stated, the machine must be isolated from the power supply and pneu-
matic supplies before any servicing work or repairs are performed!
Exceptions are permitted solely for function tests.
Reattach the safety covers following repair and maintenance work!
7
Page 8
Safety
1.06 Danger warnings
A work area of 1 m must be kept around the machine during operation to en-
sure unobstructed access at all times.
Do not reach into the needle range during the sewing operation!
Risk of injury from the needle!
Do not allow any objects to be placed on the table during the adjustment work!
The objects could become jammed or be slung away!
Risk of injury from parts fl ying around!
Danger of hands being crushed!
3
Fig. 1 - 01
2
1
Do not operate the machine without the protective cover 1!
Risk of injury from the feed band!
Do not operate the machine without the take-up lever guard 2!
Risk of injury due to movement of the take-up lever!
Do not operate the machine without the belt guard 3!
Risk of injury due to the rotating driving belt!
8
Page 9
2 Proper Use
The PFAFF 3538 is a sewing machine for effi ciently hemming pocket openings.
Proper Use
Any usage not approved by the manufacturer is deemed misuse! The manufac-
turer shall assume no liability for damage caused by misuse! Proper use also
includes compliance with the operating, maintenance, adjustment and repair
measures specifi ed by the manufacturer!
9
Page 10
Technical Data
3 Technical Data
3
.01 PFAFF 3538
Stitch type: ....................................................................................................... 401 (chainstitch)
Design B: ......................................................... for the machining of medium-weight materials
Design C: ...........................................................for the machining of medium-heavy materials
Needle thickness: ........................................................................................................ 80 – 140
Needle system: ................................................................................................................ 62x57
Thread thickness max. ........................................................................................................ 11/3
Speed max.: ................................................................................................. 4000 stitches/min.
Stitch length max: ..........................................................................................................4.5 mm
Noise data:
Noise emission level at workplace with a sewing speed of n = 2400 min-1: ...... LpA = 75 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1,ISO 11204, ISO 3744,
ISO 4871)
Motor data: ................................................................................. see motor instruction manual
Air consumption per switching cycle: ...........................................................................0.146 Nl
Net weight of sewing head with stand: ............................................................. approx. 308 kg
Gross weight of sewing head with stand: ......................................................... approx. 521 kg
Subject to alterations
KpA = 2.5 dB
10
Page 11
Disposal of the Machine
4 Disposal of the Machine
It is up to the customer to dispose of the machine properly.
The materials used for the machine include steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
The machine must be disposed of in accordance with the locally valid environmental pro-
tection regulations, with a specialised company being contracted if necessary.
Please ensure that parts coated with lubricants are disposed of separately in ac-
cordance with the locally valid environmental protection regulations!
11
Page 12
Transport, Packaging and Storage
5 Transport, Packaging and Storage
5
.01 Transport to the customer’s premises
All machines are completely packed for delivery.
5.02 Transport within the customer’s premises
The manufacturer assumes no liability for transport within the customer’s premises or to
the individual usage sites. Please ensure that the machines are only transported in a vertical
position.
5.03 Disposal of the packaging materials
The packaging materials of these machines consists of paper, cardboard and VCI fl eece. It is
up to the customer to dispose of the packaging properly.
5.04 Storage
The machine can be stored for up to 6 months when not in use. It must then be protected
from dirt and moisture. For longer storage periods, the machine’s single components,
especially its sliding surfaces, must be protected against corrosion, e.g. by an oil fi lm.
12
Page 13
Work Symbols
6 Work Symbols
Activities to be performed or important information in this instruction manual are empha-
sised by symbols. The symbols used have the following meaning:
Note, information
Cleaning, care
Lubrication
Maintenance, repairs, adjustment, service work
(only to be carried out by technical staff)
13
Page 14
Operating Controls
7 Operating Controls
7
.01 Main switch
1
Turning the main switch 1 switches the
machine on and off.
Fig. 7 - 01
7.02 Light barrier
The LED in the light barrier indicates the
following status:
– LED lights up green = Reception indica-
tor (If there is no sewing material below
it).
– LED fl ashes green or yellow = Setting
aid/soiling indicator.
– LED lights up yellow = Output indicator
(if there is no sewing material below it).
14
Fig. 7 - 02
Page 15
Operating Controls
7.03 Stop button
Press the stop button:
Machine and feed band stop.
Release the stop button:
Press the F4 key on the control panel to
start the machine or insert new pocket
blanks.
1
Fig. 7 - 03
15
Page 16
Operating Controls
7.04 Control panel
The control panel is used to display and access machine functions for set-up and sewing, to
enter parameter values and to read error messages and service settings.
1
3500 1 3,5 2000
2
Fig. 7 - 04
F1
F2
F3
F4
0
0
0
0
0
0
The control panel has the following operating and display controls:
The display 1 comprises a two-line alphanumeric LCD display with 16 characters per line
and is used to display the corresponding information and selection parameters.
The plus/minus keys 2 are used for selecting or altering the functions and parameters
shown on the display.
The function keys 3 are used for turning the corresponding function on and off.
Switched-on functions are each indicated by the lit LED.
3
16
Page 17
Operating Controls
7.04.01 Symbols on the display
In addition to clear texts and set values, the following symbols appear on the display.
Symbol Function
Current program number
Piece counter
Speed
Stitch length
SD memory card
Machine memory
Enter
7.04.02 Plus/minus keys
The corresponding set values are selected and altered using the appropriate plus-minus
keys. At the same time the set value shown above is changed slowly at fi rst by pressing
and holding the corresponding plus or minus key. If the key is held pressed for longer, the
set value changes more quickly.
3500 1 3,5 2000
Fig. 7 - 05
F1
F2
F3
F4
0
0
0
0
0
0
Plus/minus keys
+
The displayed values can be increased or decreased using the respective key on the display
–
17
Page 18
Operating Controls
7.04.03 Function keys
If a function is on, this is always indicated by the correspondingly lit LED. Detailed explana-
tion of functions:
Thread machine
The sewing head is moved back so that the machine can be threaded.
The thread tension is opened when threading.
This key corresponds to number 1 when entering the code number.
Chain cutter on/off (with subclasses 2 and 3).
The chain is separated at the start and end of the pocket during the sewing operation.
This key corresponds to number 2 when entering the code number.
Stacker on/off (with subclass 3)
The sewn pockets are automatically stacked during the sewing operation if the cover of
the stacker is closed.
This key corresponds to number 3 when entering the code number.
Label feeder on/off (with subclass 4).
This key corresponds to number 4 when entering the code number.
Fill the unit
The unit is fi lled after pressing the key. FILL 3538 appears on the display.
Now pocket blanks must be fed in until the unit is completely fi lled. The unit is fi lled
when the length entered in parameter 503 is reached. If the unit is fi lled, it automatically
switched to the sewing operation.
This key corresponds to number 5 when entering the code number.
Sew until the unit is empty (with subclasses 2 and 3)
The unit sews until all pocket blanks are sewn after pressing the key.
EMPTY 3538 appears on the display. The unit automatically switches to ready for sewing
when the unit sews until it is empty.
This key corresponds to number 6 when entering the code number.
F1
F1 key
This key is reserved for special functions.
This key corresponds to number 7 when entering the code number.
18
F2
F3
F2 key
This key is reserved for special functions.
This key corresponds to number 8 when entering the code number.
F3 key
This key is reserved for special functions.
This key corresponds to number 9 when entering the code number.
Page 19
Operating Controls
F4
F4 key
The unit continues to sew after the "Remove fabric" message although there is still mate-
rial under the initial light barrier.
Scroll
If this key is pressed, the input menus on the display are scrolled through.
TE key
The machine changes from sewing mode to stitch input mode if this key is pressed.
Piece counter / counter
0
0
0
0
0
0
These keys can be used to switch between the piece counter and the counter. If the re-
spective function is switched on, a menu appears to set the counter to a preset, variable
value when pressing the key.
Coded via parameters 811 and 812.
The piece counter key corresponds to number 0 when entering the code number.
Separate chain (with subclasses 2 and 3)
The chain cutter is activated once after pressing the key.
Raise/lower band feed
This is raised if the band feed is lowered and lowered if the band feed is raised. Coded
via parameter 813.
Raise/lower presser foot
This is raised if the presser foot is lowered and lowered if the presser foot is raised. Coded via parameter 813.
Band feed forwards
The band feed moves forward while the key is pressed.
Coded via parameter 813.
Band feed backwards
If the band feed is raised, the band feed moves backwards while the key is pressed.
Coded via parameter 813.
19
Page 20
Set-up and Initial Commissioning
8 Set-up and Initial Commissioning
The machine may only be set up and started up by qualifi ed personnel! All of
the relevant safety regulations must always be complied with in this process!
Adequate stability of the stand must be guaranteed, even during the sewing
operations.
8.01 Set-up
Suitable electrical and pneumatic supply connections must be provided at the erection site,
see Chapter 3 Technical Data.
The erection site must have a fi rm and level subsurface and adequate lighting.
The table top is lowered for packaging purposes.
The adjustment of the table height is described below.
8.01.01 Aligning the machine
20
1
Fig. 8 - 01
Loosen the adjustable feet 1.
Align the machine horizontally by turning the levelling feet.
All four levelling feet must sit fi rmly on the ground.
Tighten the lock nuts on the levelling feet 1.
1
1
Page 21
8.01.02 Mounting the reel stand
Fig. 8 - 02
Set-up and Initial Commissioning
Assemble the reel stand as shown in
Fig. 8 - 02.
Then insert the stand into the hole in the
table top and secure it with the enclosed
nuts.
21
Page 22
Set-up and Initial Commissioning
8.02 Connecting the plug-in connections and ground cable
ACHTUNG
ATTENTION
Vertauschungsgefahr
Danger of exchange
SSI
X1/B
X11/B
Sollwertgeber
Ausgänge
Eingänge
X13
X5
RS 232/1
X1/A
CAN-BUS
X11/A
X15
Fadenwächter
Motor
X8
1
E
3
5
4
D
Fig. 8 - 03
SM1
X4/B
X4/A
2
SM2
X3
B
Insert all plugs on the control box 2 in accordance with their designation.
Insert the “motor” into the bushing X 3 and the bushing X 8.
Caution!
Plugging in the connector incorrectly can damage the control unit!
Attach the following ground cables in order to discharge static electricity:
Securely attach the ground cable from the sewing head 1 to ground point A.
Securely attach the ground cable from the control point 8 to ground point B.
Securely attach the ground cable from the main switch 3 to ground point C.
D
C
B
A
22
Securely attach the ground cable from the stand 4 to ground point D
Securely attach the ground cable 5 from the motor to ground point E
Page 23
8.03 Initial start-up
Set-up and Initial Commissioning
Inspect the machine and in particular the
electric lines and pneumatic connecting
hoses for possible damage.
Remove the stopper 1 from the oil tank
2
1
2. The stopper serves solely for transit
support and may not be used during the
sewing operations.
Clean the machine thoroughly and then
oil it, see Chapter 10 Maintenance and
Care.
Have technical staff check whether the
machine’s motor may be operated at the
existing mains voltage.
Fig. 8 - 04
Never operate the machine if there are any differences.
Before the initial commissioning, have technical staff verify that parameter 201
(machine class) is set to “1”.
The machine must only be connected to a grounded socket!
Connect the machine to the compressed air system. The manometer should display a
pressure of around 6 bar. Set this value, if possible (see Chapter 10.04 Monitoring/adjust-
ing air pressure).
8.04 Switching the machine on/off
Switch the machine on, see Chapter 7.01 Main switch.
23
Page 24
Set-up
9 Set-up
9.01 Inserting the needle
Observe and comply with all regulations and instructions in this instruction
manual.
Pay particular attention to all safety regulations!
All set-up work may only be carried out by appropriately instructed personnel.
Disconnect the machine from the electricity mains for all set-up work by operat-
ing the main switch or by removing the mains plug!
Switch off the machine!
Risk of injury due to accidental
machine start-up!
Only use needles of the system
intended for the machine, see
Chapter 3 Technical Data!
2
Fig. 9 - 01
Approach the thread-in position (see
1
1
2
P. 18)
Bring the needle bar to the top position
and loosen screw 1.
Insert needle 2 up to the stop (while do-
ing so, the long needle groove must
point to the right).
Tighten the screws 1.
24
Page 25
Set-up
9.02 Threading the needle / adjusting the needle thread
1
Fig. 9 - 02
Switch off the machine!
Risk of injury due to accidental machine start-up!
Thread the needle as shown in Fig. 9-02.
Adjust the needle thread tension by turning the knurled thumb screw 1.
25
Page 26
Input
10 Input
3500 1 3,5 2000
F4
0
0
0
0
0
0
F1
Fig. 10 - 01
F2
F3
The following appear on the display (from the left):
Max. speed (e.g. 3500 revolutions per minute), it can be changed using the correspond-
ing plus/minus key. Coded via parameter 809.
Stitch length (e.g. 3.5 mm), it can be changed using the corresponding plus/minus key.
The electronically set stitch length here must be identical to the mechanically set stitch
length on the sewing head.
The following procedure should be observed to set the stitch length:
1. Set the mechanical stitch length on the sewing head.
2. Enter the electronic stitch length.
3. Feed in the pocket blank(s) and check the stitch quality.
4. Change the mechanical and/or electronic stitch length if the sewn pocket blank
is too fl at. Coded via parameter 810.
Piece counter or counter (e.g. 20000). Coded via parameters 811 and 812.
26
The function of the other keys is explained in the “Operating Controls” chapter. The sewing
cycle is started by inserting pocket blanks.
ERROR 6 appears if the sewing head is not in the sewing position after switch-
ing on the unit. The outputs to raise the band feed and move the sewing head
are not switched on (valves stay depressurised) and the user must manually
move the sewing head to the sewing position.
Page 27
Input
10.01 Sewing – automatic mode
The following work steps assume that the sewing preparations listed in the
“Set-up” chapter have been carried out thoroughly and the machine has been
programmed according to the order.
Turn on the machine at the main switch and wait for it to be ready for operation.
Press the presser foot key and raise the presser foot.
Lay the top edge of the pocket blank at the stop.
Slide the pocket blank to the left under the Plexiglas cover.
Light barrier detects the start of the pocket blank.
Feed band takes hold of the pocket blank.
Feed band moves the pocket blank to the left into the pleating attachment.
Pleating attachment folds over the top edge.
Feed band moves the folded pocket blank into the sewing position.
Top edge seam is sewn.
Pocket blank is transported out of the sewing area.
The following keys are switched on in automatic mode, see Fig. 10-02
3500 1 3,5 2000
F1
F2
F3
F4
0
0
0
0
0
0
Fig. 10 - 02
27
Page 28
Input
10.02 Sewing – Unit with cutter and rack
In contrast to the basic machine described in 10.01, the “Plus” machine sepa-
rates the pocket blanks after hemming with a cutter. An integrated extraction
device removes the loose threads during the cutting process and collects them
in a container under the work table. The individual pocket blanks are automati-
cally fanned out with an automatic racking device and placed on a round table.
Turn on the machine at the main switch and wait for it to be ready for operation.
Press the presser foot key and raise the presser foot.
Lay the top edge of the pocket blank at the stop.
Slide the pocket blank to the left under the Plexiglas cover.
Light barrier detects the start of the pocket blank.
Feed band moves the pocket blank to the left into the pleating attachment.
Pleating attachment folds over the top edge.
Feed band moves the folded pocket blank into the sewing position.
Top edge seam is sewn.
Pocket blank is transported out of the sewing area.
Light barrier triggers the “Cutting” process.
Pneumatically operated blade separates the continuing seam.
Feed band transports the pocket blank to the rack.
Rack moves back and opens the passage downwards.
Pocket blank falls down onto the round table.
Pneumatic cylinder switches the round table one step further.
Rack moves forward and closes the passage.
Unit is ready for the next pocket blank.
The blanks can be removed when the round table is full.
28
Page 29
Input
10.03 Input mode
Select the function group
No
500
F4
0
0
0
0
0
0
F1
Fig. 10 - 03
F2
F3
The desired function group must be selected using the allocated plus/minus key after chang-
ing to input mode.
Select the function group or function with the corresponding plus/minus key.
+
The upper key is + and the lower key is -.
–
The selected function group is taken over by pressing the plus/minus key under the En-
ter symbol and the machine jumps to the “Enter parameter” status after entering the code.
This display does not appear if the access code has already been entered or the function
group is not code protected.
If the TE key is pressed, the machine changes to production mode (LED off).
29
Page 30
Input
The following function groups are available:
Group Function Access rights (factory setting)
100 Operator level free
200 Mechanic level coded
300 Sewing drive positions coded
400 Times coded
500 Counter and speeds coded
600 Service coded
700 Sewing motor coded
800 Access rights coded
Access rights for the individual function groups and for the functions accessible via the keys
can be changed in the function group 800. The access code for coded functions can also be
changed (status on delivery: 3819). Coded functions can only be accessed after entering the
code. Specifi c keys as interpreted as numeric keys for input purposes (see the “Operating
Controls” chapter).
30
Page 31
Input
10.04 Input mode
Enter parameters
No
505
Fig. 10 - 04
VAL
16,4
F1
F2
F3
0
0
0
The display shows the selected parameter number on the left and the associated parameter value further to the right. Parameter 505, the clearance from the chain cutter sensor to
the chain cutter has been selected in the example above. The displayed parameter value is
16.4 mm.
The values above can be changed using the plus/minus keys. The parameter values are tak-
+
en over by advancing to another parameter number.
–
F4
0
0
0
If the TE key is pressed, the values are also taken over and the machine switches to sewing
mode.
31
Page 32
Input
10.09 Parameter list
Function group 100: Operator level
101 Display software version (0437/xxx)
102 Display motor control software version
103 Key beeper (I = OFF, II = ON)
104 Needle thread monitor (I = OFF, II = ON)
105 Bobbin thread monitor (I = OFF, II = ON)
106 Display serial number of machine
Function group 200: Mechanic level
201 Subclass(x)
202 Label feeder attached (I = OFF, II = ON)
203 Band feed acceleration (200; 50 – 999)
204 Band feed braking (250; 50 – 999)
205 Maximum stitch length when sewing in 1/10 mm
206 Switching frequency from fi ne step to full step
(2,3)
207
1: 3538-1/01 (Basic)
2: 3538-1/02 (with chain cutter)
3: 3538-1/03 (with chain cutter and stacker)
(4.0; 2.0 – 8.0)
(375; 0 – 2000)
Automatic extraction (I = OFF, II = ON)
Function group 300: Positions
301
302
303
Reference position (needle at top edge of needle plate)
Position of cover-thread carrier t.d.c. (153, 0 – 191)
Position of needle at bottom position (81, 0 – 191)
Function group 400: Times (0.01 – 2.00 s)
401 Holdoff time after initial light barrier (0.01 s)
402 Switching time for needle head to move to thread-in
position (A7) (1.00 s)
403 Wait period after sensor when sewing head in sewing
position (A7) (0.10 s)
404 Switching time to raise/lower band feed (A6) (0.85 s)
405 Switching time of presser foot upwards (A10)
(0.20 s)
406 Switching time of presser foot downwards (A10)
(0.20 s)
407 Needle thread monitor hide stitches (3, 0 – 9)
408 Bobbin thread monitor hide stitches (3, 0 – 9)
(2,3)
409
Chain cutter switch-on time (A8) (0.01 s)
32
Page 33
Input
(2,3)
410
411
412
413
414
415
416
417
418
(3)
(3)
(3)
(3)
(3)
(3)
(3)
(3)
Chain cutter travel time downwards (A8) (0.01 s)
Switching time of stacker downwards (A12) (0.01 s)
Switching time of stacker upwards (A12) (0.01 s)
Switching time of stacker to the right (A13) (0.01 s)
Switching time of stacker to the left (A13) (0.19 s)
Switching time to open stacker (A14) (0.28 s)
Switching time to close stacker (A14) (0.17 s)
Switching time to turn stacker (A4) (0.01 s)
Switching time to hold pocket (A3) (0.01 s)
Function group 500: Counter, speeds and clearances
501 Soft start stitches (0; 0-15) soft start speed (1500; 0 –
4500 rpm)
502 Stop clearance (55.0; 0 – 999.9)
503 Length when fi lling machine (370; 0 – 9999)
504 Speed of band feed in a manual process (like a sewing
head speed with a stitch length of 4 mm)
(2000, 10 – 4000)
(2.3)
505
Clearance of chain cutter sensor to the chain cutter
(16.4; 0 – 999.9)
(2.3)
506
Clearance of start of pocket to the chain cutter
(3.0; 0 – 999.9)
(2.3)
507
Clearance of end of pocket to the chain cutter
(3.0; 0 – 999.9)
(3)
508
Clearance of stacker sensor to the stacker
(90.0; 0 – 999.9)
Function group 600: Service
601 Band feed stepping motor process (X: individual steps,
XX: continuously forwards or backwards while the key
is pressed)
602 Inputs: 0123456789ABCDEF
0: free (E1 – X5.1)
1: free (E2 – X5.2)
2: free (E3 – X5.3)
3: free (E4 – X5.4)
4: free (E5 – X5.5)
5: free (E6 – X5.14)
6: free (E7 – X5.15)
7: Needle thread monitor (option) (E8 – X5.16)
8: Bobbin thread monitor (option) (E9 – X5.9)
33
Page 34
Input
9: Stacker cover (E10 – X5.10) (3)
A: Feed band stop (E11 – X5:11)
B: Stop switch (break contact) (E12 – X5.12)
C: Sewing head in sewing position (E13 – X5.13)
D: Stacker light barrier (E14 – X5.8) (3)
E: Chain cutter light barrier (E15 – X5.6) (2.3)
F: Initial light barrier (E16 – X5.7)
603 Outputs:
1: free (X13.1 and X13.2)
2: free (X13.3 and X13.4)
3: Presser foot (X13.5) ( 1: top, 0: bottom)
4: Raise band feed (X13.6) (1: top)
5: Lower band feed (X13.7) (1: bottom)
6: Sewing head sewing position (X13.8)
7: Sewing head thread-in position (X13.9)
8: Open thread tension (X13.10)
9: Extraction (X13.11) ( 1: on, 0: off) (2.3)
10: Stacker left/right (X13.12) ( 1: left, 0: right) (3)
11: Stacker down (X13.13) ( 1: bottom, 0: top) (3)
12: Open stacker (X13.25) ( 1: open, 0: closed) (3)
13: Hold pocket (X13.24) (3)
14: Turn stacker (X13.16) (3)
15: Chain cutter (X13.17) ( 1: on, 0: off) (2,3)
16: Sewing motor running (X13.18) ( 1: running, 0: at a
standstill)
604 Turn sewing motor in sewing direction
605 Run cold start
3
606
Run stacking process
34
Function group 700: Sewing motor
701 P-section speed regulator (10)
702 I-section speed regulator (50)
703 P-section position controller (20)
704 D-section position controller (30)
705 Time for position controller (25)
706 P-section position controller for rest brake (25)
707 D-section position controller for rest brake (15)
708 Maximum torque for rest brake (0)
709 Minimum machine speed (6)
710 Maximum machine speed (4500)
Page 35
Input
711 Maximum motor speed (68)
712 Positioning speed (25)
713 Acceleration ramp (35)
714 Braking ramp (30)
715 Reference position (43)
716 Dead man time (40)
717 Motor starting current (7)
718 Anti-rank fi lter (3)
719 Rotation direction assignment (1)
720 Positioning technique
(1 – time-optimised; 2 – path-optimised)
Function group 800: Access rights
801 Access rights for function group 100*
802 Access rights for function group 200*
803 Access rights for function group 300*
804 Access rights for function group 400*
805 Access rights for function group 500*
806 Access rights for function group 600*
807 Access rights for function group 700*
808 Access rights for function group 800*
809 Access rights for maximum key speed*
810 Access rights for stitch length keys*
811 Access rights for piece counter key*
812 Access rights for counter key*
813 Access rights for direct functions* (band forwards, band
backwards, raise band, presser foot up/down and chain
cutter)
821 Enter access code (in status on delivery: 3538)
* 0 – free, 1 – blocked with a code
35
Page 36
Error
10.10 Error messages
Error code Description
Error 1 System error
Error 2 Sewing motor ERROR 2/BB/xxx
BB = 20: Deadman
xxx = sewing motor control
unit error (see Motor errors)
Error 3 Ramp memory too small
Error 4 free
Error 5 Stacker not ready(3)
Error 6 Sewing head sewing position/thread-in position
Error 7 Stepping motor movement
Error 8 Needle thread monitor
Error 9 Bobbin thread monitor
Error 11 Stepping motor step frequency too high
Error 21 Power supply unit overloaded (24 V)
Error 22 Mains voltage
Error 23 Power supply 24 V too low
10: Speed
0B: StopX
0A: Reset stitch counter
09: Write parameters
05: Position t.d.c. by shortest route
03: Position t.d.c. in reverse
02: Position t.d.c. forwards
30: Timeout for increasing speed
31: Timeout from uncertain positioning
32: Timeout from deadman command
33: Timeout for deleting errors
34: Timeout for emergency stop
35: Timeout for writing parameters
36: Timeout for resetting stitch counter
37: Timeout for stop command after x stitches
38: Timeout for initialisation
39: Establishing contact when turned on
(sensor monitoring)
1. Ramp X not ready
2. Ramp Y not ready
3. Time monitoring
36
Page 37
Error
Motor errors
Error code Description
33 Invalid parameter value
35 Communication error
36 Init. not ready
37 Command overrun
64 Mains off during initialisation
65 Excess current directly after mains on
66 Short circuit
68 Excess current during operation
70 Motor blocked
71 No incremental plug
74 Incremental encoder missing for transmission/
reduction
173 Motor blocked in 1st stitch
175 Internal starting error
222 Dead man monitoring
3737
Page 38
Maintenance and Care
11 Maintenance and Care
11
.01 Maintenance intervals
Cleaning the hook area .............................daily, several times during continuous operation
Cleaning the complete machine ............................................................................... weekly
Machine oil level .................................................................................. daily, before start-up
Checking / setting the air pressure ...................................................................... as needed
Cleaning the maintenance unit air fi lter ............................................................... as needed
These maintenance intervals are based on an average running time of a single
shift production shop. Shorter maintenance intervals are recommended for in-
creased running times.
11.02 Cleaning the machine
The required cleaning cycle for the machine depends on the following factors:
Single or multi-shift operation
Dust formation caused by the workpieces
Optimal cleaning instructions can therefore only be determined on a case-by-case basis.
Disconnect the machine from the electricity mains for all cleaning work by shut-
ting off the main switch or removing the mains plug! Risk of injury due to acci-
dental machine start-up!
The following tasks are recommended during a single shift operation to avoid operational er-
rors:
Open the hook area cover.
Clean the hook area daily, more frequently during continuous operation.
Close the gripper area cover!
Only operate the machine when the hook room cover is closed!
Risk of injury due to moving parts!
38
Page 39
Maintenance and Care
11.03 Checking / topping up the oil level of the oil tank for the front parts
2
max.
min.
1
Fig. 11 - 01
Check the oil level before every start-up.
The oil level must not drop below the “min.” marking or rise above the “max.”
marking.
The oil level must always be visible in the sight glass 1.
Add oil to the container through the hole 2 as needed
Only use oil with a centre viscosity of 22.0 mm
0.865 g/cm3 at 15 °C.
We recommend PFAFF sewing machine oil part no. 280-1-120 144.
2
/s at 40 °C and a density of
39
Page 40
Maintenance and Care
11.04 Checking / topping up the oil level of the gear mechanism
Fig. 11 - 02
2
1
Switch off the machine!
Risk of injury due to accidental machine start-up!
Open the side cover and check the oil level before every machine start-up.
The oil level must always be visible in the sight glass 1 (if no air bubble is visi-
ble, then the oil level is too high.)
Remove the screw 2 as needed and add only enough oil for an air bubble to remain
visible.
Replace the screw 2.
Only use oil with a centre viscosity of 22.0 mm
0.865 g/cm3 at 15 °C.
2
/s at 40 °C and a density of
40
We recommend PFAFF sewing machine oil part no. 280-1-120 144.
Page 41
Maintenance and Care
11.05 Checking / setting the air pressure
Check the air pressure on the manome-
2
ter 1 before every start-up.
The manometer 1 must show a pressure
of 6 bar.
Adjust this value if needed.
Pull up the button 2 for this and turn it
out of position accordingly.
1
Fig. 11 - 03
11.06 Emptying / cleaning the maintenance unit’s water tank
Switch the machine off.
Detach the compressed air
tube on the maintenance unit.
Empty the water tank
The water tank 1 empties itself auto-
matically after the compressed air tube
for the maintenance unit has been removed.
Clean the fi lter
2
Unscrew the water tank 1 and take out
the fi lter 2.
Clean the fi lter with compressed air or
1
Fig. 11 - 04
isopropyl alcohol, part number 95-665
735-91.
Screw in the fi lter 2 and screw on the
water tank 1.
41
Page 42
Wearing Parts
12 Wearing Parts
11-173 174-15
This list shows the most important wearing parts.
A detailed parts list for the complete machine can be downloaded at www.
pfaff-industrial.de/de/service-support/downloads/technical. As an
alternative to the Internet download, the parts list can also be requested as a
hard copy under order no. 296-12-19 292.
11-108 171-15 (2x)
91-264 154-25 (2x)
11-108 171-15 (2x)
11-174 089-15
11-174 089-15 (4x)
System 62 x 57
11-174 173-25
11-330 082-15 (2x)
91-172 843-05 (2x)
91-000 250-15
42
95-353 031-05
95-353 171-05 (4x)
95-353 030-05
91-293 154-91 (XB1)
91-293 155-91 (XB5)
91-293 156-91(XB6)
91-293 157-91(XB7)
91-292 930-91(XB8)
91-292 934-91
Page 43
Notes
Page 44
PFAFF Industriesysteme
und Maschinen GmbH
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
Telefon: +49 - 6301 3205 - 0
Telefax: +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 authorized licensee of the PFAFF trademark.
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