Pfaff 3588-05/020 Instruction manual

3588

-05/020

-15/020

INSTRUCTION MANUAL

This instruction manual applies to machines from serial number 2 760 129 and software version

0380/003, 0381/003 onwards

296-12-19 094/002

Betriebsanleitung engl. 0

8.12

This instruction manual applies to all versions and subclasses listed under

"Specifi cations".

Reprinting, copying or translation of PFAFF instruction manuals, whether in whole or in part, is not permitted without our prior permission and not without written indication of the source.

PFAFF Industriesysteme und Maschinen AG

Hans-Geiger-Str. 12 - IG Nord

D-67661 Kaiserslautern

Index

Contents ..................................................................................Page

Register 01

.................................................................................................5

1

Safety

1

.01 Directives

1

.02 General notes on safety ......................................................................................................... 7

1

.03 Safety

1

.04

1

.05

Important notes for the user .................................................................................................. 8

Notes for operating and technical staff .................................................................................. 9

1

.05.01 Operating

1

.05.02 Technical

1

.06 Danger

Register 02

.................................................................................................9

2

Proper

3

Specifi cations ..................................................................................................................... 12

4

Disposal of Machine .......................................................................................................... 13

5

5

.01

Transportation, packing and storage ................................................................................ 14

Transportation to customer‘s premises ............................................................................... 14

5

.02

5

.03

Transportation inside the customer‘s premises ................................................................... 14

Disposal of packing materials .............................................................................................. 14

5

.04 Storage

6

Explanation of symbols ..................................................................................................... 15

Register 03

...............................................................................................15

7

Controls

7

.01 On/off

7

.02 Stopptaster

7

.03 Switch for the loading function ............................................................................................ 18

7

.04 Double-start

7

.05 Handwheel

7

.06 Control

Register 04

............................................................................................... 19

8

Mounting and commissioning the machine .................................................................... 21

8

.01 Mounting

8

.02 Removing the transit support bracket .................................................................................. 22

8

.03 Mounting the spool holder ................................................................................................... 22

8

.04 Commisioning

8

.05 Switching the machine on/off .............................................................................................. 24

8

.06 PC

8

.07

8

.08

8

.09

Selecting the language ........................................................................................................ 25

Adjusting the control panel .................................................................................................. 26

Checking / adjusting the zero points .................................................................................... 27

Index

Contents ..................................................................................Page

Register 05

...............................................................................................31

9

Preparation

9

.01

9

.02

Inserting the needle ............................................................................................................. 33

Winding the bobbin thread, adjusting the thread tension .................................................... 34

9

.03

9

.04

9

.05

9

.06

Changing the bobbin / adjusting the bobbin thread tension ................................................ 35

Threading the needle / adjusting the needle thread tension ................................................ 36

Selecting the program number ............................................................................................ 37

Selecting / confi guring a sequence ...................................................................................... 38

9

.06.01 Selecting a sequence ........................................................................................................... 38

9

.06.02 Confi guring a sequence ....................................................................................................... 39

9

.07 Slide

9

.08

9

.08.01

9

.08.02

9

.09

9

.10

9

.11

Jig monitor (optional) ........................................................................................................... 41

Activating jig monitor ........................................................................................................... 41

Determining the jig code ..................................................................................................... 42

Setting the bobbin thread stitch counter .............................................................................. 43

Changing the part set .......................................................................................................... 44

Loading the pre-cut parts ..................................................................................................... 46

12

12

.01

12

.02

12

.03

12

.04

12

.05

12

.06

12

.07

12

.08

12

.09

Register 06

...............................................................................................45

10

Sewing

10

.01

10

.02

Automatic sewing mode ...................................................................................................... 48

Manual sewing mode .......................................................................................................... 49

10

.03 Sewing with sequences ....................................................................................................... 51

10

.04 Program

10

.05 Error

11

Input

11

.01

11

.02

Overview of the functions in the input mode ...................................................................... 54

Creating / editing seam programs ........................................................................................ 56

11

.02.01 Block

11

.02.02 Image

11

.02.03 Inserting

11

.02.04 Other

11

.03 Seam programming example ............................................................................................... 66

11

.04 Program

11

.05 Rights of access .................................................................................................................. 79

Register 07

...............................................................................................81

Care and maintenance ....................................................................................................... 83

Care and maintenance intervals ........................................................................................... 83

Cleaning the machine .......................................................................................................... 84

Cleaning the hook ................................................................................................................ 85

Cleaning the blower air fi lter ................................................................................................ 85

Cleaning the air fi lter of the air-fi lter/lubricator .................................................................... 86

Checking/adjusting the air pressure ..................................................................................... 86

Checking the oil level of the sewing head lubrication .......................................................... 87

Lubricating the needle bar frame eccentric ......................................................................... 87

Lubricating sewing jig feed .................................................................................................. 88

Index

Contents ..................................................................................Page

12

.10 Lubricating the pocket plate guide ....................................................................................... 89

13

Adjustment

13

.01

13

.02

Notes on adjustment ........................................................................................................... 90

Tools, gauges and other accessories for adjusting ............................................................. 90

13

.03 Abbreviations

13

.04

13

.05

Removing/inserting sewing head ......................................................................................... 91

Adjusting the sewing head .................................................................................................. 92

13

.05.01 Spacing between sewing head and bedplate ...................................................................... 92

13

.05.02 Sewing head position in relation to the bedplate ................................................................. 93

13

.05.03 Upper and lower toothed belt guards ................................................................................ 94

13

.05.04 Counterweight

13

.05.05 Preadjusting the needle height ............................................................................................ 96

13

.05.06 Zero

13

.05.07 Centering the needle in the needle hole .............................................................................. 98

13

.05.08 Zigzag stitch movement ....................................................................................................... 99

13

.05.09 Needle bar rise, hook-to-needle clearance, needle height and needle guard .................... 100

13

.05.10 Bobbin case opener stroke ................................................................................................ 102

13

.05.11 Counter presser lifting stroke............................................................................................. 103

13

.05.12 Counter presser height ...................................................................................................... 104

13

.05.13 Counter presser position ................................................................................................... 105

13

.05.14 Zigzag stitch width ............................................................................................................. 106

13

.05.15 Resting position of the roller lever / radial position of the control cam .............................. 107

13

.05.16 Thread catcher height ........................................................................................................ 108

13

.05.17 Thread catcher position and knife height ........................................................................... 109

13

.05.18 Knife

13

.05.19 Bobbin thread clamp spring ................................................................................................111

13

.05.20 Manual cutting test .............................................................................................................112

13

.05.21 Presser

13

.05.22 Bobbin

13

.05.23 Needle thread tension release ............................................................................................115

13

.05.24 Thread check spring and slack thread regulator ..................................................................116

13

.05.25 Sewing head lifting cylinder ................................................................................................117

13

.05.26 Hook

13

.06 Adjusting the folding, feed and stacker devices ................................................................. 120

13

.06.01 Aligning the sewing jig ....................................................................................................... 120

13

.06.02 Height of the pocket plate guide ........................................................................................ 121

13

.06.03 Aligning the pocket plate arm ............................................................................................ 122

13

.06.04 Aligning the pocket plate guide .......................................................................................... 123

13

.06.05 Front pocket plate position ................................................................................................. 125

13

.06.06 Monitoring the sewing jig feed .......................................................................................... 126

13

.06.07 Positioning the edge folding unit ........................................................................................ 127

13

.06.08 Aligning the die .................................................................................................................. 129

13

.06.09 Control sequence of the folder plates ................................................................................ 130

13

.06.10 Position of folder plates ..................................................................................................... 131

13

.06.11 Position of corner folders ................................................................................................... 132

13

.06.12 Aligning the seam in relation to the pocket........................................................................ 133

13

.06.13 Seam backtack distance .................................................................................................... 134

13

.06.14 Stacking

Index

Contents ..................................................................................Page

13

.06.15 Aligning the feed rollers ..................................................................................................... 136

13

.07 Shaping folder plates ......................................................................................................... 137

13

.07.01 New installation / self-manufacture of folder plates........................................................... 137

13

.07.02 Slanting the lateral folder plates ......................................................................................... 138

13

.08 Service

13

.08.01 Coldstart

13

.08.02 Loading / updating the operating program ......................................................................... 141

13

.09 Sewing motor adjustments ................................................................................................ 142

13

.10 Parameter

13

.10.01 Selecting and altering parameters. .................................................................................... 143

13

.10.02 List of parameters .............................................................................................................. 144

13

.10.03 Carriage start (NIS) ............................................................................................................. 149

13

.10.04 Zig-zag delay on/off ............................................................................................................ 150

13

.10.05 Stacker rolling time ............................................................................................................ 150

Register 08

............................................................................................. 149

14 Control

............................................................................................................................. 151

14

.01 Basic setting / Diagnosis / Pin assignment ........................................................................ 151

14

.01.01 Basic control unit A20 ........................................................................................................ 151

14

.01.02 Sewing

14

.01.03 Stepping motor drive A21 .................................................................................................. 155

14

.01.04 Stacker motor drive ............................................................................................................ 156

14

.01.05 AC-Line-Controller

14

.02 Description of the error messages .................................................................................... 157

14

.02.01 General

14

.02.02 CAN-errors

14

.02.03 Stitch generation error ....................................................................................................... 160

14

.02.04 Sewing motor errors .......................................................................................................... 161

14

.02.05 Errors – Stepping motor drive ............................................................................................ 162

14

.02.06 Errors - Stacker drive .......................................................................................................... 163

14

.03 List of outputs and inputs .................................................................................................. 164

14

.03.01 CAN-Nodes

14

.03.02 CAN-Nodes

14

.03.03 CAN-Nodes

14

.03.04 Special

14

.04 Boot

15

Pneumatics-switch

16

Circuit

Register 09

.............................................................................................131

Register 10

.............................................................................................131

Miscellaneous

Safety

1 Safety

1

.01

Directives

The machine has been constructed in accordance with the requirements listed in the

EC Declaration of Conformity and the Declaration of Incorporation.

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 before 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 maintenance 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 expressly 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.

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 devices.

Before threading, changing bobbin and needle, cleaning etc. switch off main switch.

I

8

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 machine 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 working order.

● The user must ensure that only authorized persons operate and work on the machine.

For further information please refer to your PFAFF agency..

1

.05

1

.05.01

Safety

Notes for operating and technical staff

Operating staff

Operating staff are the persons responsible for setting up, operating and cleaning the machine 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 adjusting 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!

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!

1

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!

4

6

2

5

8

3

Fig. 1 - 01

7

Do not operate the machine without protective covers 1, 2, 3, 4 and 5!

Danger of crushing between moving parts of the pneumatic or feed systems!

Do not operate the machine without take-up lever guard 6!

Danger of injury by the movement of the take-up lever!

Do not operate the machine without the fi nger guard 7!

Danger of injury by the needle!

Do not put your hands or fi ngers in needles 8 of the fabric retainer!

With the needle strip engaged (needles up) there is danger of injury near the needle strip due to the projecting needles!

10

Proper use

The PFAFF 3588-05/020 and PFAFF 3588-15/020 is used for folding and sewing on pockets on jeans, workwear and similar garments.

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!

11

Specifi cations

3 Specifi cations

▲

Sewing head: ..................PFAFF sewing head for mechanized sewing units with vertical hook

Max. speed:

PFAFF 3588-05/020 ........................................................................................... max. 4000 spm

PFAFF 3588-15/020 ........................................................................................... max. 3600 spm

Stitch length: ............................................................................................................ max. 6 mm

Stitch type: ..........................................................................................................301 (lockstitch)

Needle system: .......................................................................................................... 134, 1955

Needle size: .................................................................................... 100 - 140 Nm / MR3 - MR5

Motor speed: .....................................................................................................max. 4000 rpm

Connection voltage: .......................................................................230 V ± 10%, 50 - 60 Hz AC

Power requirement: ........................................................................................................2.2 kW

Leakage current ........................................................................................................... < 5 mA

◆

Max. control range:

PFAFF 3588-05/020 ............................................................................................. 250 x 250 mm

PFAFF 3588-15/020 ............................................................................................. 280 x 280 mm

Storage capacity: ......................................................................................... 5 000.000 stitches

Working air pressure: ................................................................................................. min. 6 bar

Air consumption: .......................................................................................... approx. 25 l / cycle

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 4000 spm ........................................................................ L pA

< 78 dB(A) ■

(Noise measurement in acc. with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)

Dimensions of machine:

Length: .......................................................................................................... approx. 2250 mm

Width: .............................................................................................................approx. 1150 mm

Height: ........................................................................................................... approx. 1450 mm

Table height: ....................................................................................................... 870 - 1170 mm

Net weight: ..................................................................................................................... 600 kg

▲

Subject to alteration

◆

Due to the use of network fi lters there is a nominal leakage current of < 5 mA.

■

K pA

= 2,5 dB

12

4

Disposal of Machine

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 regula-tions; 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!

13

Transportation, packing and storage

5

5

.01

Transportation, packing and storage

Transportation to customer‘s premises

The machines are delivered completely packed.

5

.02

5

.03

5

.04

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.

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.

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.

14

6

Explanation of symbols

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)

15

7 Controls

7

.01

On/off switch

Controls

1

Fig. 7 - 01

● By turning on/off switch 1, the power supply to the machine is switched on or off.

7

.02

Stopptaster

1

● By pressing the stop switch 1, the complete work cycle is stopped, see chapter

10.04 Program interruption.

Fig. 7 - 02

17

Controls

7

.03

Switch for the loading function

1

● The function of the switch 1 can be adapted to the various requirements for loading the workpiece.

The adjustment is made with parameter "113" and "114", see

Chapter 13.10.02 Parameter

List.

With the needle strip engaged

(needles up) there is danger of injury near the needle strip due to the projecting needles!

Fig. 7 - 03

18

7

.04

Double-start keys

1

1

Controls

7

.05

Fig. 7 - 04

● In MANUAL operation mode, when both double-start keys 1 are activated simultaneously the folder is moved lowered.

● In AUTOMATIC operation mode, when both double-start keys 1 are activated simultaneously the entire program sequence is started.

● The double-start keys 1 also are used to continue the program after the bobbin has been replaced or the program has been interrupted.

Handwheel

● By turning and simultaneously pushing the handwheel 1 in, the needle bar can be positioned manually as required.

1

Fig. 7 - 05

19

Controls

7

.06

Control panel

1

Fig. 7 - 06

The current operating conditions are displayed on control panel 1. Operation takes place in a constant dialogue between the control unit and the operator. For this purpose, depending on the operating condition of the machine, different symbols and/or texts are displayed. If the symbols or texts are framed, these show functions which can be selected by pressing the appropriate position on the monitor. By pressing the corresponding function this is carried out or switched on or off immediately, or a further menu appears, e.g. for entering a value.

Activated functions are shown with inverted symbols. Unframed symbols or texts are only used for display purposes and cannot be selected by pressing.

Description of the functions

Normal symbol = function switched off (inactive)

Inverted symbol = function switched on (active)

20

8

8

.01

Mounting and commissioning the machine

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!

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).

Fig. 8 - 01

● Lift the machine with a forklift from the shipping pallet.

For machines without vertical adjustment:

● Align the machine horizontally just above the fl oor and move the four legs accordingly before setting the machine down on the ground.

For machines with vertical adjustment:

● Set down the machine on the ground and align it by turning the four spindles.

The vertical adjustment is available as an optional feature.

Fig. 8-01 shows a machine with vertical adjustment.

21


8

.02

Removing the transit support bracket

1

Before the machine is commissioned, transit support bracket

1 must be removed!

Transit support bracket 1 serves to secure the sewing machine during transit and must not be used during sewing.

Fig. 8 - 02

8

.03

Mounting the spool holder

● Mount the spool holder according to

Fig. 8.03.

22

Fig. 8 - 03

8

.04

Commisioning


Fig. 8 - 04

● 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.

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 12.06 Checking / regulating air compression).

23


8

.05

Switching the machine on/off

2

1

4

2

6

8

100

150

10

12

200

230

16

14

0

50

0

3

Fig. 8 - 05 Fig. 8 - 06

● Check air pressure on pressure gauge 1 and, if necessary, adjust air pressure with adjusting knob 2.

● Turn main switch 3 to position "I".

24

● After booting the machine control unit, to start the machine, move it back to its basic position.

● Carry out a test run, see Chapter 10 Sewing.

When commissioning the machine, the zero points must be checked or adjusted (see Chapter 8.09 Checking / adjusting the zero points).

● To switch off the machine, turn main switch 3 to position "0".

Description of other functions on the display

Input menu

This function is used to call up the input mode, see Chapter 11 Input.

8

.06

PC interface


● To read sewing programs or install machine software, use the sd-card-slot in the control panel.

● Socket 2 is for connecting the programming system OSCA.

With OSCA existing CAD data records can be used to generate seam programs.

2

1

2 GB max.

8

.07

Fig. 8 - 07

Selecting the language

● Switch on the machine.

● Call up the input menu.

● Call up the settings menu

● Select the appropriate language.

25


8

.08

Adjusting the control panel


● Call up the input mode.

● Select the service menu.

● Select control panel functions.

26

● Change the display contrast.

● Switch the key tone off or on.

Never reduce the display contrast to the extent, that the display can no longer be read!

● Conclude the input.

8

.09


Checking / adjusting the zero points

When commissioning the machine and after changing the control unit or one of the initiators of the sewing jig feed unit, it is necessary to adjust the zero points!


● Select the service menu.

● Call up the "adjusting the zero points" function and enter the code number with the number keys.

27


● Call up the "teach-in position" function.

1

Fig. 8 - 08

● Check if adjustment pin 1 can be inserted in the holes of the sewing jig and table when the sewing jig is in this position.

28

● If necessary, correct the position of the sewing jig accordingly using the direction symbols.

● Save the setting.

If this position is altered, the needle position must also be adjusted, as described in the following section!

● To quit the menu without taking over the change in position, use the "Esc" function.


● Call up the "needle position" function

1

2

3

Fig. 8 - 09

● Fix adjustment pin 1 in the needle bar with screw 2.

● By turning balance wheel 3, check whether adjustment pin 1 can be guided into the hole in the sewing jig.


● Save the setting, loosen screw 2 and remove adjustment pin 1.

29


● Call up the "folder position".

1

Fig. 8 - 10

● Check whether adjustment pin 1 can be guided into the adjustment hole of the sewing jig and the pocket plate.



● Conclude the zero points input.

30


● Move the machine to its basic position, the machine is ready for operation.

31

Preparation

9 Preparation

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!

9

.01

Inserting the needle

2

1

Switch the machine off!

Danger due to unintentional starting of the machine!

Only use needles from the system intended for the machine, see Chapter 3 Specifi cations.

● Raise the needle bar to its highest postion by turning the handwheel.

● Loosen screw 1 and insert needle 2 in the needle bar as far as it will go.

● Align needle 2 in such a way that the long needle groove is pointing to the folder station and tighten screw 1.

Fig. 9 - 01

33

Preparation

9

.02

Winding the bobbin thread, adjusting the thread tension

4

+

-

34

7

5

1

3

2

6

Fig. 9 - 02


● Place an empty bobbin 1 onto bobbin shaft 2.

● Thread the bobbin in accordance with Fig. 9-02 and wind it anti-clockwise around bobbin

1 a few times.

● Switch on the bobbin winder while at the same time pressing bobbin winder spindle 2 and lever 3.

The bobbin fi lls up during sewing.

● The tension of the thread on bobbin 1 can be adjusted with knurled screw 4.

● The bobbin winder stops automatically when bobbin 1 is full.

● Remove the fi lled bobbin 1 and cut the thread on knife 5.

If the thread is wound unevenly, loosen nut 6 and turn thread guide 7 accordingly. Retighten nut 6 after the adjustment

To adjust the fi lling capacity, see Chapter 13.05.22 Bobbin winder.

9

.03

Preparation

Changing the bobbin / adjusting the bobbin thread tension

1

2

+

-

4

3

Fig. 9 - 03

● When the number of stitches entered previously under the "bobbin thread stitch counter" function (see Chapter 9.09) have been sewn, the sewing jig moves automatically to the folding station and stops there. Hook compartment cover 1 opens.

● Changing the bobbin /adjusting the bobbin thread tension, see following section.

● Confi rm the bobbin change.

● Press the double start keys, see Chapter 7.04 Double start keys.

(Program cycle continues) or

● Call up the "change bobbin" function.

● Changing the bobbin /adjusting the bobbin thread tension (see following section).

● Press the double start keys (hook compartment cover 1 closes).

Changing the bobbin / adjusting the bobbin thread tension

● Lift latch 2 and remove empty bobbin.

● Insert a full bobbin into the hook so that it rotates in the direction of the arrow when pulling the thread.

● Close latch 2.

● Guide the thread fi rst through the groove, then around the horn of bobbin case 3 and fi nally into the recess of latch 2.

● Adjust the bobbin thread tension by turning screw 4.

35

Preparation

9

.04

Threading the needle / adjusting the needle thread tension

36

3

2

1

Fig. 9 - 04


● Lower the presser foot 1 and open thread trapper 2.

● Thread the needle thread as shown in the above illustration.

● Adjust the needle thread tension by turning knurled screw 3.

● Start the sewing cycle or

● Move the machine to its basic position.

9

.05

Preparation

Selecting the program number

When changing to a different seam program, please make sure that the part set

(folder, pocket plate and sewing jig) correspond to the new seam program.

If the wrong combination of parts and seam program is used, the machine may be damaged seriously!


● Call up the program number input menu.

● Select the desired program number (0 – 9999) using the number block.

● Confi rm the selection and quit the selection menu.

Description of the other functions

Clear

This function sets the value at "0".

Arrow keys

These functions increase or reduce the value.

Esc

This function stops the input without taking over the value entered.

Sequence selection

This function opens the menu for selecting or confi guring the sequence, see Chapter 9.06

Selecting / confi guring the sequence.

Parts program

This function opens the menu for entering the parts program number.

37

Preparation

9

.06

9

.06.01

Selecting / confi guring a sequence

Selecting a sequence

Instead of selecting a program number, it is also possible to select a corresponding sequence, providing that individual seam programs have been allocated to a sequence, see

Chapter 9.06.02 Confi guring a sequence


● Call up the menu for entering the program number.

● Call up the menu for entering the sequence.

● Select the desired sequence number (0 – 9) using the number block.

● Confi rm the selection and quit the selection menu.


Clear

This function sets the value at "0".

Arrow keys


Esc


Program selection

This function opens the menu for selecting a program, see Chapter 9.05 Selecting a program number.

Parts program

This function opens the menu for entering the parts program number.

38

9

.06.02

Preparation

Confi guring a sequence

Up to 4 seam programs can be allocated to a sequence. Each seam programs is allocated to a parts program. During sewing, the seam programs of a selected sequence appear as a function on the display with the parts program, and can be selected directly.

● Call up the menu for entering the sequence and select the desired sequence number without leaving the selection menu, see 9.06.01 Selecting a sequence.

● Call up the sequence programming function.

● Confi gure the sequence from existing seam programs by entering the program numbers on the number block.

● The cursor in the window shows, which seam program has been taken out of the group, or at which position a new seam program has been inserted. The cursor is moved with the arrow keys.

● If applicable, insert (INS) the seam program or parts program at the current cursor position, or delete (DEL) the marked seam program from the sequence.

● Conclude the sequence programming function.

To enable, for example, quicker access to up to 4 different seam programs, the function for automatic switching to the next seam program of a sequence function can be switched off with parameter "112", see Chapter 13.10.02 List of parameters.

39

Preparation

9

.07

Slide confi guration

Different slide confi gurations can be allocated to the program stations (1 – 4) with parameters "116" to "119". Individual programs can also be allocated to slide confi gurations with parameter "115".



● Call up the parameter input function.

● Select parameters "115" to "119" and alter the values accordingly, see Chapter 13.10.02

List of parameters.

● Quit the parameter input function.

40

9

.08

9

.08.01

Preparation

Jig monitor

(optional)

To make it possible to monitor the jig, the sewing jig is given a code using magnets which the control can recognize via an additional device. This is a means of preventing pairing a sewing program with the wrong sewing jig which could cause the needle to break.

If the machine is equipped with this optional device, the JIG MONITOR function must be activated, and a jig code must be entered in the sewing program in order to use the jig monitor.

Activating jig monitor




● Select parameter "108" and set the value at "1", see Chapter 13.10.02 List of parameters.

● Quit the parameter input function.

41

Preparation

9

.08.02

Determining the jig code

2

1

Fig. 9 - 05

The jig code is entered in the sewing program as a number value (0-99).

The code is created on the jig as a binary number by arranging up to eight magnets 1 in a particular way on carrier 2.

Bit assignment

Example: decimal number ( 3 5 ) is equal to the binary combination ( 1 1 0 0 1 0 1 0 ) tens place ( 3 ) ones place ( 5 )

Ones place

Tens place

0

1

4

5

2

3

8

9

6

7

Bit 0

Bit 4 free magnet free magnet free magnet free magnet free magnet

Bit 1

Bit 5 free free magnet magnet free free magnet magnet free free

Bit 2

Bit 6 free free free free magnet magnet magnet magnet free free

Bit 3

Bit 7 free free free free free free free free magnet magnet

42

9

.09

Setting the bobbin thread stitch counter


● Call up the menu for entering the number of bobbin thread stitches.

Preparation

● Enter the number of stitches on the number block.

● Conclude the input.

After sewing the number of bobbin thread stitches, the machine stops automatically for changing the bobbin.


Clear (on number block)

This function sets the input value at "0".

Arrow keys


Esc


Clear (in foot text)

This function sets the bobbin thread counter (number of stitches sewn) at "0".

43

Preparation

9

.10

Changing the part set

The seam program, parts program and parts (folding set, pocket plates and sewing jig) must match and always be used together!

If the wrong combination of parts and seam program is used, the machine may be damaged seriously!

6

7

5

1

3

Fig. 9 - 06



● Call up "changing the part set" function.

4

2

44

● Loosen screws 1 and 2, and remove both sewing jig 3 and pocket plate 4.

● Insert a new pocket plate and a matching sewing jig.

● Tighten screws 1 and 2.

● Confi rm change of pocket plat and sewing jig.

Preparation

● Unscrew the compressed air supply 5.

● Loosen screw 6 and remove folder set 7.

● Insert the folder set which matches the pocket plate and the sewing jig, tighten screw 6 and screw the compressed air supply 5 back on.

● Conclude the part set change.

● Move to the basic position, the machine is ready for operation.

Select the matching program number to the part set!

Incorrect combinations can cause severe damage to the machine!

45

Preparation

9

.11

Loading the pre-cut parts

46

Fig. 9 - 07


● Place the pre-cut parts on the loading table or slide them onto the pocket plate and align them.

The insertion and alignment of the pre-cut parts depends on the selected menu combination, see Parameter 113 and 114 in Chapter 13.10.02.

Menu combination: "Basic position pocket plate front/plain-materialfabric on"

● Slide the pre-cut pocket part onto the pocket plate according to Fig. 9-07.

Menu combination: "Basic position pocket plate back/plain-fabric on"

● Actuate the loading function switch twice pocket plate moves forward.


Menu combination: "Basic position pocket plate front/plain-materialfabric off"


● Activate the inserting function switch - the pocket plate is lowered.

● Activate the inserting function switch to raise the pocket plate so that the trousers cutting can be aligned.

● Activate the inserting function switch to lower the pocket plate again.

Menu combination: "Basic position pocket plate back/plain-fabric off"

● Actuate the loading function switch to move the pocket plate forward.

● Slide the pocket cutting onto the pocket plate according to Fig. 9-07.

● Actuate the loading function switch twice: the pocket plate is lowered and raised slightly to allow positioning of the pre-cut trouser part.

Sewing

10 Sewing

The machine may only be operated by appropriately instructed personnel! The operating staff must make sure that only authorized persons are in the danger area of the machine!

In particular for the production, in addition to the input mode, see Chapter 11 Input, the sewing mode is available. Here, depending on the program selection and the machine status, all relevant functions and settings for the production are shown on the display. Automatic operation is standard, but it is possible to switch to manual operation when setting up and checking operating sequences.

Before production the following conditions must be fulfi lled:

● All safety devices must be attached and all covers closed see, Chapter 1.06 Danger warnings.

● The machine must be properly installed and commissioned in accordance with Chapter

8 Installation and commissioning.

● All setting-up work must have been carried out, see Chapter 9 Setting-up.

● Switch on the machine

● Select either automatic or manual sewing. The current operating mode is shown as an inverse symbol.

47

Sewing

10

.01

Automatic sewing mode


● Select the automatic sewing mode.

48

● Insert and align the pre-cut parts, see Chapter 9.11 Inserting the pre-cut parts.

● Start the program cycle with the double start keys, see Chapter 7.04 Double start keys.


Program number selection

This function opens the menu for entering the program number. The current program number is shown in the symbol together with the appropriate parts program number.

Standard stitch length

This function opens the menu for entering the standard stitch length. The current stitch length is shown in the symbol.

Maximum speed

This function opens the menu for entering the maximum speed. The current maximum speed is shown in the symbol.

Input menu

This function is used to call up the "input mode" see Chapter 11 Input.

Daily piece counter

Here the day number of pieces is indicated.

Automatic / manual sewing

This function is used to switch between automatic and manual sewing. The appropriate symbol of the current operating mode is shown respectively.

Bobbin thread stitch counter

This function opens the menu for entering and resetting the number of stitches for the bobbin thread, see Chapter 9.09 Setting the bobbin thread stitch counter.

Jig up/down

This function is used to raise or lower the jig.

10

.02

Sewing

Sewing foot up/down

This function is used to raise or lower the sewing foot. In addition the thread trapper is opened or closed.

Bobbin change

This function makes it possible to change the bobbin.

Stacker up/down

This function is used to open or close the stacker.

Basic position

This function is used to move the jig guide, sewing station and jig drive unit to the basic position.

Stop (only during the program cycle)

This function is used to stop the entire program cycle, see Chapter 10.04 Program interruption.

Manual sewing mode


● Call up the manual sewing mode.



This function opens the menu for entering the program number. The current program number is shown in the symbol together with the appropriate parts program number.



Maximum speed


Input menu


49

Sewing

Daily piece counter






Jig up/down


Sewing foot up/down


Stand height adjustment

This function opens a menu for adjusting the stand height (only when the machine is in its basic position).

Bobbin change


Stacker up/down


Sewing start

This function is used to start the sewing operation.

Basic position

This function is used to move the machine to the basic position.

Tacting backwards

This function is used to move backwards in sections in the seam pattern tact for tact. The seam cycle is sewn automatically, if the function is pressed longer.

Tacting forwards

This function is used to move forwards in sections in the seam pattern tact for tact. The seam cycle is sewn automatically, if the function is pressed longer.

Single step (after pressing the double start keys)

This function is used to move the folder and jig feed tact for tact.

50

10

.03

Sewing

Sewing with sequences

To sew with sequences, parameter "114" must be set at value "1", see Chapter

13.10.02 List of parameters.


● Select the desired sequence, see Chapter 9.06.01 Selecting a sequence.

● Insert the pre-cut parts.

● Start the program cycle by pressing the double start keys, see Chapter 7.04 Double start keys.



This function opens the menu for entering the program number. The current program number is shown in the symbol. If the function for moving automatically to the next sequence is activated, the sequence symbol is shown as inverse.



Maximum speed


Input menu


Individual program

This function depends on the setting of parameter "112" (moving automatically to next sequence), see Chapter 13.10.02 List of parameters.

If the function for moving automatically to the next sequence is activated (value "I", this) function is used to show the symbol for the next individual program to be sewn as inverse.

If the function for moving automatically to the next sequence is deactivated (value "0",) this function is used for the quick selection of the highlighted seam programs.

Daily piece counter


51

Sewing

10

.04





Jig up/down


Sewing foot up/down


Bobbin change


Stacker up/down


Basic position

This function is used to move the machine to the basic position.

Stop (only during the program cycle)

This function is used to stop the entire program cycle, see Chapter 10.04 Program interruption.

Program interruption

The program cycle can be interrupted by operating the „stop“ function on the control panel or by pressing the stop keys.

By pressing this button the folder goes in home position.

52

If the machine is stopped in this way, the sewing station and the folder are not in their basic position!

● Continue the program cycle by operating the appropriate function or

● Press the double start keys, see Chapter 7.04 Double start keys.

10

.05

Sewing

Error messages

If a malfunction occurs, an error code appears on the display. An error message may be caused by incorrect operation, machine defects, as well as by overload conditions.

(For a description of the error codes see Chapter 14.02 Description of the error codes).

Errors when connecting outputs

If an error occurs when connecting an output, the output concerned is shown with the desired switching state (0) or (I).

In this case (0) means the output should be disconnected and (I) means that the output should be connected.

In the next line the cause leading to the error is displayed.

The target state for maintaining undisturbed operation is shown in brackets.

In the following example the output Y1.1 is to be connected.

Requirement: E1.1 must be set at (1).

Pocket plate forwards

Pocket plate at front

Target state


Target state


● Check E1.1 and eliminate error.

● Acknowledge elimination of the error..

53

Input

11 Input

In addition to the functions for entering or editing seam programs, in the input mode there are functions for displaying information, for program management, for machine confi guration and settings (country settings and rights of access ), as well as for supporting service and adjustment work.

In the input mode the machine start function is blocked to avoid an unintentional start-up of the machine.

11

.01

Overview of the functions in the input mode




Conclude input

This function is used to conclude the input, and the machines changes to the sewing mode.

Seam program input

This function is used to call up the menu for entering or editing seam programs, see Chapter

11.02 Creating / editing seam programs.

Program management

This function is used to manage the data from the machine memory and CD-Card, see

Chapter 11.04 Program management.

Parameter settings

This function is used to call up the menu for altering parameter settings, see Chapter 13.10

Parameter settings.

54

Info

This function opens a menu for displaying the following information:

- current software status of the machine

- current fi rmware status of the machine

- current fi rmware status of the control panel

- day piece counter

- operating hours counter

- production hours counter

The day piece counter can be reset with the "Clear" function.

Input

Country settings

This function opens a menu for selecting the language shown on the control panel, see

Chapter 8.07 Selecting the language.

Rights of access

This function opens a menu for fi xing the rights of access, see Chapter 11.05 Rights of access.

Stepping motors / reference points

This function opens a menu for moving the stepping motors, and for moving to reference points with the "test" function.

Changing part set

This menu opens a menu for changing the part set, see Chapter 9.10 Changing part set.

Sewing motor

This function opens a menu for testing and adjusting the sewing motor, see Chapter 13.09

Sewing motor settings.

Service menu

This function is used to call up the menu for selecting various service functions, see Chapter

13.08 Service menu.

55

Input

11

.02

Creating / editing seam programs



● Call up the seam program input function.

● Lower the jig.

● Confi rm operation.

● Reinsert the desired program number or select the desired program.

● Confi rm the seam number selection.

56


Input menu

This function ends the programming operation and opens the basic input menu, see Chapter

11.01 Overview of the functions in the input mode.

Input

Conclude input

This function is used to conclude the input, and the machine changes into the sewing mode.

Mark block start

This function is used to defi ne the start of a block, see Chapter 11.02.01 Block functions.

Mark block end

This function is used to defi ne the end of a block, see Chapter 11.02.01 Block functions.

Block functions

This function opens a menu for entering block functions, see Chapter 11.02.01 Block functions.

Image functions

This function opens a menu for entering image functions, see Chapter 11.02.02 Image functions.

Coordinate reference points

This function is used to set the coordinates on the display at "0", in this way creating a new reference point.

Edit

After selecting this function, the current section can be edited.

Insert

This function is used to insert functions or blocks, see Chapter 11.02.03 Inserting functions.

Delete

This function is used to delete the current section.

Sewing foot up/down


Search

With this function the sewing head is raised and the carriage can be moved near the desired seam pattern point with appropriate direction symbols. After the position has been confi rmed, the machine moves towards the nearest point of the seam pattern.

Tacting forwards

This function is used to move forwards in sections in the seam pattern tact for tact. The seam cycle is sewn automatically, if the function is pressed longer.

Tacting backwards

This function is used to move backwards in sections in the seam pattern tact for tact. The seam cycle is sewn automatically, if the function is pressed longer.

57

Input

11

.02.01

Block functions




● Defi ne block start and block end

After a desired point in the program has been selected with the tacting through the program function, it is possible to defi ne the block start with the "mark block start" function.

The block marking must be concluded by defi ning a block end. To do so, tact through the program till reaching the desired point and then operate the "mark block end" function.

When tacking through the program, the marked block can be recognised by the inverse symbol of the section number.

● Call up the block functions.

58


Conclude input


Enlargement factor X-axis

This function is used to enlarge or reduce the block in the X-direction.

Enlargement factor Y-axis

This function is used to enlarge or reduce the block in the Y-direction.

Mirror

This function is used to mirror the block. Mirroring takes place on the straight line, which runs parallel to the Y-axis and through the block start point.

Turn

This function is used to turn the block. The block is turned around the block start point in an anti-clockwise direction.

Input

Shift block

After this function has been selected, a new point must be approached with the jig drive.

With the enter function, this point is taken over and the block shifted.

Delete

When this function is selected, the block is deleted.

Enter

Conclude the block function input and carry out block manipulation.

59

Input

11

.02.02

Image functions




● Call up image functions.

60


Conclude input


Enlargement factor X-axis

This function is used to enlarge or reduce the image in the X-direction. The operation is concluded by selecting the point of symmetry either with the number keys or with the control keys.

Enlargement factor Y-axis

This function is used to enlarge or reduce the image in the Y-direction. The operation is concluded by selecting the point of symmetry either with the number keys or with the control keys.

Mirror

This function is used to mirror the image. The operation is concluded by selecting the point of symmetry either with the number keys or with the control keys.

Turn

This function is used to turn the image. The image is turned in an anti-clockwise direction.

The operation is concluded by selecting the point of symmetry either with the number keys or with the control keys.

Shift image

After this function has been selected, a new point must be approached with the jig drive.

With the enter function, this point is taken over and the image is shifted from the current position to the end of the program.

Input

Point of symmetry using number keys

The point of symmetry is defi ned by entering the coordinates with number keys.

Point of symmetry using control keys

With this function the point of symmetry is approached (entered) by pressing the appropriate direction symbols.

61

Input

11

.02.03

Inserting functions




● Call up "insert" functions.

62


Conclude input (in status bar)


Straight line

A straight line is a direct connection between two points.

To enter a straight line, a stitch length must be defi ned.

Single stitch

A single stitch or feed motion is entered without taking the stitch length into consideration.

The single stitch or feed motion can be max. 6 mm.

Fast motion

The fast motion function is used for the quick motion of the jig drive. Both axes are moved independently from each other to the end point as quickly as possible. The resulting distance moved is therefore not a straight line (watch out for obstacles on the jig). If the path has to be exact, it is necessary to work with a straight line or curve without start sewing.

Curve check points

It is possible to enter any number of check points. The control unit calculates the course of the curve, taking the stitch length into consideration. Check points do not necessarily have to be end points. A stitch length must be defi ned. The greater the number of check points entered, the more exact the course of the curve.

Curve end

This function changes a curve check point into a curve end point.

Input

Circle

To enter a circle, three points are necessary. The fi rst point is automatically the starting points. The two missing points still have to be entered. A stitch length must be defi ned.

Circular arc

For the circular arc the same applies as for the circle, whereby the last point defi nes the end of the circular arc.

Start sewing

This function is used to start sewing. All following sections are sewn until the thread trimming function is selected.

or

Thread trimming

The thread is cut. The start sewing function must have been activated previously.


This function is used to defi ne the stitch length, which will be used predominantly in the program. During sewing the standard stitch will be displayed in the status bar and can be altered on the machine with the stitch alteration function, without changing into the programming mode.

Stitch length

A stitch length is defi ned for a certain seam sector.

This stitch length is not displayed in the status bar during sewing and can only be altered in the programming mode.

Stitch width

This function carries out a zig-zag motion with the jig drive on the base line. Here the stitch length indicates the feed motion along the base line from needle penetration to needle penetration and must be selected accordingly. The stitch width is carried out vertically to the base line. The position of the zig-zag to the base line must also be defi ned. If the stitch width function is to be switched off, the width must be entered as 0.0.

Other functions

This function is used for the selection of more functions, see Chapter 11.02.04 Other functions.

Insert block

This function is used to insert a marked block after the current position.

63

Input

11

.02.04

Other functions




● Call up "insert" functions.

● Call up other functions.

64


Conclude input (in status bar)


Programmable outputs

The corresponding outputs (1 to 2) are activated with the menu.

Secondary thread tension (depending on machine status)

This function is used to open or close the secondary thread tension.

Zig-zag seam (depending on machine status)

If sewing with a straight seam has been selected, this function is used to select sewing with zig-zag.

Straight seam (depending on machine status)

If sewing with zig-zag has been selected, this function is used to select sewing with a straight seam.

Wide variable sewing slit (depending on machine status)

If the narrow variable sewing slit has been selected, this function is used to select the wide variable sewing slit.

Narrow variable sewing slit (depending on machine status)

If the wide variable sewing slit has been selected, this function is used to select the narrow variable sewing slit.

Input

Wait for input (inputs 1 to 2)

The processing of the program is stopped until the appropriate input (1 to 2) has reached the selected level.

Wait for time

The processing of the program is stopped until the programmed time has elapsed.

Speed

A speed is entered permanently in the program.

Reduced speed (depending on machine status)

This function is used to sew at a reduced speed or to switch off the reduced speed.

Programmed stop

A stop is programmed in the program.

Processing is continued by calling up the "start" function.

Flap stop

This function is used to defi ne the fl ap stop. The fl ap program is processed from this point on.

Adjustment parameters

This function is used to adjust the activation or deactivation of various functions. The number of stitches is entered for activating or deactivating the corresponding function sooner or later.

Esc

Conclude input without taking over the inputs.

65

Input

11

.03

Seam programming example

The following example describes the seam program input. A drawing with the corresponding coordinate values serves as a programming guideline, see following illustration.

For the use of the seam program, the sewing jig and the corresponding part set must match.

122 mm

6,4 mm x+

Schablonennullpunkt y+ xy-

61 mm




● If necessary, enter appropriate code number.

66

● Lower jig.

● Confi rm operation.

● Enter desired program number (e.g. "115") to create a new seam program.

Input

● Confi rm program number selection

● Tact forwards.

● Call up section editing function.

● Enter jig code (e.g. "99").

● Confi rm input.

67

Input

● Tact forwards.

● Call up jig with obstacles with the "edit" function.

● Tact forwards.

68

● Call up the "Esc" function, to change the starting point.

Input

● Move to the starting point with the corresponding direction symbols.


● Call up the "insert" function.

● Call up the "start sewing" function

.

69

Input

● Call up the "standard stitch length" function.

● Enter the value for the standard stitch length, e.g. 3.40 mm.

● Confi rm input

.

● Call up the "straight line" function to insert a straight line.

● Move to the end point of the straight line with the corresponding direction symbols.

70


● Conclude straight line input.


Input

● Call up the "zig-zag seam" function.

● Call up the "stitch length" function.

● Enter the value for the stitch length, e.g. 0.23 mm.

● Confi rm input.




71

Input



● Call up "straight seam" function

.

● Call up "standard stitch length" function

.

72

Input




● Use the corresponding direction symbols to move to the next straight line end point.






73

Input

● Conclude the straight line input.


● Call up the "zig-zag seam" function

.

74

● Call up the "stitch length" function.

● Enter the value for the stitch length, e.g. 0.23 mm.

● Confi rm input.

Input






● Call up "straight seam" function.

● Switch on the thread trimming function.

75

Input

● Conclude the seam program input (function in status bar).

To be able to sew with the newly-created or edited seam program, the stitch generation must be carried out. Incomplete or incorrect programs also can be ended with the "Esc" function without stitch generation. In this case, when the seam program is called up in the sewing mode, an appropriate error message will appear.

● Carry out the stitch generation.

● Move to the basic position.

● After entering the appropriate program number, the created seam program can be selected and processed.

To begin with tact through a newly-created or corrected seam program on the machine, to make sure that it matches the jig!

76

11

.04

Input

Program management

The program management function is used to manage seam programs as well as confi guration and machine data. Files can be selected from the machine memory or from a SD-Card and be copied or deleted.



● Call up the program management function.

Both data carriers with the corresponding fi les appear on the display:

- Machine memory ("C:\DATEN\") is currently selected

- SD-Card ( ) is currently inserted

The data carrier is selected by touching the appropriate box, and the content of the appropriate data carrier is also updated. The selected drive is shown as a invers symbol, the selectet fi les are shown blue.

Seam programs are fi led at a different level to that for the confi guration and machine data, in order to avoid the confi guration and machine data being processed by mistake.

77

Input


Input mode

This function is used to change to the initial state of the input mode.

Update drives

This function is used to update (upload) the drives.

Conclude input

This function is used to conclude the input and change to the sewing mode.

Data selection

With these functions the desired fi les are marked in the current drive. Individual fi les are selected with the arrow keys. In combination with the lock key (*) several fi les can be selected at one time with the arrow keys.

Copy

This function is used to copy the fi les selected from the current data carrier onto the second data carrier.

Delete

This function is used to delete the selected fi les.

MDAD/KONF

This function is used to call up the level for the confi guration and machine data. The current settings and the machine confi guration are stored in the fi les "MDAT3588" and "KONF3588.

BIN". In this way the machine data can be copied on to a CD-Card as a backup, or several machines with the same designation can be confi gured quickly by reading in the machine data.

Format

This function is used to format the CD-Card inserted.

In the course of the formatting operation, all data on the CD-Card is deleted!

78

11

.05

Input

Rights of access

The functions, which can be selected on the control panel, are ordered by code numbers and can be protected from unauthorized access. For this purpose the control unit differentiates between three user groups (User 1, 2 and 3), which are all assigned a corresponding

PIN. If a function is selected, to which the user does not have access, the user is requested to enter a PIN. After the corresponding PIN has been entered, the selected function is executed. In addition to the 3 user groups, the control unit also recognises the so-called "super user". The super user is equipped with a key switch and has access to all functions, and is also authorised to defi ne the rights of access.

● Insert the key switch and switch on the machine.


● Call up the menu for entering rights of access.


Input mode

This function is used to change from the initial state to the input mode.

Conclude input


Enter PIN

With this function it is possible to defi ne an individual PIN for each user.

Function selection

This function is used to select the code number for the functions to be blocked or authorised.

Locking/releasing

These functions are used to lock or release the function for the appropriate user.

79

Input

Allocation of the code numbers

Function


Enter stitch length

Enter speed

Input

Create program

Program management

Parameter settings

Parameter group 100

General settings

Parameter group 200

Seam parameters

Parameter group 300

Sewing motor positions

Parameter group 400

Times

Parameter group 500

Counters

Parameter group 600

Info

Reset day piece counter

Reset bobbin thread stitch counter

Clear operating hours counter

Clear production hours counter

Country settings

Rights of access

Service

Carry out a cold start

Symbol

Code number

User 1

Standard setting

User 2 User 3

0

1

2

3

4

5

6

7

-

-

-

8

9

-

-

10

11

12

16

23

24

21

22

19

20

17

18

80

Function

Machine confi guration

Load software

Set contrast control panel

Thread trimming cycle

Needle position

Set zero points

Input

Symbol

Code number

Standard setting

User 1 User 2 User 3

25

26

27

28

29

30

81

12

12

.01

Care and maintenance

Care and maintenance intervals

Care and maintenance

Clean the entire machine ...........................................................................................weekly

Clean the hook compartment ................................................................. several times daily

Clean needle area ................................................................................... several times daily

Check oil level for sewing head lubrication ..................................................daily before use

Lubricate needle bar frame eccentric ..........................................................every 2 months

Lubricate jig guides ......................................................................................every 2 months

Lubricating the pocket plate guide ...............................................................every 2 months

Clean the blower air fi lter .................................................................................... as required

Check air pressure .......................................................................................daily before use

Clean air fi lter of the air fi lter/lubricator unit ........................................................ as required

These maintenance intervals are calculated for the average running time of a single-shift operation. If the machine is operated more often, shorter intervals are recommended.

83


12

.02

Cleaning the machine

The required cleaning cycle for the sewing machine is dependent on the following factors:

● Single or multi-shift operation

● Accumulation of dust from the various fabrics

Thus, appropriate cleaning instructions can only be determined on an individual basis for each machine.

1

1

Fig. 12 - 01

To avoid operation disturbances, we recommend the following cleaning work for a machine in single shift operation:

● Clean the hook compartment and the needle area of the sewing head several times daily.

● Clean the entire machine at least once a week.

Procedure:


● Call up manual sewing.

● Call up the "bobbin change" function.

● After cleaning press double start keys 1 at the same time.

84

12

.03

Cleaning the hook

1

3


5 mm

1

● Unscrew screws 1.

● Remove hook gib 2.

● Turn handwheel until the tip of the bobbin case 3 penetrates the hook race groove by approx. 5 mm.

● Remove the bobbin case 3.

● Clean the hook race.

● Reinsert bobbin case 3.

● Screw on hook gib 2.

● Press double-start keys.

Fig. 12 - 02

2

1

12

.04

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.

1

Fig. 12 - 03

85


12

.05

Checking/adjusting the air pressure

1

0.4

0.2

0

+ -

0.6

0.8

1

2

● Before operating the machine, always check the air pressure on gauge1.

● Gauge 1 must show a pressure of 6 bar.

● If necessary adjust to this reading.

● To do so, pull knob 2 upwards and turn it so that the gauge shows a pressure of

6 bar.

3

Fig. 12 - 06

Bar

4,5

5

6

Confi guration of the pressure controller:

● Turn screw 3 until the green arrow points to 4.5 bar.

The machine is automatically switched off if a pressure of < 4.5 bar is reached, and can be automatically reactivated, once pressure reaches a value > 5.0 bar.

134-010

MPa

= 0,45

= 0,5

= 0,6 psi

= 65

= 73

= 87

12

.06

Cleaning the air fi lter of the air-fi lter/lubricator

2

1

Fig. 12 - 07

0.4

0.2

0

+ -

0.6

0.8

1

Switch the machine off!

Disconnect the air hose at the air-fi lter/lubricator.

134-011

To drain water bowl 1:

● Water bowl 1 drains itself automatically when the compressed-air hose is disconnected from the air-fi lter/lubricator.

Cleaning fi lter 2:

● Unscrew water bowl 1.

● Take out fi lter 2.

● Clean fi lter 2 with compressed air or isopropyl alcohol (part No. 95-665 735-91).

● Screw in fi lter 2 and screw on water bowl 1.

86

12

.07


Checking the oil level of the sewing head lubrication

● The oil level in drum 1 must be checked daily before use of the machine.

● The oil level must be between the upper and lower markings of drum 1.

● When necessary, pour oil through hole 2.

2

Only use oil with a viscosity of

22.0 mm

2

/s at 40° C and a density of 0.865 g/cm 3 at 15°C!

1

● Before the machine is fi rst operated or whenever the machine has been at a standstill for a longer period of time, also add a few drops of oil to the hook race.

Fig. 12 - 06

We recommend PFAFF sewing-machine oil, part

No. 280-1-120 144.

12

.08

Lubricating the needle bar frame eccentric

1

2

Switch off the machine and ensure that it cannot be switched on accidentally!

Turn off compressed air!

Only use Isofl ex Topas L32, high-performance grease, part

No. 280-1-120 210.

● Unscrew the cover on the reverse side of the sewing head.

● Grease eccentric 1 via grease nipple 2 using a grease gun every 2 months for single-shift operation and monthly for double-shift operation.

● Screw on cover.

Fig. 12 - 07

87


12

.09

Lubricating sewing jig feed

3

1

2

Fig. 12 - 08



Only use Isofl ex Topas L32, high-performance grease, part No. 280-1-120 210.

● Unscrew the cover of the sewing jig feed.

● Grease the guides via grease nipple 1, 2 and 3 using a grease gun every 2 months for single-shift operation and monthly for double-shift operation.

● Screw on cover.

88

12

.10

Lubricating the pocket plate guide

1




Only use Isofl ex Topas L32, high-performance grease, part

No. 280-1-120 210.

● Grease the guide at grease nipple 1 using a grease gun every two months for single-shift operation and monthly for twoshift operation.

Fig. 12 - 09

89

Adjustment

13 Adjustment

Please observe all notes from Chapter 1 Safety!

In particular care must be taken to see that all protective devices are refi tted properly after adjustment, see Chapter 1.06 Danger warnings!

13

.01

Notes on adjustment

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.

Unless stated otherwise, during all adjustment work the machine must be disconnected from the electric and pneumatic power supply!

Danger of injury if the machine is started accidentally!

13

.02

Tools, gauges and other accessories for adjusting

● 1 set of screwdrivers with blade widths from 2 to 10 mm

● 1 set of wrenches with jaw widths from 6 to 22 mm

● 1 set of Allan keys from 1.5 to 6 mm

● 1 universal screwdriver with interchangeable blades

● 1 metal ruler

● 1 adjustment pin (zero point adjustment)

● 1 adjustment gauge (for adjustments to sewing head), part no. 61-775 913-15

● 1 adjustment gauge (for adjustments to sewing head), part no. 61-778 162-15

● 1 adjustment gauge (for adjustments to feed)

● 1 needle rise gauge, part no. 61-111 600-01

● 1 adjustable clamp, part no. 08-880 137 00

13

.03

Abbreviations t.d.c. = top dead centre b.d.c. = bottom dead centre

90

13

.04

Adjustment

Removing/inserting sewing head

Turn off compressed air!

Switch off main switch and ensure that it cannot be turned back on accidentally.

1

7

4

3

5

2

6

Fig. 13 - 01

● To remove the sewing head, remove the protective cover 1 (screws 2).

● Remove the cover plate 3 (screws 4; 6 screws altogether)

● Unplug pneumatic power supply 5 and electrical power supply 6.

● Unhook catch 7 and fold down sewing head.

● Remove V-belt from belt pulley on motor.

● Lift sewing head and remove from its bracket.

● Remove the ground cable of the sewing head.

● To insert the sewing head, carry out the steps above in reverse.

91

Adjustment

13

.05

Adjusting the sewing head

13

.05.01

Spacing between sewing head and bedplate

Requirement

When the sewing head is lowered, the distance from the lower edge of the shaft 1 to the bedplate must be 132.8 mm.

4

3

1

1

2

Fig. 13 - 02

● Check the distance between the shaft 1 and the bedplate using adjustment gauge 2

(part no. 61-775 913-15).

● If required, turn plunger 3 (nut 4) according to the requirement.

92

13

.05.02

Sewing head position in relation to the bedplate

Adjustment

Requirement

When the sewing head is lowered, after the screws 3 have been loosened, the presser bar 4 must pass exactly through the corresponding hole in the adjustment gauge 1.

3

3

4

1

5

4

2

1

5

Fig. 13 - 03

● Unscrew needle plate and screw on adjustment gauge 1 (part no. 61-778 162-15).

● Unscrew presser 2.

● Loosen screws 3 and guide presser bar 4 into the hole in the adjustment gauge 1.

● If required, move sewing head (screws 5) according to the requirement.

● Move presser bar 4 back to its original position and tighten screws 3 lightly.

Adjustment gauge 1 remains screwed on for further adjustments.

The precise adjustment of the presser bar 4 is described in chapter 13.05.21

Presser height.

93

Adjustment

13

.05.03

Upper and lower toothed belt guards

Requirement

The upper and lower toothed belt guards must be positioned as close as possible over the toothed belt sprockets without touching them.

2

1

1

4

3

Fig. 13 - 04

● Move the upper 1 (screw 2) and lower toothed belt guards 3 (screws 4) at the underside of the sewing head according to the requirement.

Carry out the adjustment carefully!

Otherwise, when the sewing head is raised up, the toothed belt could disengage!

94

Adjustment

13

.05.04

Counterweight

Requirement

In needle bar position BDC the largest eccentricity of the counterweight 1 must be at the top.

1 2

1

Fig. 13 - 05

● Move needle bar to BDC.

● Turn counterweight 1 (screws 2) according to the requirement.

95

Adjustment

13

.05.05

Preadjusting the needle height

Requirement

At needle bar position TDC, the distance between the needle point and the adjustment gauge must be approx. 22 mm.

2

1

22 mm

Fig. 13 - 06

● Move needle bar 1 (screws 2) without twisting it according to the requirement.

96

Adjustment

13

.05.06

Zero stitch

Requirement

When the cylinder plunger 1 is fully extended (straight stitch position), the crank 2 must not carry out any movement when the handwheel is turned.

4

2 3 1

Fig. 13 - 07

● Pull out cylinder plunger 1 fully.

● Turn crank 2 (screw 3) according to the requirement.

In order to better recognize the movement of the crank, insert an Allan key into screw 4.

97

Adjustment

13

.05.07

Centering the needle in the needle hole

Requirement

When the cylinder plunger 5 is fully extended (straight stitch position), adjustment pin 1 must fi t precisely into the corresponding adjustment hole of the adjustment gauge 8.

4

3

6

7

2

5

1

Fig. 13 - 08

● Insert adjustment pin 1 into the needle bar and screw tight.

● Loosen screws 2, 3 and 4.

● Pull out cylinder plunger 5 until it stops.

● Move needle bar frame 6 according to the requirement.

● Turn shaft 7 according to the requirement.

● Tighten screws 2, 3 and 4.

● Unscrew adjustment gauge 8 (part no. 61-778 162-15) and adjustment pin 1.

8

98

Adjustment

13

.05.08

Zigzag stitch movement

Requirement

When the needle is in TDC, the needle bar 1 must not carry out any movement when the lever 4 is operated.

1

2 3

4

Fig. 13 - 09

● Bring needle bar 1 to TDC.

● Turn eccentric 2 (screw 3), without twisting it, according to the requirement.

99

Adjustment

13

.05.09

Needle bar rise, hook-to-needle clearance, needle height and needle guard

Requirement

In straight stitch position and with the needle bar 2.4 past BDC,

1. the hook point must be at the middle of the needle; the distance between the needle and the hook point must be from 0.05 to 0.1 mm.

2. the top edge of the needle eye must be 1.0 mm below the hook point, and

3. the needle guard 4 must touch the needle lightly.

4

6

0,05 - 0,1 mm

7

3

1

2

2

Fig. 13 - 10

● Set the stitch length control to straight stitch position.

● Loosen the fastening screws of the bevel gear 1 and screws 2.

● Move the needle bar to BDC.

● In this position, slide the 2.4 mm thick feeler gauge of the needle bar rise gauge closely under the needle bar bearing.

● Move adjustable clamp (part no. 08-880 137 00) against feeler gauge as far as possible and screw it onto the needle bar.

● Remove the feeler gauge and turn the handwheel 3 in the direction of the arrow until the adjustable clamp is resting on the needle bar.

100

Adjustment

● Unscrew the hook gib and remove the bobbin case.

● Position the hook point at the center of the needle and move the hook bearing according to requirement 1. Make sure that the needle is not pressed against by the needle guard 4.

● Tighten screws 2.

● Taking the backlash of the toothed gear into account, tighten the fastening screws of the bevel gear 1.

● If required, move the needle bar (screw 5) without twisting it according to requirement

2.

● Turn eccentric 6 (screw 7) according to requirement 3.

● Insert bobbin case and screw on hook gib.

101

Adjustment

13

.05.10

Bobbin case opener stroke

Requirement

1. The front edges of the retaining spring 1 and the retaining trip 7 must be fl ush with each other.

2. When the bobbin case opener 5 is at its rear point of reversal, the distance between the bobbin case base 6 and the retaining spring 1 must be equal to the thread thickness.

4

3

5

1

1

7

2

6 thread thic kness

6

Fig. 13 - 11

● Align the retaining spring 1 (screw 2) according to requirement 2.

● Move shaft 3 (screw 4) according to requirement 1.

102

Adjustment

13

.05.11

Counter presser lifting stroke

Requirement

At needle bar position BDC, the counter presser 3 must be positioned at its top point of reversal.

1

2

2

Fig. 13 - 12

● Move needle bar to BDC.

● Turn eccentric 1 (screws 2) according to the requirement.

3

103

Adjustment

13

.05.12

Counter presser height

Requirement

When the needle bar is at BDC, the top edge of the counter presser 6 must be 1 mm over the closed hook compartment cover 3.

104

3

6

Fig. 13 - 13

● Position lever 1 (nut 2) at its lower stop (see arrow).

● Fit hook compartment cover 3 and turn bracket 4 (screw 5) according to the requirement.

Adjustment

13

.05.13

Counter presser position

Requirement

In straight stitch position, when the needle penetrates, it must be centered in the needle hole of the counter presser 2.

2

3

2

3

Fig. 13 - 14

● Pull out plunger 1 until it stops (straight stitch position).

● Adjust the counter presser 2 (screws 3) according to the requirement.

1

105

Adjustment

13

.05.14

Zigzag stitch width

Requirement

At the maximum zigzag stitch width, the needle must not strike against the edge of the counter presser.

1

2

Fig. 13 - 15

● Turn screw 1 (nut 2) according to the requirement.

By turning screw 1, the bartack width can be adjusted.

106

Adjustment

13

.05.15

Resting position of the roller lever / radial position of the control cam

Requirement

1. When the plunger 1 is retracted, there must be a distance of 0.1 mm between the outer edge of the control cam 6 and the roller of the roller lever 5.

2. When the thread trimmer is switched on beforehand, the control cam 6 must have just brought the roller lever 5, in TDC take-up lever, to its resting position.

7

6

3

4

0,1 mm

4

2

5

1

8

6

5

9

Fig. 13 - 16

● Retract the plunger 1 in cylinder 2 until it stops.

● Move the cylinder carrier 3 (screws 4) according to requirement 1.

● Bring the take-up lever to BDC and push the roller lever 5 into the control cam 6 by hand.

● By turning the handwheel 7 in the direction of the arrow, bring the take-up lever to TDC and check requirement 2.

● If required, turn the control cam 6 (screws 8) according to requirement 2.

On plunger 1, the thread should be approx. 1 mm above the lock nut 9.

107

Adjustment

13

.05.16

Thread catcher height

Requirement

The lower edge of the thread catcher 3 must be positioned at a distance of 0.8 mm above the bobbin case 4.

3

4

2

6

1

7

8

3

108

4

5

Fig. 13 - 17

● Loosen screws 1 and 2.

● Position the thread catcher 3 above the bobbin case 4.

● Move the thread catcher 3 (screw 5) according to the requirement.

● Determine the vertical play of shaft 6, move retaining collar 7 against bearing housing 8 and tighten screw 2.

Screw 1 remains slightly unscrewed for further adjustments.

Adjustment

13

.05.17

Thread catcher position and knife height

Requirement

When the thread trimmer is in resting position,

1. the front edges of the thread catcher 3 and the knife 5 must be fl ush with each other.

2. the upper edges of the thread catcher 3 and the knife 5 must be even.

3

5

6

6

5

2

1

4

Fig. 13 - 18

● Bring the needle bar to BDC.

● Move roller lever 1 against control cam 2 by hand.

● Turn the thread catcher 3 according to requirement 1.

● Tighten screw 4.

● Check the knife height according to requirement 2.

To adjust the height, disassemble knife 5 (screws 6) and insert shim

(part no. 91-141 402-05) according to the requirement.

To align the knife see chapter 13.05.18 Knife pressure.

109

Adjustment

13

.05.18

Knife pressure

Requirement

When the point of the thread catcher 4 is 6 mm in front of the front edge of the knife 4, the cutting edge of the knife must lightly press against the thread catcher 4.

6

6

4

5

6 mm

3

2

1

Fig. 13 - 19

● Bring the take-up lever to BDC.

● Press the roller lever 1 into the control cam 2.

● Turn the handwheel 3 in the direction of the arrow until the thread catcher 4 is approx. 4 mm in front of the knife 4.

● Move the knife 5 (screws 6) according to the requirement.

● Check requirement 1 from chapter 13.05.17 Thread catcher position and knife height.

110

13

.05.19

Bobbin thread clamp spring

Requirement

The clamp spring 1 must

1. not be pressed down during the movement of the thread catcher.

2. clamp the bobbin thread reliably after it is cut

3. not obstruct insertion and removal of the bobbin case.

Adjustment

1

3

2

2

Fig. 13 - 20

● Bring the thread trimmer to resting position.

● Move the clamp spring 1 (screws 2) so that the clamp lips are as close as possible to the inside wall and to the front edge of the thread catcher 3.

● Adjust the height by bending the clamp spring 1 so that between the upper side of clamp spring 1 and the lower side of the thread catcher 3 there is a distance of approx. 0.1 mm.

111

Adjustment

13

.05.20

Manual cutting test

Requirement

1. When it is moving forward, the thread catcher 1 must not push along the bobbin thread 3 in front of it.

2. At the front point of reversal of the thread catcher 1, the bobbin thread 3 must lie approx. 2 mm behind the lug of the thread catcher 1.

3. At the end of the cutting operation, the needle and bobbin threads must be cut perfectly. The bobbin thread 3 must be clamped.

2

1

3

1

2 mm

3

112

Fig. 13 - 21

● Carry out the cutting operation manually.

● Check requirement 1. If necessary, readjust the thread catcher 1 according to chapter

13.05.16 Thread catcher height.

● Check requirement 2. If necessary, readjust the thread catcher 1 according to chapter

13.05.17 Thread catcher position and knife height.

● Check requirement 3. If necessary, readjust the bobbin thread clamp spring 2 according to chapter 13.05.19 Bobbin thread clamp spring.

Adjustment

13

.05.21

Presser height

Requirement

1. When the take-up lever is at TDC, the needle point must not extend under the presser 1 when the presser 1 is raised.

2. The presser 1 must be aligned laterally so that the sewing thread is blown out from under the presser 1 when the sewing jig is moved into position.

2

4

4

1

1

3

1

Fig. 13 - 22

● Screw on presser 1.

● Bring the take-up lever 2 to TDC.

● Move the presser bar 3 (screws 4) according to requirement 1 and/or turn according to requirement 2.

113

Adjustment

13

.05.22

Bobbin winder

Requirement

1. When the bobbin winder is switched on, the bobbin winder spindle must move securely with the winder.

2. When the bobbin winder is switched off, friction wheel 5 must not be driven by drive wheel 1.

3. The bobbin winder must switch off automatically when the bobbin has been fi lled approx. 1 mm from the edge.

2

1 5

114

4

3

Fig. 13 - 23

● Move drive wheel 1 (screws 2) according to requirements 1 and 2.

● Move pin 3 (screw 4) according to requirement 3.

13

.05.23

Needle thread tension release

Adjustment

Requirement

For the tension release, the distance between the tension disks must be 0.5 mm.

0,5 mm

Fig. 13 - 24


2

1

115

Adjustment

13

.05.24

Thread check spring and slack thread regulator

Requirement

1. The stroke of thread check spring 7 must be completed when the needle point penetrates the material (travel of the spring approx. 7 mm).

2. When the thread loop is at its largest when going round the hook, the thread check spring 7 must be lifted slightly above support 1.

6

1

7

3

2

5

116

Fig. 13 -25

● Position rest 1 (screw 2) according to Requirement 1.

● To adjust the spring tension, turn screw 3 (screw 4).

● Position thread regulator 5 (screw 6 ) according to Requirement 2.

For technical reasons, it may be necessary to deviate from the travel of the spring and/or the spring tension indicated here.

13

.05.25

Sewing head lifting cylinder

Requirement

The up and down movement of the sewing head must be uniform.

Adjustment

4

6

2

Fig. 13 - 26

● Insert the sewing head and connect. (See chapter 13.04 Removing/inserting sewing head).

● Adjust the speed (screw 1) and shock absorbing action (screw 2) of the upwards movement of the sewing head, and the speed (screw 3) and shock absorbing action (screw 4) of the downwards movement of the sewing head according to the requirement.

The pressure for the downward movement can be regulated with screw 5

(standard setting 4.5 bar).

When adjusting the shock absorbing action, make sure that the cylinder 6 moves as far as it can go especially for the downward movement of the sewing head!

117

1

3

5

Adjustment

13

.05.26

Hook lubrication

Requirement

When the machine is running, after approx. 10 seconds a fi ne line of oil must form on a paper strip 2 held next to the hook.

1

3

4

2

118

Fig. 13 - 27

● Unscrew the hook compartment cover.

● Remove the cover from sensor 1 with metal gauge.



● Call up the "sewing motor adjustment" function, see Chapter 13.09 Sewing motor adjustments.

● Set the speed at 2000 min

-1 .

When the sewing motor is running, do not reach into the needle area!

Danger of injury by the moving parts!

Adjustment

● Run the sewing motor for 2 – 3 minutes.

● With the motor running, hold a strip of paper 2 next to the hook and check the requirement.

● If necessary, adjust the oil supply with screw 3.

● Switch the machine off and screw on the hook compartment cover.

The wick used for lubricating the front parts must always be impregnated with oil. However, oil must not drip onto the bedplate!

● If necessary, regulate the amount of oil with screw 4.

119

Adjustment

13

.06

Adjusting the folding, feed and stacker devices

13

.06.01

Aligning the sewing jig

Requirement

The lowered sewing jig must lie evenly and lightly on the table top at both the folding and the sewing stations, and hold the workpiece securely.

4

Y

5 5

1

X

X

Y

2

3

Fig. 13 - 28

● Loosen screws 1 on both sides of the machine.

● Align the sewing jig by turning screws 2 (nuts 3) on both sides of the machine so that it is parallel to the table top in the x-direction.


● Align the sewing jig by moving the carrier 4 (screws 5 on both sides of the machine) so that it is parallel to the table top in the y-direction.

120

13

.06.02

Height of the pocket plate guide

Requirement

The lowered pocket plate must be parallel to the top edge of the table.

Adjustment

2

3

5

4

1 1

6

Fig. 13 - 29

● Check the requirement using a metal ruler.


● Adjust the height of the guide 3 with screw 4 (nut 5) according to the requirement.

● Turn the plunger (lock nut) of cylinder 6 until the guide 3 is parallel to the table top.

● Tighten screws 1 and 2.

121

Adjustment

13

.06.03

Aligning the pocket plate arm

Requirement

The lowered pocket plate 4 should be resting evenly on the table top.

122

1

3

1

3

2

2

Fig. 13 - 30

● Loosen screws 1.

● Turn screws 2 (nuts 3) according to the requirement.


Re-check the height of the pocket plate Chap. 13.06.02.

13

.06.04

Aligning the pocket plate guide

Adjustment

Requirement

Guide 7 must be positioned perpendicular to guide 8 of the sewing jig feed.

90°

8

7

2

1

1

Fig. 13 - 31


● Bring the machine into the basic position.

● Taschenblech entnehmen und Taschenblech-Lehre 1 einsetzen.

● Call up "folder position", see Chapter 8.09 Checking / adjusting the zero points.

● Mittels Absteckstift 2 die Regel überprüfen.

● Druckluft abnehmen.

123

Adjustment

90°

8

7

4

4

6

5

1

Fig. 13 - 32

● Slide pocket plate gauge 1 to the back and mark front position.



3

3

1

2

124

Adjustment

13

.06.05

Front pocket plate position

Requirement

When the folder is positioned at zero point, the adjustment holes of the pocket plate and the sewing jig must be aligned.

2

1

3

3

Fig. 13 - 33


● Bring the machine into the basic position.

● Remove the pocket plate and insert the pocket plate gauge 1.

● Call up "folder position", see Chapter 8.09 Checking / adjusting the zero points.

● Set the value for the y-axis to „0".

● Check the requirement using the adjustment pin 1.

● Change the value for the x-axis according to the requirement via the control panel and store.

● Move the pocket plate arm 2 (screws 3) according to the requirement.

125

Adjustment

13

.06.06

Monitoring the sewing jig feed

Requirement

1. It should not be possible to move sewing jig 5 beyond its zero point in y-direction, and not more than 5 mm down or more than the value of measurement x up.

2. Initiator 3 should be positioned 0.2 mm below cam switch 1.

PFAFF 3588-05/020: X = 260 mm

PFAFF 3588-15/020: X = 290 mm

2

2

1

4

4

3 x

0

5 mm

5

Fig. 13 - 34

● Move the switch vane 1 (screws 2) according to requirement 1.

● Move the proximity switch 3 (screw 4) according to requirement 2.

126

Adjustment

13

.06.07

Positioning the edge folding unit

Requirement

When the edge folding unit and pocket plate are lowered

1. Folder arm 4 must be parallel with pocket plate arm 3 and the table top.

2. The pins in folder arm 4 and the bushes 2 in pocket plate gauge 1 must be aligned, and

3. there must be a clearance of 19 mm between folder arm 4 and pocket plate gauge.

4. The folder arm must rest lightly on the table top and hold the workpiece securely.

4

2 2

3 4

1

Fig. 13 - 35

● Remove pocket plate and edge folder

● Insert pocket plate gauge 1 and bushes 2.


● Call up manual sewing.

● Press the double start buttons.

● Operate the "single step" function, until pocket plate arm 3 and folder arm 4 have been lowered.

● Loosen screw 5.

127

Adjustment

2

4

2

1

3 4

6

5

5

5

5

6

8

7

Fig. 13 - 36

● Carry out the adjustment in accordance with requirements 1 and 2 by twisting and moving folder arm 4 and by twisting screws 6.


● Turn shock absorber 7 (nut 8) according to requirement 3.

● Remove pocket plate gauge 1 and fi t the folding unit.

● Apply Tesamoll (adhesive tape) to the edge folder frame to fulfi l requirement 4.

128

Adjustment

13

.06.08

Aligning the die

Requirement

When the folder is lowered and the pocket plate is raised at the same time,

1. the bottom edges of the die’s 1 strips must be at a distance of approx. the thickness of the fabric under the underside of the pocket plate.

2. and they must be positioned on all sides at the same distance of 0.3 to 1 mm (depending on the fabric) to the pocket plate edges.

4

4

4

3

3

2

3

2

2

1

Fig. 13 - 37

● Align the bottom edges of the die’s 1 strips with the underside of the pocket plate via screws 2 (nuts 3).

● Turn damper 9 (nut 10) - see Fig. 13-37 - according to requirement 1.

● Align die 1 (screws 4) according to requirement 2.

129

Adjustment

13

.06.09

Control sequence of the folder plates

Pocket style

1. Switching position



4. Switching position a + b c + d e f + g a + b c + d + e f g + h a + b c + d e f a + b c + d + e f g a + b c + d e f + g

130

Fig. 13 - 38

The control sequence and the number of folder plates (and the number of switching positions) depends on the pocket style. The folder installation shown in

Fig. 13-38 is for the third pocket style.

For other pocket styles, refer to the above table for the cylinders corresponding to the relevant switching positions.

Adjustment

13

.06.10

Position of folder plates

Requirement

1. The front edges of the folder plates 1 must be parallel to the die 4.

2. In the initial position, the folder plates 1 must be positioned on all sides approx.

0.1 mm under the lower edges of the strips of the die 4.

2

2

4

3

3

3

1

1

3

3

1

3

3

1

3

1

2

2

2

2

2

2

Fig. 13 - 39

● Remove the folder.

● Align folder plate 1 (screws 2) according to requirement 1.

● Insert the folder plates 1 one after another according to the control sequence (see chapter 13.06.09 Control sequence of the folder plates) and align according to requirement

2 (screws 3).

● Remount the folder.

131

Adjustment

13

.06.11

Position of corner folders

Requirement

1. In folder position, the corner folders 4 must be parallel under the slanted side of the folder plate and overlap by 1 to 2 mm.

2. The corner folders 4 must be positioned 1 to 2 mm under the folder plates depending on the fabric thickness.

5

3

4

1 - 2 mm

5

4

1

2

5

4

4

132

Fig. 13 - 40

● Preadjust the clamps 1 (screws 2) according to requirement 1.

● For the fi nal adjustment, turn stop screws 3 according to requirement 1.

● Adjust the corner folders 4 (screws 5) according to requirement 2.

13

.06.12

Aligning the seam in relation to the pocket

Requirement

The seam is to be at the same distance on all sides to the pocket edge.

Adjustment

Fig. 13 - 41


● Using parameters "608" and "609" adjust the seam in accordance with the requirement, see Chapter 13.10 Parameter settings.

● Switch off the machine.

133

Adjustment

13

.06.13

Seam backtack distance

Requirement

The distance between the seam backtack and the pocket opening is to be approx. 1 mm.

1

2

2

2

2

1

Fig. 13 - 42

● Adjust stops 1 (screws 2) on the pocket plate according to the requirement.

134

Adjustment

13

.06.14

Stacking device

Requirement

When it is in operating position, the stacking device 2 must hold the workpiece with the least amount of pressure possible.

4

2

0

6

8

100

150

10

50

0

200

250

1

12

14

1

2

Fig. 13 - 43

● Adjust the pressure at pressure reducing valve 1 according to the requirement.

To carry out the adjustments, the outputs Y 52 and Y 51 must be switched, see

Kapitel 13.08 Servicemenu.

135

Adjustment

13

.06.15

Aligning the feed rollers

Requirement

The lowered feed follers 4 must rest lightly and evenly on the table top, and be positioned parallel to the front edge of the table.

4

4

1

2

1

3

1

2

1

Fig. 13 - 44

● Turn screws 1 (loosen screws 2 slightly) and the plunger of the cylinder 3 according to the requirement.

136

13

.07

Shaping folder plates

13

.07.01

New installation / self-manufacture of folder plates

Adjustment

c g e

2 f h d c

3 e f d c

1, 4 d c

5 d f

30°

30° g f g e e

Fig. 13 - 45

● Make and/or install the folder plates according to Fig. 13-45.

When newly installing or making the folder plates, make sure that they lie behind the corners of the pocket plate by at least the amount of the fabric thickness on the marked spots.

For the fi fth pocket style, the folder plates e, f and g must be additionally slanted by 30°.

137

Adjustment

13

.07.02

Slanting the lateral folder plates

Do not begin with this work process until the adjustments in chapters 13.06.12

Aligning the seam in relation to the pocket and 13.06.13 Seam backtack distance have been carried out!

1 - 2 mm

30°

1 1

1 - 2 mm

30°

138

2

Fig. 13 - 46

● With the folder plates fully extended, transfer the front edges of the stops 1 and the outer edge of the pocket plate 2 to the lateral folder plate.

● Trace slanted edge of 30°.

● Work the folder plate up to 1 - 2 mm before the trace.

● Round off the edges of the folder plate and polish.

13

.08

Adjustment

Service menu

The status of the digital and analog inputs is displayed in the service menu. The outputs can be set or reset manually. In addition it is also possible to call up functions for carrying out a cold start, for loading the operating program and for setting the control panel.



● Call up the service menu.

Explanation of the functions

Input mode


Conclude input

This function is used to conclude the input and change into the sewing mode.

Can-nodes

This function is used to select the required Can-node. The currently selected Can-node is shown as an inverse symbol.

Special outputs

This function is used to set or reset special outputs.

Plus/minus keys

These functions are used to set (+) or reset (-) the selected output.

Arrow keys

These functions are used to select the desired outputs.

Cold start

This function is used to carry out a cold start, see Chapter 13.08.01 Cold start.

Loading the operating program

This function is used to load the machine operating program, see Chapter 13.08.02 Loading/ updating the operating program.

139

Adjustment

Control panel settings

This function is used to call up a menu for changing the display contrast and for switching the key tone on or off, see Chapter 8.08 Setting the control panel.

Adjusting the zero points

This function is used to call up a menu for setting the zero points, see Chapter 8.09 Adjusting the zero points.

13

.08.01

Coldstart

When a cold start is carried out, all newly created or edited programs, as well as all altered parameter settings are deleted!

The machine memory is deleted or set back to the status at the time of delivery.

● Switch on the machine and call up the input mode.

● Call up the service menu.

● Call up the cold start function.

140

● Confi rm that a cold start is to be carried out.

Explanation of further functions

Input mode


Service menu

This function is used to return to the service menu, see Chapter 13.08 Service menu.

Conclude input

This function is used to conclude the input and change into the sewing mode.

Esc

The input is interrupted.

Adjustment

13

.08.02

Loading / updating the operating program

To boot a new machine software, a sd-card with the needed fi les has to be plugged in the sd-slot of the control panel.

During the loading of the operating program all data in the machine memory is deleted!

● Switch on the machine and push the button "FORCE UPDATE".

● Start the bootsequence with the key "ENTER".

Install update 79-001 103-80/003 for the machine KL3588?

Installing the update, Please wait....

- COPYING 3588.EXE FROM SD-CARD

TO C:\UPDATE\3588.EXE

● To install the software, push the key "NEXT".

Update successfully copied.

Press NEXT to install the update in control box and start the application

141

Adjustment

13

.09

Sewing motor adjustments



● Call up the "sewing motor adjustments".


Conclude input


Speed adjustment

This function is used to increase or reduce the set speed.

Start

This function is used to start the motor running.

Stop

This function is used to stop the motor running.

Thread trimming cycle

This function is used to run the thread trimming cycle.

Needle position

The present set position of the needle is displayed.

To adjust the needle bar position to t.d.c., bring the needle bar into the appropriate position by turning the balance wheel, and then operate the "POS" function to take over this position.

142

13

.10

Adjustment

Parameter settings

All parameters, which can be altered, are shown in the list of parameters, see Chapter

13.10.02 List of parameters. A description of how to select parameters and alter the values is given below.

13

.10.01

Selecting and altering parameters.

● Switch on the machine and call up the input mode.


● Select the parameter separately by group (hundred fi gure) and parameter within the function group.

● Alter the value of the selected parameter.

● Quit parameter input function.

143

Adjustment

13

.10.02

List of parameters

100 101 Bobbin thread monitor

(0 = off; 1 = counter; 2 = sensor; 3 = sensor +stop)

102 Needle thread monitor

(0 = off; 1 = on)

103 Fade-out stitches needle thread monitor. The number of stitches, during which the needle thread monitor is not activated during sewing, is changed.

104 Fade-out stitches bobbin thread monitor. The number of stitches, during which the bobbin thread monitor is not activated during sewing, is changed.

105 Reaction time needle thread monitor. The sensitivity of the needle thread monitor is altered (1 = quickest reaction, max. sensitivity)

106 Retracing stitches

The number of stitches which are automatically retraced after a needle thread error, is changed.

107 Sewing

(0 = off; 1 = on)

108 Jig monitoring

(0 = off; 1 = on)

109 Intermediate stop

0 = off;

1 = 1st stop after folder lowered;

2 = 2nd stop after folding operation;

3 = 1st and 2nd stop

Press the double start keys to continue operation.

110 Alternate folding

(0 = off; 1 = on)

111 Continuous carriage feed

(0 = off; 1 = on)

112 Automatic switching to next sequence

(0 = off; 1 = on)

0 - 3

0 -1

0 – 99

0 – 99

1 - 9

0 - 99

0 - 1

0 - 1

0 - 3

0 - 1

0 - 1

0 - 1

1

1

5

5

1

15

1

0

0

0

0

1

144

Adjustment

100

113 Uni-material

This parameter changes the function of the loading switch

0 = reverse suction air and ventilate pocket plate

1 = reverse suction air

2 = reverse ventilation pocket plate, 1st position: ventilated

3 = reverse ventilation pocket plate, 1st position: down

114 Basic position pocket plate

0 = forwards; 1 = back

115 Slide confi guration

Y9 = value 8

Y8 = value 4

Y7 = value 2

Y6 = value 1

Calculate sum of valves to be switched.(e.g.: Switch valves Y9 and Y7 -> 8 + 2 = 10)

116 Slide confi guration Program station 1

Y9 = value 8

Y8 = value 4

Y7 = value 2

Y6 = value 1

Calculate sum of valves to be switched.

(e.g.: Switch valves Y8 and Y6 -> 4 + 1 = 5)


Y9 = value 8

Y8 = value 4

Y7 = value 2

Y6 = value 1


(e.g.: Switch valves Y9 and Y6 -> 8 + 1= 9)


Y9 = value 8

Y8 = value 4

Y7 = value 2

Y6 = value 1



0 - 3

0 - 1

0 - 15

0 - 15

0 - 15

0 - 15

0

0

15

15

15

15

145

Adjustment

146

100


Y9 = value 8

Y8 = value 4

Y7 = value 2

Y6 = value 1



120 Tilt sewing head

0 = off; 1 = on

121 Folding version

0 = standard

1 = version 1 (only pre-cut part is moved to sewing station)

2 = version 2 (pre-cut part and pocket are moved to sewing station without folding)

3 = version 3, pre-folded pockets

4 = version 4, as standard but for round pockets

122 Jig version

0 = standard

1 = fl ap version 1 (fl ap completed)

2 = fl ap version 2 (fl ap open)

3 = variable sewing slit

4 = cargo

123 Stop in case of undervoltage

0 = off; 1 = on

124 Reverse needle positioning

0 = off; 1 = on

200 201 Tilting sewing head

0 = not fi tted; 1 = fi tted

202 Hook

0 = horizontal hook; 1 = vertical hook

203 Jig monitor


204 Height adjustment


205 Cargo unit


209

Machine typ

0 = Standard (with P200 and QE5542)

1 = Standard (with MMC 1002 and QE5540)

0 - 15 15

0 - 1

0 - 4

0 - 4 0

0 - 1

0 -1

0 -1

0 - 1

0 - 1

0 - 1

0 - 1

0 - 1

0

0

0

0

1

0

0

0

0

Adjustment

300

301 NIS (carriage start) [°], see Chap. 13.10.03

302 Take-up lever tdc [°]

303 Thread trimming on [° ]

Point at which impulse for thread trimming is given to thread trimming valve is changed (° = degrees after tdc needle bar).

305 Thread trimming off [° ]

400

500

306

401

501

Open thread tension

Time for label clamp closed [0.01 s]

Reduced speed

80 – 150

70 – 90

110

75

160 – 360 200

Parameter

303 / 302

5 - 20

10 – 256

345

15

20

200 – 4000 3600

502 Cutting speed (positioning speed)

503 Speed for slow start stitches

504 Slow start stitches

Number of stitches, which are to be sewn at reduced speed when sewing starts, is changed

505 Delay stitches zig-zag on

This parameter is used to enter the number of stitches after which the "zig-zag on" command is given later, see Chapter 13.10.04 Delay zig-zag on/off

506 Delay stitches zig-zag off

This parameter is used to enter the number of stitches after which the "zig-zag off" command is given later, see Chapter 13.10.04 Delay zig-zag on/off

600

601 Direction of slow rolling stacker

0 = backwards: 1 = forwards

602 Slow rolling time stacker [0.01 s]

This parameter is used to enter the time for the slow rolling motion of the stacker roller, see Chapter

13.10.05 Stacker rolling time

50 - 250

200 - 700

0 – 99

0 - 99

0 - 99

0 - 1

0 - 999

200

700

2

3

3

1

50

603 Quick rolling time stacker [0.01 s]

This parameter is used to enter the time for the quick rolling motion of the stacker roller, see Chapter

13.10.05 Stacker rolling time

0 - 999 35

147

Adjustment

600 604 Delay time for stacker frame back [0.01s]

The parameter is used to enter the delay time between stacker roller roll slowly and stacker frame back.

605 Time for folder slide back [0.01s]

The parameter is used to enter the delay time for the folder slide.The time should be set so that the folder does not move up until the folder plate is in its rear end position.

606 Time for pocket plate open [0.01s]

The parameter is used to enter the delay time between pocket plate back and pocket plate open. If the time selected is 0.00 s, the pocket plate opens when the end switch pocket plate back (E1.2) is activated.

607 Speed feed unit [%]

The parameter is used to enter the speed of the sewing jig feed unit from the folding to the sewing station.

608 Seam correction X [0.01 mm]

This parameter is used to change the position of the seam on the pocket in x-direction.

609 Seam correction Y [0.01 mm]

This parameter is used to change the position of the seam on the pocket in y-direction.

610 Stacker cycle

0 = standard

1 = short part

2 = off (basic position retracted)

3 = off (basic position extended)

0 - 999

0 - 999

0 - 999

20 - 100

-20 - +20

-20 - +20

0 - 3

0

30

50

100

0

0

0

148

13

.10.03

Carriage start

(NIS)

This function changes the time for starting the motors of the jig drive

(º = degree after t.d.c. needle bar).

Adjustment

Needle at t.d.c.

0°

Needle leaves the material, carriage start at approx. 270°

Needle pierces the material, carriage stops, command for carriage start is given at approx. 110°

Needle in material, continuous area of

180°

The command for the carriage start is given when the needle pierces the material. The carriage, however, starts half a revolution later (180º), when the needle leaves the material.

Under certain circumstances the stitch formation can be infl uenced by the setting.

149

Adjustment

13

.10.04

Zig-zag delay on/off

Due to the delay of the valve and cylinder, output of the commands for DELAY

ZIGZAG ON and OFF must be delayed as a function of the speed.

Zick-Zack on

Zick-Zack off

Delay correct

Delay too short, increase stitch count

Delay too long, decrease stitch count

Fig. 13 - 47

Delay correct

Fig. 13 - 48

Delay too short, increase stitch count

Delay too long, decrease stitch count

13

.10.05

Stacker rolling time stacker frame workpiece slow rolling time, correct rolling direction

Fig. 13 - 49 slow rolling time, change rolling direction if necessary

150

14 Control

14

.01

Basic setting / Diagnosis / Pin assignment

14

.01.01

Basic control unit A20

Control unit

In the factory, the basic control unit is equipped with the necessary operating and ramp software. This may only be replaced by appropriately trained personnel.

Pin locations

Key for booting the software

X5, SM-axis 1

X6, SM-axis 2

X7, SM-axis 3

X11, Main drive

Index

Thread monitor

5 V CPU,

Si 2A/T

24 V, max. 5 A

Periphery, Si,3 A/T

Mains connection

X4, Com2

X3, Com1

X8 CAN-Bus

1

8 V/AC, Si 0,5 A/T

Network, Si 1.25 A/T

151

Control unit

Operation indicators/Voltage supply

LEDs for various operating voltages are provided on top of the device (see sticker on the device).

These LEDs are for + 12V, + 15.1V and + 24V.

Fuses

2,0 AT / 5V / CPU

6,3 AT / 24V / Periphery

0,5 AT / 16V / Control panel

1,25 AT / 230V / Main

Pin assignment

X3 (COM1) and X4 (COM2)

PIN

1

2

3

4

5

Signal

Vterm1

RxD

TxD bridged to PIN 6

GND

PIN

6

7

8

9

Signal gedrückt an PIN 6

RTS

CTS

Vterm2

X5 or X3 (Sewing motor)

6

7

8

PIN

1

2

3

4

5

Signal

Puls + direction +

Fkt1 +

Fkt2 +

Vex +

Inp2 +

Inp1 +

X8 (CAN-Bus)

PIN

1

2

3

4

5

Signal

DoRi +

GND

PIN

9

10

11

12

13

14

15

PIN

6

7

8

9

Signal

Puls direction -

Fkt1 -

Fkt2 -

Vex -

Inp2 -

Inp1 -

Signal

DoRi -

GND

152

X11 (Main drive)

8

9

10

11

12

13

4

5

6

7

PIN

1

2

3

Signal

Puls + direction +

Fkt1 +

Fkt2 +

Vex +

Inp2 +

Inp1 +

R1_A

R1_B

R2_A

R2_B

GND

21

22

23

24

25

26

17

18

19

20

PIN

14

15

16

Control unit

Signal

A_A

A_B

B_A

B_B

I_A

I_B

GND

A_OC

B_OC

I_OC

V2

GND

Vex

14

.01.02

Sewing drive A22

Before leaving the factory, the sewing drive controller is equipped with the necessary operating software. This software may only be replaced by appropriate specialist personnel.

The LED Power on indicates if (the sewing drive) is ready to operate. There are no diagnostic functions and fuses available. If error messages occur in the machine display, please refer to chapter 14.02.04

Sewing motor errors.

X1 or X7 (Synchronizer)

PIN

1

2

3

4

5

Signal

FA

FB

SM

ADTC1

+ 5V

PIN

6

7

8

9

Signal

GND

X2 (Commutating signal generator)

PIN

3

4

5

1

2

Signal

ADTC2

+ 5V

PIN

6

7

8

9

Signal

KA

KB

KC

GND

153

Control unit

X3 (Interface)

8

9

10

11

12

13

4

5

6

7

PIN

1

2

3

X1 or X14 (motor)

Signal

PE

U

V

W

Signal

GND

TxD

RxD

TxD\

RxD\

GND

REF1

REF1\

REF2

REF2\

GND

21

22

23

24

25

26

17

18

19

20

PIN

14

15

16

Signal

A

A\

B

B\

Index

Index\

154

14

.01.03

Stepping motor drive A21

The stepping motor controller has the following initial setting:

DIP switch

OFF ON

*

*

*

*

Step no.: 1000

Step no.:

Current reduction active

Enable

Control unit

Rotary switch

B

Position B ==> phase current 5.4 A

For information on the status indications via LED please refer to chapter 14.02.05 Errors – Stepping motor drive.

Pin assignment

X5 (Stepping motor 1) or X6 Stepping motor 2)

PIN

1

7

8

5

6

2

3

4

Signal

Pulse +

Direction +

Current contro +

Ready +

PIN

9

10

11

12

13

13

15

Signal

Pulse -

Direction -

Current contro -

Ready -

155

Control unit

14

.01.04

Stacker motor drive

Before leaving the factory, the stacker motor drive has been set and/or programmed to meet the requirements of this machine. It may only be replaced by a programmed drive.

Operation controls

LED H1 (yellow) off

LED H2 (green) off on off

Discription

Power off, no function

Power on, after approx

0,5s of self-test ready for operation drive has been started off on on on fl ashes off overload protection active see chapter 14.02.06Errors -

Stacker drive

156

14

.01.05

AC-Line-Controller

The AC-Line-Controller is set in the factory to the requirements of this machine.

An exchange is only permissible after prior adjustments.

Default setting

Potentiometer

UL (upper limit)

LL (lower limit) off Delay

Value

260V

195V

Min

Operation displays

LED H1 (green) off on on

LED H1 (red) off off on

Discription line off, no function machine functional,

voltage outside the set range machine functional,

voltage within the set range

14

.02

Description of the error messages

14

.02.01

General errors

Display Description

Control unit

ERROR: 3

ERROR: 4

ERROR: 5

ERROR: 6

ERROR: 7

ERROR: 8

ERROR: 10

ERROR: 11

ERROR: 12

ERROR: OPERATING

DATA CHECK SUM (COLD

START CARRIED OUT)

NEW OPERATING SOFT-

WARE (COLD START CAR-

RIED OUT)

COLD START CARRIED

OUT

ERROR: 15

ERROR: 101

ERROR: 102

(#node no.)(status)

ERROR: 103

ERROR: 104

ERROR: 105

ERROR: 201 (#sewing motor error)

ERROR: 210

ERROR: 211

ERROR: 212

ERROR: 213

ERROR: 214

ERROR: 215

ERROR: 216

ERROR: 217

ERROR: 219

ERROR: 220

ERROR: 221

ERROR: 240 (cause)

ERROR: 241 (cause)

Error in allocation EMS memory

C167 not reacting

Boot fi le (c167boot.bin) cannot be opened

Error in fl ash-programming

Error when opening a fi le

Battery

CAN-error (reset)

CAN-error (no. of nodes)

Communication main drive

Operating data check sum

New operating software

Cold start

Main drive changed

C167-error

CAN-error, status = Bit1 - node inactive,

Bit 8 - short circuit

End stage (SmX)

End stage (SmY)

Error compressed air

Sewing motor error (see Chapter 14.02.04 Sewing motor errors)

Command byte of NM-interface not free,command could not be given

Coordinates outside sewing area

Stitch length too long (> 6 mm)

Carraige initiators not found

Remove material

Ramp not completed

Insert material

No jig inserted, program number could not be read

Wrong jig

Wrong jig code

No carriage start (NIS)

Move to starting point blocked

Move to Home blocked

157

Control unit

Display

ERROR: 242 (cause)

ERROR: 243 (cause)

ERROR: 244 (cause)

ERROR: 245 (cause)

ERROR: 246 (cause)

ERROR: 247 (cause)

ERROR: 248 (cause)

ERROR: 249 (cause)

ERROR: 250 (cause)

AC

ERROR: 261

ERROR:301

ERROR: 302

ERROR: 303

ERROR: 305

ERROR: 306

ERROR: 308

ERROR: 310

ERROR: 311

ERROR: 312

ERROR: 313

ERROR: 314

ERROR: 315

ERROR: 316

ERROR: 317

ERROR: 318

ERROR: 319

ERROR: 320

ERROR: 321

ERROR: 322

ERROR: 323

ERROR: 324

ERROR: 325

ERROR: 326

ERROR: 327

ERROR: 328

ERROR: 329

ERROR: 330

(#Stitch generation error)

(#Section number)

ERROR: 331 Stitch too large (> 6 mm)

Description

Move to folder blocked

Move from folder to mach. zero point blocked

Move from folder to stacker point blocked

Move to stacker point blocked

Tacting blocked

Moving in sewing program blocked

Shifting to fl ap slit blocked

Move from stacker point to mach. zero point blocked

Sewing blocked

Undervoltage (error 255)

Bobbin thread error

Carriage position invalid

Needle position (carriage) invalid

Folder position invalid

Confi guration invalid

Needle position (t.d.c.) invalid

Machine not in basic position

File not on source

Source reading error, fi le cannot be opened

Target writing error, fi le cannot be opened

Source reading error

Target writing error

File confi guration cannot be opened

Error when opening MDAT-fi le

Writing error in MDAT-fi le

Machine data identifi cation incorrect

Reading error in MDAT-fi le

Prog. with incorrect machine class

Prog. with incorrect machine version

Prog. with incorrect data set version

Incorrect program number

No carriage start, NIS

Memory overfl ow when writing fi le to fl ash

Flash writing error

Image leaves sewing area

Block not marked or incorrectly marked

Program too large

Conversion error

158

Display

ERROR: 332

ERROR: 341

(#sewing motor error)

ERROR: 342

(# program number)

ERROR: 343

(# program number)

ERROR: 344

(# program number)

ERROR: 345

(# program number)

ERROR: 401

ERROR: 402

ERROR: 403

ERROR: 501

ERROR: 502

14

.02.02

CAN-errors

Error byte bit7 bit6 bit5 bit4 bit3 bit2 bit1 bit0

Description

-

-

End stage error (short circuit)

Receive status (waiting for input object)

Transmit status (transmit output object)

Transmit status

Node time out

Node active

Control unit

Description

Check-point not permitted

Sewing motor error,

(see Chapter 14.02.04 Sewing motor errors)

Program incomplete

Program too large

Program does not exist

Flash reading error or program defective

Text fi le cannot be opened

Error when reading text fi le

Error in allocation of storage space for texts

Error when opening fi le "pikto.hex" or "vorlagen.hex"

No acknowledgement from control panel

159

Control unit

16

17

18

19

10

11

12

13

14

15

20

21

22

23

24

5

6

3

4

7

8

9

29

30

31

25

26

27

28

14

.02.03

Stitch generation error

Display

1

2

Description

Incorrect machine identifi cation

Section "jig type" or section "obstacle" missing or on wrong place

Increment too large

Program end without thread trimming

Impermissible stitch length data

Incorrect element in geometrical data set

Quick motion although machine is sewing



Circle check-point = circle end point

Division by zero


No coordinates section before curve check-point

Sewing area limit exceeded

Curve without end point

Mach. function buffer overfl ow

Start sewing command in loading point program

Incorrect curve check-point




Stitch length not initialised

Loading point program not ended

Stitch width command in loading point program

Impermissible value for section stitch direction

Cutting command, although thread cut

Start sewing command, although machine sewing

Cutting command in sewing-off-area

Sewing-off command, although thread cut

Cutting command directly after start sewing command

Start bartack too long

160

Control unit

14

.02.04

Sewing motor errors

Display

1

2

3

4

30h (48)

31h (49)

32h (50)

33h (51)

34h (52)

35h (53)

36h (54)

37h (55)

38h (56)

39h (57)

3Ah (58)

3Bh: (59)

3Ch: (60)

3Dh: (61)

3Eh: (62)

3Fh: (63)

40h - 4Fh -

50h: (80)

51h: (81)

52h: (82)

53h: (83)

54h: (84)

55h: (85)

56h: (86)

57h: (87)

58h: (88)

59h: (89)

5Ah: (90)

5Bh: (91)

5Ch - 69h -

6Ah: (106)

6Bh: (107)

6Ch: (108)

6Dh: (109)

6Eh: (110)

6Fh: (111)

70h: (112)

71h - FFh -

Description

Transmission error

Timeout serial interface

Check sum error in incoming data

Timeout command

Timeout-slave expired (command string incomplete)

Incorrect command code

Framing or parity error

Check sum incorrect

Incorrect date request

No parameter programmable (motor operation)

Parameter does not exist

Incorrect parameter value

EEPROM being programmed

Incorrect machine speed

Incorrect position

Path for guided positioning too short

Reset of position counter not possible (motor running)

Turning to tdc after mains on not permitted

System mark not recognised

Target position < 3 incr. away from count position

Network control (failure of 2 network half waves)

Error power electronics during initialization

Short circuit in motor

Mains voltage off recognized

Error power electronics in operation

No increments

Motor blocked

Commutation transmitter connector missing

Increment transmitter connector missing

Fault in motor running (target speed not reached)

-

Regulating algorithm blocked

EEPROM not programmable

EEPROM missing

-

Master reset carried out

Residual path for path-controlled, guided delay ramp too short

Slave has received 5 successive garbled messages

Time-out over

161

Control unit

14

.02.05

Errors – Stepping motor drive

If problems occur with the stepping motor drive during the operation, an error might have occurred in the stepping motor controller.

The error message is indicated by LEDs on the stepping motor controller.

LED

01 ROT. ERROR

06 READY

07 FAULT

08 TEMP

09 OVER-VOLT

10 LOW-VOLT

09 + 10

Meaning goes out when

- the motor blocks

- the stepping motor amplifi er is not ready

- the Enable input is not activated

- a breakage has occurred in the supply and/or blocking detection

line is lit up when

- the amplifi er is driven correctly

- the supplied voltage is in the rated range lights up if a short-circuit occurs between two motor phases lights up if the temperature at the cooling device is too high (>75ºC) lights up if there is an over-voltage (>400 V) during braking lights up if there is a low voltage (< 200 V) are lit if the Enable input is not activated

162

Control unit

14

.02.06

Errors - Stacker drive

If problems occur with the stacker drive during operation, an error might have occurred in the motor drive.

In this case, a fl ashing LED on the motor controller indicates the error.

Correction/

Comment

H1(yellow) Condition/

fl ashes cause

once

|_________|_________

twice

| |________| |________ low voltage

three times

| | |_______| | |_______

I > 180% I

N

short-circuit

four times

| | | |______| | | |______ acts as generator processor error on again (Reset) power off automatic reset power off due to overcurrent overcurrent or motor check drive

fi ve times

| | | | |_____| | | | |_____

six times

| | | | | |____| | | | | |____

converter

seven times

| | | | | | |___| | | | | | |___

eight times

| | | | | | | |__| | | | | | | |__ temperature too high

nine times

| | | | | | | | |_| | | | | | | | |_

I*t power off motor

I*t power off frequency motor temperature too high frequency converter check mounting conditions

Error in the EEPROM switch the mains off and back fl ashes until UZK <65V, check drive/motor cable check mains, motor overloaded, frequency converter overloaded, check bridge X5/10-11 frequency converter overloaded, switch mains off and on

163

Control unit

14

.03

List of outputs and inputs

14

.03.01

CAN-Nodes 1

Output

OUT9

OUT10

OUT11

OUT12

OUT13

OUT14

OUT15

OUT16

OUT1

OUT2

OUT3

OUT4

OUT5

OUT6

OUT7

OUT8

Term

Y5U2

Y6

Y7

Y8

Y9

Y10

Y35U1

Y35U2

Y1U1

Y1U2

Y2U1

Y2U2

Y3

K4

K20

Y5U1

Function


Pocket plate backwards

Pocket plate up

Pocket plate down

Pocket plate ventilation on

Stamp solenoid on

Pocket plate solenoid on

Folder up

Folder down

Corner slide forwards

Folder slide 1 forwards



Suction air on

Jig up

Jig down

Input

IN8

IN9

IN10

IN11

IN12

IN13

IN14

IN15

IN16

IN1

IN2

IN3

IN4

IN5

IN6

IN7

Term

E1U1

E1U2

E2U2

Function


Pocket plate at back

Pocket plate down

E5U1

E5U2

TSAUG

TDOPP1

TDOPP2

E35U1

E35U2

PRESS

FKEY

TSSTOP

AC_OK

Folder up

Folder down

Key suction

Double start key 1

Double start key 2

Jig up

Jig down

Compressed air ok

Key (for secured functions)

Separate stop key

Undervoltage monitoring

Remark

Impulse valve

Impulse valve

Impulse valve

Impulse valve

Valve

Solenoid

Solenoid

Impulse valve

Impulse valve

Valve

Valve

Valve

Valve

Valve

Impulse valve

Impulse valve

164

Control unit

14

.03.02

CAN-Nodes 2

Output

OUT1

OUT2

OUT3

OUT4

OUT5

OUT6

OUT7

Term

Y30

Y31U1

Y31U2

K32

Y34

Y36

Y37

OUT8

OUT9

OUT10

OUT11

OUT12

OUT13

OUT14

OUT15

OUT15

OUT16

Y38

Y50

Y51

Y52

Y33

OUT1

OUT2

Y39

Y39U2

Y39U1

Funktion

Sewing foot down, thread clamp open

Raise sewing head

Lower sewing head

Thread tension on

Blower needle cooling on

Zig-zag on (prog. Outlet 3)

Secondary thread tension on

(prog. Outlet 5) ready made fl aps

Roller down

Clamp strap open

Stacker frame back

Thread trimming on

Programmable outlet 1

Programmable outlet 2

Bobbin cover open (with vertical hook)

Bedplate up (with horizontal hook)

Bedplate down (with horizontal hook

Remark

Valve

Impulse valve

Impulse valve

Solenoid

Valve

Valve

Valve

Valve

Valve

Valve

Valve

Valve

Dig. Signal

Dig. signal

Valve

Impulse valve

Impulse valve

Input

IN5

IN6

IN7

IN8

IN1

IN2

IN3

IN4

IN9

IN10

IN11

IN12

IN13

IN14

IN15

IN16

Term

E30

E31U1

E31U2

THERR

IN1

IN2

E39U2

E39U1

E50U1

E50U2

Function

Sewing foot raised

Sewing head raised

Sewing head lowered

Needle thread error

Programmable inlet 1

Programmable inlet 2

Bedplate up (with horizontal hook)

Bedplate down (with horizontal hook)

Bobbin cover closed (with vertical hook)

Roller down

Roller up

E52

SM1LI-

MIT

SM2LI-

MIT

E62

Stacker frame back

Zero position SM1

Zero position SM2

Defl ector down (cargo)

165

Control unit

14

.03.03

CAN-Nodes 3

Output

OUT1

OUT2

Term

Y11

OUT3

OUT4

OUT5

OUT6

OUT7

OUT8

OUT9

OUT10

OUT11

OUT12

OUT13

OUT14

OUT15

OUT16

Funktion Remark

Y12U1

Y12U2

Y40

STR

STL

S1IND

S2IND

K53

Y60

Y61

Y62

Label holding jig open

(with manual label feed)

Swing folder slide 3 (with folder slide 4)

Flap position off or var. sewing slit narrow

Flap position on or var. sewing slit wide

Valve

Impulse valve

Impulse valve

BOBRES Reset for bobbin thread monitor

Hook lubrication on

Start stacker motor clockwise rot.

Start stacker motor anti-clockwise rot.

Stacker motor frequency 1

Stacker motor frequency 2

Stand height adjustment on

Swing in defl ector (cargo)

Defl ector forwards (cargo)

Defl ector down (cargo)

Dig. Signal

Valve

Dig. Signal

Dig. Signal

Dig. Signal

Dig. Signal

Relay

Valve

Valve

Valve

Input

IN9

IN10

IN11

IN12

IN13

IN14

IN14

IN15

IN16

IN5

IN6

IN7

IN8

IN1

IN2

IN3

IN4

Term jigcode jigcode jigcode jigcode jigcode jigcode jigcode jigcode

BOBERR

Funktion

Jig code bit 0

Jig code bit 1

Jig code bit 2

Jig code bit 3

Jig code bit 4

Jig code bit 5

Jig code bit 6

Jig code bit 7

Bobbin thread error

ETINKL

E14

E12U2

E12U1

E54U1

E54U2

Label in clamp, man. label feed

Jig with obstacles

Flap pos. switched off or sewing slit wide

Flap position activated (for fl ap version 2)

Stand up

Stand down

166

14

.03.04

Special outputs

Term

S1

S2

S3

S4

S5

Funktion

Stacker motor forwards slowly

Stacker motor backwards slowly

Stacker motor forwards quickly

Stand up

Stand down

Control unit

Remark

14

.04

Boot key

1

This work may only be carried out by properly instructed personnel!

Do not touch any live parts!

Danger to life through electric voltage!

167

Pneumatics-switch diagram

Version 26.05.99

95-775 774-95

Part 1

The control elements and valves are in the machine‘s basic position.Main switch -ON, compressed air -ON

168

95-775 774-95

Part 2 Version 26.03.99


169


Version 04.11.15

95-775 774-95

Part 3

170

95-775 774-95



171


Version 26.05.99

95-775 774-95

Part 5

172

95-775 774-95



173


Version 19.05.06

95-778 520-95

174

14 Stromlaufpläne

Reference list

A60

K4

K32

K53

K54

Z1

E1

T1

C1

Q1

A21

A22

A23

A24

A11

A12

A13

A20

A25

A26

M1

M2

M3

M4

M5

M6

M7

A42+A43

Reference list for circuit diagrams

Stepping motor 1

Stepping motor 2

Sewing motor

Stacker motor

Height-adjustment motor

Suction motor

Ventilator control cabinet

CAN node 1

CAN node 2

CAN node 3

Controller BS 3

Stepping motors end phase (dual output amplifi er)

Sewing motor, end phase

Synchronizer

Needle thread monitor, monitoring results

Needle thread monitor, sensor

Control panel

Stepping motors end phase (two individual output amplifi ers)

Rotary switch motor current, setting B = 5.4.A

Description of LEDs

1 DC bus live

2 Operational, power amplifi er authorised, motor live

3 Short circuit between 2 motor phases or against protective earth

4 Static = excessive power amplifi er temperature,

blinking = excessive motor temperature

5 Overvoltage (DC bus > 420VDC)

6 Undervoltage (DC bus > 180VDC)

7 Error message on rotation monitoring

8 Encoder connected and operational

5+6 Power amplifi er deactivated, motor currentless

3 - 6 Frequency too high at signal point

Frequency converter

Stamp solenoid

Thread tension is released

Switching relay, height adjustment / stacker

Voltage supervision relay

Line fi lter

Sewing lamp

Transformer for sewing lamp

Capacitor for M6 (-4/01)

On/off switch

175

Inputs

E39.2

E50.1

E50.2

E52

E54.1

E54.2

E62 in1 in2 sm1limit sm2limit tdopp1 tdopp2 tsaug press fkey tsstop therr boberr eterr etrdy etinkl jigcode

E14

E30

E31.1

E31.2

E35.1

E35.2

E39

E39.1

E1.1

E1.2

E2.2

E5.1

E5.2

E12.2

E13


Pocket plate at rear

Pocket plate down

Folder up

Folder down

Flap position off / sewing slit wide

Linkage monitoring

Jig with obstacles

Presser foot up

Sewing head lifted

Sewing head lowered

Jig up

Jig down

Bobbin cover closed

Bedplate down

Bedplate up

Roller down

Roller up

Stacker frame at front

Frame up

Frame down

Defl ector down

Programmable input 1

Programmable input 2

Neutral position SM1


Double-start key 1

Double-start key 2

Suction key (foot switch)

Air pressure OK

Key (for secured functions)

Separate stop key

Needle thread disturbance

Bobbin thread disturbance

Label feed error

Label feed completed

Label in clamp

Jig code

176

X33

X34

X35

X36

X37

X38

X39

X29

X30

X31

X32

X25

X26

X27

X28

X40

X41

X42

X43

X21

X22

X23

X24

X17

X18

X19

X20

X1

X10

X11

X12

X13

X15

X16

Distribution strip 230 V and 24 V



Feed roller down (stacker)

Feed roller up (stacker)

Central electric plug sewing head

E31.1 (sewing head lifted)

E31.2 (sewing head lowered)

K32 (Thread tension is released) tdopp1 and tdopp2 (double-start keys)

E54.1 and E54.2 (frame up/down)

Foot switch - suction key (tsaug )

M6 (suction motor)

M5 (height adjustment)

E1.1 (folder)

E1.2 (folder)

E2.2 (folder)

E4.1 (folder)

E4.2 (folder)

E5.1 (folder)

E5.2 (folder)

E39 (bobbin cover opens)

Rotor position

Sewing motor

Press (air fi lter/lubricator unit)

Linkage monitoring

Key for secured function (fkey (

E13 (linkage monitoring)

Separate stop key

E35.2 jig down

E35.1 jig up

Label in clamp (etinkl )

E12.2 Flap positioning / variable sewing slit

E12.2 Flap positioning / variable sewing slit

Connections

177

Outputs

Y1.1

Y1.2

Y2.1

Y2.2

Y3


Pocket plate at back

Pocket plate on

Pocket plate off

Pocket plate ventilation on

Y6

Y7

Y8

Y9

K32

K33

Y33

Y34

Y36

Y37

Y38

Y39

Y11

Y12.1

Y12.2

Y30

Y31.1

Y31.2

Y39.2

Corner folder at front

Edge folder 1 at front



No pressure on label retaining clamp, or it is open

Flap positioning on / var. sewing slit narrow

Flap positioning off / var. sewing slit wide

Presser foot up / Thread trapper up

Raise head (arm)

Lower head (arm)

Thread tension release on (Thread tens. up)

Thread cutting on (vertical hook system)

Thread cutting on (horizontal hook system)

Air blast / needle cooling on

Zigzag on (programmable output 3)

Secondary thread tension (prog. output 4)

Ready made fl aps or cargo slide

Bobbin cover open

Bedplate on (tilt)

Y51

Y52

K53

Clamp strap on

Stacker stand at front

Frame height adjustment on

A60.5

A60.6

A60.3

A60.4

A60.6

A60.7

A60.10

LUST-converter "S1 ind"

LUST-converter "S2 ind"

Peter-converter "STR"

Peter-converter "STL"

Peter-converter "S1 ind"

Peter-converter "S2 ind"

Peter-converter "GND"

178

91-191 367-95

Version

Terminals X 1

179

Cirguit diagrams

Version

91-191 570-95

Part 1

180

91-191 570-95

Part 1a Version

Cirguit diagrams

181

Cirguit diagrams

Version

91-191 570-95

Part 2

182

91-191 570-95

Part 2a Version

Cirguit diagrams

183

Cirguit diagrams

Version

91-191 570-95

Part 3

184

91-191 570-95

Part 4 Version

Cirguit diagrams

185

Cirguit diagrams

Version

91-191 570-95

Part 5

186

91-191 570-95

Part 6

Version

Cirguit diagrams

187

Cirguit diagrams

Version

91-191 570-95

Part 7

188

91-191 570-95

Part 8 Version

Cirguit diagrams

189

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: [email protected]

Printed in Germany

Pfaff 3588-05/020 Instruction manual

INSTRUCTION MANUAL

PFAFF Industriesysteme und Maschinen AG

Safety

1

Safety symbols

8

1

Important notes for the user

Preparation

9

Threading the needle / adjusting the needle thread tension

36

3

2

1

11

Input

Program management

77

14 Control

14

Basic setting / Diagnosis / Pin assignment

14

Basic control unit A20

Control unit

151

14

CAN-Nodes 2

14

Special outputs

Control unit

14

Boot key

1

167

Pneumatics-switch diagram

95-775 774-95

170

Pneumatics-switch diagram

95-778 520-95

174

Outputs

178

PFAFF Industriesysteme und Maschinen AG

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Table of contents