Pfaff Powerline 2545, Powerline 2546 Instruction Manual
2545
2546
INSTRUCTION MANUAL
This instruction manual applies to machines from the
following serial numbers onwards:
# 2 798 767
296-12-19 219/002
Betriebsanleitung engl. 09.12
This Instruction Manual is valid for all models and subclasses listed in the
chapter "Specifi cations".
The adjustment manual for the machines can be downloaded free of
charge from the internet address
www.pfaff-industrial.com/pfaff/de/service/downloads.
As an alternative to the internet download the adjustment manual can also be
ordered in book form under part no.296-12-19 220/002.
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
Index
Contents ..................................................................................Page
1 Safety .................................................................................................................................... 5
1.01 Directives ...............................................................................................................................5
1.02 General notes on safety ......................................................................................................... 5
1.03 Safety symbols ......................................................................................................................6
1.04 Important points for the user ................................................................................................. 6
1.05 Operating and specialist personnel ........................................................................................ 7
1.05.01 Operating personnel .............................................................................................................. 7
1.05.02 Specialist personnel ............................................................................................................... 7
1.06 Danger warnings .................................................................................................................... 8
2 Proper use............................................................................................................................. 9
3 Specifi cations ..................................................................................................................... 10
3.01 PFAFF 2545 / 2546 (BASIC, CLASSIC and PLUS) ............................................................... 10
3.02 Maximum speed ................................................................................................................. 11
3.03 Machine equipment and options ......................................................................................... 12
4 Disposal of Machine .......................................................................................................... 13
5 Transportation, packing and storage ................................................................................ 14
5.01 Transportation to customer‘s premises ............................................................................... 14
5.02 Transportation inside the customer‘s premises ................................................................... 14
5.03 Disposal of packing materials ..............................................................................................14
5.04 Storage ................................................................................................................................ 14
6 Explanation of symbols ..................................................................................................... 15
7 Controls .............................................................................................................................. 16
7.01 On/off switch ...................................................................................................................... 16
7.02 Sewing lamp switch (only on the PFAFF 2545 / 2546 CLASSIC and PLUS) ........................ 16
7.03 Pedal .................................................................................................................................... 17
7.04 Keyboard on machine head (only on the PFAFF 2545 / 2546 CLASSIC and PLUS) .............18
7.05 Knee switch (option) ............................................................................................................21
7.06 Knee lever (only on the PFAFF 2545 / 2546 BASIC) ............................................................. 21
7.07 Lever for lifting the presser foot ........................................................................................... 22
7.08 Adjusting the stitch length (on the PFAFF 2545 / 2546 BASIC and CLASSIC) ..................... 22
7.09 Adjusting the stitch length (on the PFAFF 2545 / 2546 PLUS) ............................................. 23
7.10 Reverse feed lever ............................................................................................................... 23
7.11 Adjusting the top feed stroke (on the PFAFF 2545 / 2546 BASIC and CLASSIC) ................. 24
7.12 Adjusting the top feed stroke (on the PFAFF 2545 / 2546 PLUS) ........................................ 24
Index
Contents ..................................................................................Page
7.13 Switchable needle thread tension (only on the PFAFF 2545 / 2546 BASIC ) .......................25
7.14 Bobbin thread monitor with remaining thread recognition by sensor (sub-class -926/06)
Bobbin thread control by reverse stitch counting (with P74 ED-L + PF 321) ....................... 25
7.15 Bobbin thread control by stitch-counting (with PicoDrive) ...................................................26
7.16 Control panel ........................................................................................................................26
8 Preparation ........................................................................................................................ 27
8.01 Inserting the needle ............................................................................................................. 27
8.02 Winding the bobbin thread, regulating the winder tension .................................................. 28
8.03 Bobbin-changing/threading, and regulating the bobbin thread tension ................................ 29
8.04 Setting the bobbin thread control function by reverse stitch counting .....................................29
8.04 .01 Machines with P45 PD2-L and P74 ED-L ..................................................................................29
8.04 .02 Machines with PF 321 ..............................................................................................................29
8.05 Setting the bobbin thread monitor with remaining thread recognition by sensor
(sub-class -926/06) ............................................................................................................... 30
8.05 .01 Machines with P74 ED-L ...................................................................................................... 30
8.05 .02 Machines with P74 ED-L ...........................................................................................................30
8.06 Threading needle thread and regulating its tension on the 2545 ............................................31
8.07 Threading needle thread and regulating its tension on the 2546 ............................................32
9 Care and maintenance ....................................................................................................... 33
9.01 Servicing and maintenance intervals ................................................................................... 33
9.02 Cleaning the machine .......................................................................................................... 33
9.03 Lubricating ........................................................................................................................... 34
9.04 Checking/regulating the air pressure ................................................................................... 35
9.05 Emptying/cleaning the water bowl of the air fi lter/regulator ................................................ 35
10 Wearing parts ..................................................................................................................... 36
Safety
1 Safety
1
.01 Directives
This machine is constructed in accordance with the European regulations contained in the
conformity and manufacturer’s declarations.
In addition to this Instruction Manual, also observe all generally accepted, statutory and
other regulations and legal requirements and all valid environmental protection regulations!
The regionally valid regulations of the social insurance society for occupational accidents or
other supervisory organizations are to be strictly adhered to!
1.02 General notes on safety
● This machine may only be operated by adequately trained operators and only after having
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 may only be used for the purpose for which it is intended and may not be
operated without its safety devices. All safety regulations relevant to its operation are to
be adhered to.
● When exchanging sewing tools (e.g. needle, roller presser, needle plate and bobbin),
when threading the machine, when leaving the machine unattended and during mainte-
nance work, the machine is to be separated from the power supply by switching off the
On/Off switch or by removing the plug from the mains!
● Everyday maintenance work is only to be carried out by appropriately trained personnel!
● Repairs and special maintenance work may only be carried out by qualifi ed service staff
or appropriately trained personnel!
● Work on electrical equipment may only be carried out by appropriately trained personnel!
● Work is not permitted on parts and equipment which are connected to the power supply!
The only exceptions to this rule are found in the regulations EN 50110.
● Modifi cations and alterations to the machine may only be carried out under observance
of all the relevant 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 which are not supplied by us have
not been tested and approved by us. The installation and/or use of any such products can
lead to negative changes in the structural characteristics of the machine. We are not liable
for any damage which may be caused by non-original parts.
5
Safety
1.03 Safety symbols
Danger!
Points to be observed..
Danger of injury for operating and specialist personnel!
Caution
Do not operate without fi nger guard and safety devices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.
I
1.04 Important points for the user
● This Instruction Manual is an integral part of the machine and must be available to the
operating personnel at all times.
● The Instruction Manual must be read before operating the machine for the fi rst time.
● The operating and specialist personnel is to be instructed as to the safety equipment of
the machine and regarding safe work methods.
● It is the duty of the user to only operate the machine in perfect running order.
● It is the obligation of the user to ensure that none of the safety mechanisms are removed
or deactivated.
● It is the obligation of the user to ensure that only authorized persons operate and work
on the machine.
Further information can be obtained from your PFAFF agent.
6
Safety
1.05 Operating and specialist personnel
1
.05.01 Operating personnel
Operating personnel are persons responsible for the equipping, operating and cleaning of
the machine as well as for taking care of problems arising in the sewing area.
The operating personnel is required to observe the following points and must:
● always observe the Notes on Safety in the Instruction Manual!
● never use any working methods which could adversely affect the safety of the machine!
● not wear loose-fi tting clothing or jewelery such as chains or rings!
● also ensure that only authorized persons have access to the potentially dangerous area
around the machine!
● always immediately report to the person responsible any changes in the machine which
may limit its safety!
1.05.02 Specialist personnel
Specialist personnel are persons with a specialist education in the fi elds of electrics, electro-
nics and mechanics. They are responsible for the lubrication, maintenance, repair and adjust-
ment of the machine.
The specialist personnel is obliged to observe the following points and must:
● always observe the Notes on Safety in the Instruction Manual!
● switch off the On/Off switch before carrying out adjustments or repairs, and ensure that
it cannot be switched on again unintentionally!
● wait until the luminous diode on the control box is no longer blinking or on before begin-
ning adjustment or repair work.
● never work on parts which are still connected to the power supply! Exceptions are explai-
ned in the regulations EN 50110.
● replace the protective coverings and close the electrical control box afer all repairs or
maintenance work!
7
Safety
1.06 Danger warnings
A working area of 1 m must be kept free both in front of and behind the machi-
ne, so that easy access is possible at all times.
Never put your hands or fi ngers in the sewing area during sewing!
Danger of injury by the needle!
While setting or adjusting the machine do not leave any objects on the table nor
in the needle plate area! Objects may be trapped or fl ung out of the machine!
2
3
Fig. 1 - 01
6
1
4
5
Do not run the machine without fi nger guard 1!
Danger of injury by up and down movement of needle!
Do not run the machine without take-up lever guard 2!
Danger of injury by moving take-up lever!
Do not run the machine without belt guards 3 and 4!
Danger of injury by rotating v-belt!
Do not operate the machine without tilt lock 5!
Danger of crushing between sewing head and table!
Do not operate the machine without support 6! Danger due to top-heavy
sewing head! Machine can tip over backwards when tilted!
8
Proper use
2 Proper use
The PFAFF 2545 BASIC, CLASSIC and PLUS are special high-speed, single needle lock-
stitch sewing machines with unison feed and a large, respectively extra large hook.
The PFAFF 2546 BASIC, CLASSIC and PLUS are special high-speed, two needle lockstitch
sewing machines with unison feed and a large, respectively extra large hook.
The machines are used for sewing lockstitch seams in the textile 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 includes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!
9
Specifi cations
3 Specifi cations
.01 PFAFF 2545 / 2546 (BASIC, CLASSIC and PLUS)
3
Stitch type: .........................................................................................................301 (lockstitch)
Needle system: .............................................................................................................. 134-35
Version CN; CN9; CN12: ............................................. for processing medium-heavy materials
Version DN; DN12: .................................................................... for processing heavy materials
Needle size in 1/100 mm:
Version CN9: .............................................................................................................. 110 – 140
Version DN12: ........................................................................................................... 150 – 200
Max. stitch length:
Version CN; DN: ...............................................................................................................6 mm
Version CN9: ....................................................................................................................9 mm
Version CN12; DN12: .....................................................................................................12 mm
Max.thread size (synthetic):
Version CN.. : .................................................................................................................. 15/3
Version DN.. : .................................................................................................................... 8/3
❋
▲
▲
Presser foot clearance: ..................................................................................................20 mm
Clearance width: ..........................................................................................................350 mm
Clearance height: .........................................................................................................120 mm
Bed plate dimensions: .......................................................................................640 x 200 mm
Noise data:
Noise emission level at workplace with a sewing speed of 2400 spm: ............ LpA < 80 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO
Motor data: .................................................................... See instruction manual for the motor
Leakage current ........................................................................................................... < 5 mA
Air consumption per switch cycle: ...............................................................................0.146 NI
Net weight of sewing head: .................................................................................approx. 72 kg
Gross weight of sewing head : .............................................................................approx. 82 kg
❋
Subject to alterations
◆
Due to the use of network fi lters there is a nominal leakage current of < 5 mA.
▲
synthetic, or other sizes of comparable thread types
■
KpA = 2,5 dB
■
◆
10
Specifi cations
3.02 Maximum speed
Top feed lift
1 - 2 mm up to 9 mm
2,5 - 4 mm up to 9 mm
4,5 - 5 mm up to 9 mm
Stitch length range
Max. speed / spm
3800
3200
2600
on version C and with
large hook
◆
◆
◆
Max. speed / spm on
version C and with
3400
2800
2200
extra-large hook
◆
◆
◆
Max. speed / spm
3000
2800
2400
on version D and with
large hook Max. speed / spm on
◆
◆
◆
version D and with
2700
2700
2200
5,5 - 7 mm up to 9 mm 2000 1800 1800 1800
7,5 - 9 mm up to 9 mm 1800 1800 1600 1600
1 - 2 mm 9,5 - 12 mm
2,5 - 4 mm 9,5 - 12 mm
4,5 - 5 mm 9,5 - 12 mm
2200
2200
2200
◆
◆
◆
2200
2200
2200
◆
◆
◆
2200
2200
2200
◆
◆
◆
2200
2200
2200
5,5 - 7 mm 9,5 - 12 mm 2000 1800 2000 1800
7,5 - 9 mm 9,5 - 12 mm 1800 1800 180 0 1800
◆
The max. speed on the PFAFF 2546 with needle gauge larger than 20 mm is 2000 spm.
extra-large hook
◆
◆
◆
◆
◆
◆
11
Specifi cations
3.03 Machine equipment and options
PFAFF 2545 / 2546
Vetical hook, large
Vetical hook, extra large
Thread trimmer (-900/81), < 13 mm rest thread
Thread trimmer (-900/82), < 5 mm rest thread
Thread puller (-909/12), controlled
Presser foot lift, manual via knee lever
Presser foot lift (-910/04), electropneumatic
Manual backtacking with mech. hand switch
Automatic backtacking (-911/35), electropneumatic
1 preselectable stitch length
2 preselectable stitch lengths, can be switched alternately
2 preselectable thread tensions, one can be switched on manually
2 preselectable thread tensions, one can be switched on electropneumatically by hand switch
1 presser foot stroke, manually adjustable, top feed stroke up to max. 9 mm
2 presser foot strokes, manually adjustable, preselectable quick stroke
adjustment with hand switch (electropneumatically controlled)
Drop feed, adjustable
Oil level control through inspection glass
Oil level on display, with warning light on machine head
Presser foot pressure, manually adjustable
Clutch motor
DC-motor functionality PicoDrive P45 PD-L
DC-motor functionality P74 ED-L, PF 321
Control panel - PicoTop
Remaining bobbin thread recognition function by stitch counting with
LED display
Bobbin thread monitor with remaining thread recognition by sensor
(sub-class -926/06
Integrated multiple switch on machine head + programmed multi switch
Integrated LED sewing lamp on sewing head, dimmable
Bobbin thread winding device
Attachment slider
Skip stitch detector SSD -
Bobbin thread monitoring with thread detection -
Safety coupling
BASIC
CLASSIC
PLUS
●●●
❍❍❍
-
●●
-
❍❍
-
❍❍
--
●
-
●●
●●●
-
●●
●●
--
●
-
●●
--
●●●
●●●
-
●●●
●
❍
-
-
-
--
-
❍●●
●●●
●●●
●●●
-
●
--
●●
-
●
●●
--
--
●●
●●
●●
❍
●●
❍❍
❍❍
12
● = standard, ❍ = optional
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