-918/55
Supplement to the instruction
and adjustment manual for the
PFAFF 487, 489 and 5487
296-12-18 647/002
Betriebsanleitung engl. 06.2009
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Index
Contents ..................................................................................Page
1
Proper use.............................................................................................................................5
2
Controls ................................................................................................................................6
Knee Switch...........................................................................................................................6
Control panel..........................................................................................................................6
Keyboard................................................................................................................................7
2.01
2.02
2.03
3
3.01
3.02
3.02.01
3.02.02
Installation and commissioning .........................................................................................9
Connecting the plug-in connections and earth cables ...........................................................9
Basic position of the machine drive unit .............................................................................. 10
With control unit P320 ED ................................................................................................... 10
With control unit P323 MS .................................................................................................. 12
4
Preparation......................................................................................................................... 13
Selecting the program number............................................................................................ 13
Inputting fullness ................................................................................................................. 14
Entering / altering the code number .................................................................................... 15
Adjusting the control panel .................................................................................................. 17
4.01
4.02
4.03
4.04
5
5.01
Sewing................................................................................................................................ 18
Manual sewing..................................................................................................................... 18
Entering the seam start and seam end in manual sewing mode ........................................20
Sewing with fixed programs................................................................................................21
Programmed sewing............................................................................................................23
Program interruption............................................................................................................25
Error messages....................................................................................................................25
5.01.01
5.02
5.03
5.03.01
5.04
6
6.01
Input....................................................................................................................................26
Seam program input ............................................................................................................27
Basic settings for seam program input ................................................................................27
Seam program input with the "Creating/adjusting a program" functionen"..........................29
Seam program input with the "Creating/adjusting a program" function...............................31
Entering the functions at the beginning of the seam during seam programming...................33
Entering the functions at the end of seam section during seam programming...................34
Examples of how to create a seam program.......................................................................36
Example of a seam program input with the "creating/adjusting a program" function ..........36
Example of a seam program input using the "teach-in" function..........................................39
Seam program administration..............................................................................................41
6.01.01
6.01.02
6.01.03
6.01.04
6.01.05
6.02
6.02.01
6.02.02
6.03
7
7.01
7.02
7.02.01
7.02.02
7.03
Adjustment differing from the basic machine.................................................................43
Basic setting of the differential adjustment device..............................................................43
Parameter settings...............................................................................................................44
Overview of the parameter functions..................................................................................44
Example of a parameter input..............................................................................................45
List of parameters................................................................................................................46
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Index
Contents ..................................................................................Page
7.04
Sewing motor errors............................................................................................................48
Explanation of the error messages......................................................................................49
Table of inputs......................................................................................................................50
Table of outputs ...................................................................................................................50
Service menu.......................................................................................................................51
Carry out a cold start ...........................................................................................................52
Internet update of the machine software ............................................................................53
7.05
7.06
7.07
7.08
7.09
7.10
8
Circuit diagrams ................................................................................................................54
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Proper use
1
Proper use
The PFAFF 487-918/55, 489-918/55 and the PFAFF 5487-918/55 are single-needle,
ultra-high-speed sewing machines with programmable fullness control.
The PFAFF 487-918/55 and the 489-918/55 are used to sew lockstitch seams in
industry.
The PFAFF 5487-918/55 is used to sew two-thread chain stitch seams in industry.
Any and all uses of this machine which have not been approved of by the
manufacturer are considered to be inappropriate!The manufacturer cannot be
held liable for any damage caused by the inappropriate use of the machine!
The appropriate use of the machine includes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!
5
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Controls
2
Controls
2.01
Knee Switch
Manual sewing:
● By operating knee switch 1 it is possi-
ble to alternate between two pre-set
amounts of fullness.
Programmed sewing:
● By operating knee switch 1 the amounts
of fullness are changed according to the
program selected.
1
Fig. 2 - 01
2.02
Control panel
2 GB
max.
2
1
Fig. 2 - 02
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.
6
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Controls
Activated functions are shown with inverted symbols. Unframed symbols or texts are only
used for display purposes and cannot be selected by pressing.
To read sewing programs or install machine software, use the sd-card 2 in the control
panel.
Description of the functions
Normal symbol = function switched off (inactive)
Inverted symbol = function switched on (active)
2.03
Keyboard
The keyboard is used for the quick operation of the machine during sewing and when selec-
ting the fullness. With the corresponding LED of the 20 keys, active key functions are displa-
yed (Function active = LED lit).
PFAFF 487-918/55, 489-918/55
PFAFF 5487-918/55
Fig. 2 - 03
Single stitch
● If the single stitch key is pressed, the machine sews a single stitch.
Stitch condensation (only on the PFAFF 5487)
● The stitch condensation is switched on and off by pressing a key.
(When programming the seam: Sew the seam section with condensed stitches)
7
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Controls
Reverse sewing direction (only on the PFAFF 487), 489
● As long as the reverse sewing key is pressed, the machine sews in reverse. For the pro-
gramming and learning functions, the relevant seam section is programmed "in reverse".
Bartack suppression
● If the bartack function is activated, by pressing this key once the next bartack and by
pressing it twice the next two bartacks are not sewn.
Correction value + / correction value -
● If this key is pressed, the fullness value is increased or reduced in 2 steps. Fullness va-
lue 0 is not corrected. To make this possible, a correction value different to 0 must be
entered in parameter 209.
Number keys 0 - 14
● The previously allocated amount of fullness is called up by pressing a key.
When two neighbouring number keys are pressed simultaneously, the corresponding
average value is selected.
● In the manual sewing mode, the fullness can be allocated to the individual keys. The
current fullness value (which can be set on the touch-screen) is allocated to a key if it is
pressed for a long time (>3s). A bleep signalizes that the value has been saved.
Following values are pre-set and can be altered as described above.
Key 0:
No fullness will be applied.
Key 14:
Maximum fullness is selected.
The fullness values are designed for a basic stitch length of 2.5 mm. When se-
wing with shorter stitch lengths, the gathering intensity is increased, with lon-
ger stitch lengths it is reduced accordingly.
8
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Installation and commissioning
3
Installation and commissioning
The machine must only be mounted and commissioned by qualified personnel!
All relevant safety regulations are to be observed!
3.01
Connecting the plug-in connections and earth cables
C
D
1
A
B
2
Fig. 3 - 01
● Connect all plugs as labelled to the control box .
● Screw the earth cable from the sewing head to earth point A.
● With an earth cable connect earth point C and D to earth point A.
● Screw the earth cable from the main switch 1 to earth point A.
● Screw the earth cable 2 from the motor to earth point B.
9
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Installation and commissioning
3.02
Basic position of the machine drive unit
3.02.01
With control unit P320 ED
● Switch on the machine.
● Call up the input mode.
● Call up the service function.
● Call up the motor service function.
● Press this key for the machine to learn the transmission ratio.
Attention!
After this key has been operated, the machine sews 3 stitches at a speed of
approx. 360 rpm.
10
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Installation and commissioning
● Call up the input mode.
● Call up parameter "301".
301
● Turn the balance wheel in the direction of rotation until the needle point, descending
from above, is flush with the top edge of the needle plate.
● Conclude the input.
● Switch off the machine.
11
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Installation and commissioning
3.02.02
With control unit P323 MS
● Switch on the machine.
● Call up the input mode.
● Call up the service function.
● By turning the balance wheel in the sewing direction, ascertain the number of incre-
ments per turn (this maximum value appears under "POS" in the display before the rea-
ding jumps back to "0".
● Call up the input mode.
● Call up parameter "721".
721
127
● Enter the calculated max. value.
● Conclude the input.
● Switch off the machine.
12
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Preparation
4
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.
4.01
Selecting the program number
● Switch on the machine.
● Call up the program number input menu.
● Select the desired program number.
● Confirm the selection and quit the selection menu.
The sewing method is determined by the program number selected,
see Chapter 5 Sewing.
Program number 0:
Manual sewing
Program number 1 and 2:
Program number 3 to 49:
Sewing with fixed programs
Programmed sewing
13
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Preparation
4.02
Inputting fullness
● Switch on the machine.
● Call up the program number input menu.
● Select program number "0"..
● Confirm the selection and quit the selection menu.
● Enter the desired value with the appropriate arrow keys.
Fig. 4 - 01
● If necessary, allocate the current fullness amount to one of the number keys (0-14) on
the keyboard. To do so, press the required key until a beep is heard.
14
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Preparation
4.03
Entering / altering the code number
● Switch on the machine.
● Call up the input mode.
● Select parameter "800".
800
● Select the code number input menu.
● Enter the code number on the number keys (factory code setting is "3800").
15
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Preparation
● Take over the code number entered.
800
The code input remains stored until the machine is switched off at the main
switch. As long as the machine is not switched off, all parameters are freely ac-
cessible without having to enter the code number again.
● Select parameter "810"
800
● Call up the code number input menu and enter the desired code number.
0487
● Take over the new code number.
● Conclude input.
Do not forget the code!
Without the appropriate code, the protected functions cannot be called up!
Help is then only possible through PFAFF service staff.
16
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Preparation
4.04
Adjusting the control panel
● Switch on the machine.
● Call up the input mode.
● Select the service menu.
● Select control panel functions.
● 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!
17
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Sewing
5
Sewing
In the sewing mode all relevant settings for the sewing operation are displayed on the
screen and can be altered with the corresponding functions.
In the sewing mode a difference is made between manual sewing, sewing with fixed pro-
grams and programmed sewing.
The selection is made with the corresponding program number:
0: Manual sewing
1 and 2: Sewing with fixed programs
3 to 49: Programmed sewing
(with up to 15 seam sections for both the left and right seam)
5.01
Manual sewing
In the manual sewing mode the fullness values are displayed on the control panel and can
be altered directly by using appropriate function, just as the functions at the beginning and
the end of the seam and the needle and sewing foot positions.
Switch on the machine and select program number "0", see Chapter 4.01 Selecting the pro-
gram number.
Explanation of the functions
Program selection
This opens the menu for entering the program number, see Chapter 4.01 Selecting the pro-
gram number.
Input mode
Exit the sewing mode and select the input mode.
Fullness
Alters the value for fullness, see Chapter 4.02 Inputting fullness
Seam start
Opens the menu for entering the functions at the beginning of the seam, see Chapter
5.01.01 Entering the seam start and seam end functions in the manual sewing mode.
18
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Sewing
Seam end
Opens the menu for entering the functions at the end of the seam, see Chapter 5.01.01 En-
tering the seam start and seam end functions in the manual sewing mode.
Needle raised
Moves the needle to its highest position
Needle position raised
When this function is activated, the needle moves to its highest position after sewing stops.
Thread trimming
When the function is activated, enables thread trimming with the pedal function.
Sewing foot raised
When this function is activated, the sewing foot is raised after sewing stops.
Sewing foot lowered after thread trimming
When this function is activated, the sewing foot is not raised after thread trimming.
● Sewing is carried out with the pedal functions.
19
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Sewing
5.01.01
Entering the seam start and seam end in manual sewing mode
After the appropriate function has been selected, the menu for entering the value for con-
densed stitches or for backtacks appears.
PFAFF 487, 489
PFAFF 5487
● PFAFF 487, 489
Switch on the single start backtack function and call up the menu for entering the values.
(1 – 9 stitches can be entered).
or
● Switch on the double start backtack function and call up the menu for entering the values.
(1 – 9 stitches can be entered).
● PFAFF 5487
Switch on the condensed stitches function and call up the menu for entering the values.
(1 – 30 stitches can be entered).
● In each case change the number of stitches for the condensed stitches or the number of
backtack stitches with the appropriate arrow keys.
● Change the value for the maximum speed during the condensed stitches or backtacking
operation (100 – 1500 spm can be entered).
● Choose whether the condensed stitches or the backtacking operation at the beginning of
the seam should be carried out at a fixed speed (normal symbol) or at a pedal-controlled
speed (inverse symbol).
● Conclude the input.
● In the manual sewing mode, the functions for the seam end are entered in the same way
as those for the seam start.
20
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Sewing
5.02
Sewing with fixed programs
Fixed programs are stored under the program numbers 1 and 2.
The fixed programs are used for the quick and easy production of seams with different
amounts of fullness. When sewing with fixed programs, 2 or 3 seam sections are sewn af-
ter each other. With the knee switch it is possible to move to the next section. The fixed pro-
grams are designed as cyclic running programs, i.e. at the end of the last seam section, the
machine moves back to the first seam section. The fullness value can be selected for each
seam section, the settings for needle and foot positions apply to all sections and can be alte-
red at any time with the appropriate function.
The fullness values are designed for a basic stitch length of 2.5 mm. When se-
wing with shorter stitch lengths, the gathering intensity is increased, with lon-
ger stitch lengths it is reduced accordingly.
● Switch on the machine and select program number "1" or "2", see Chapter 4.01 Selecting
the program number.
Explanation of the displays and functions
Program selection
This opens the menu for entering the program number, see Chapter 4.01 Selecting the
program number.
Seam section
Shows the number of seam sections in the sewing program.
Input mode
Exit the sewing mode and select the input mode.
Fullness
Alters the fullness value, see Chapter 4.02 Inputting fullness.
Seam start
Opens the menu for entering the functions at the beginning of the seam, see Chapter
5.01.01 Entering the seam start and seam end functions in the manual sewing mode.
Seam end
Opens the menu for entering the functions at the end of the seam, see Chapter 5.01.01 En-
tering the seam start and seam end functions in the manual sewing mode.
21
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Sewing
Needle raised
Moves the needle to its highest position
Needle position raised
When this function is activated, the needle moves to its highest position after sewing stops.
Thread trimming
When the function is activated, enables thread trimming with the pedal function.
Sewing foot raised
When this function is activated, the sewing foot is raised after sewing stops.
Sewing foot lowered after thread trimming
When this function is activated, the sewing foot is not raised after thread trimming.
● Sewing is carried out with the pedal functions.
22
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Sewing
5.03
Programmed sewing
With the program numbers 3 - 49 it is possible to call up previously programmed seams. In
programmed sewing all seam sections for pre-gathering a sleeve are set in one seam pro-
gram. The information about the seam program, such as program number, number of pro-
grammed seam sections, programmed comments is displayed.
For better orientation a seam sketch is shown with the programmed seam sections. The
seam start, seam end, the seam sections already sewn, the current seam section and the
seam sections still to be sewn are illustrated by symbols and different types of lines with dif-
ferent thicknesses. For the current seam section the corresponding parameters for seam
section number, fullness with fullness adjustment and the number of stitches (length of
seam section) are displayed. To control the seam sequence, the current seam (left or right
seam) and the automatic changeover from left to right seam can be switched over or swit-
ched on.
● Switch on the machine, select the desired program number from "3" to "49", see
Chapter 4.01 Selecting the program number.
Explanation of the displays and functions
Program selection
This opens the menu for entering the program number, see Chapter 4.01 Selecting the pro-
gram number.
Seam section right/left
Shows the number of seam sections in the seam program for the right/left sleeve seam.
Input mode
Exit the sewing mode and select the input mode.
Fullness
Shows the current fullness value.
Current seam section
Shows the current seam section.
23
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Sewing
Current seam
This function is used to select and display the current seam (right/left).
Automatic seam change
When this function is activated, the machine changes automatically from the right to left seam.
Needle raised
Moves the needle to its highest position
Program interruption
Interrupts the program sequence, see Chapter 5.03.01 Program interruption
Thread trimming
When the function is activated, enables thread trimming with the pedal function.
Sewing foot raised
When this function is activated, the sewing foot is raised after sewing stops.
Sewing foot lowered after thread trimming
When this function is activated, the sewing foot is not raised after thread trimming.
● Sewing is carried out with the pedal functions.
24
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Sewing
5.03.01
Program interruption
● With the "program interruption" function the programmed seam sequence is interrupted
(e.g. if the thread breaks).
● Interrupt program sequence.
● If necessary, tact forwards or backwards through the sections of the seam program.
● If necessary, change the values and carry out the other functions as in manual sewing,
see Chapter 10.01 Manual sewing.
● If necessary, call up programmed sewing again..
5.04
Error messages
If an error occurs, the text "ERROR" appears on the display, together with an error code. An
error message is caused by incorrect settings, defective elements or seam programs and by
overload conditions.
For an explanation of the error codes see Chapter 7.05 Explanation of the error messages.
● Eliminate the error.
● Confirm error elimination.
25
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Input
6
Input
In the input mode the functions parameter input, information, creating/adjusting a sewing
program, teach-in, program administration and service are available.
● Switch on the machine.
● Call up the input mode.
Explanation of the functions
Sewing mode
Quit the input mode and call up the sewing mode.
Parameter selection
Select the hundred and unit figures of the desired parameters, see Chapter 7.02.02 Examp-
le of a parameter input.
Altering the parameter value
Change the value of the selected parameter, see Chapter 7.02.02 Example of a parameter
input.
Software information
Calls up information about the current machine software.
Creating/adjusting a program
Opens the menu for entering or altering a seam program, see Chapter 6.01.02 Seam pro-
gram input with the "Creating/adjusting a program" function.
Teach In
Opens the menu for entering seam programs after sewing a sample, see Chapter 6.01.03
Seam program input with the "Teach in" function.
Program administration
Opens the menu for seam program administration, see Chapter 6.03 Seam program admi-
nistration.
Service
Opens the service menu, see Chapter 7.08 Service menu.
26
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Input
6.01
Seam program input
Seam programs can be created by entering parameters in the "Creating/adjusting a seam
program" function, or by sewing a sample with the "Teach in" function.
Irrespective of which function is being used, first of all it is necessary to select the program
number and the basic settings of the seam program, which is to be sewn.
6.01.01
Basic settings for seam program input
The basic settings in the "creating/adjusting a program" and the "teach-in" functions are the
same.
● Switch on the machine.
● Call up the input mode.
● Call up the "Creating/adjusting a seam program" or the "Teach in" function.
● If necessary, change the selected program number and confirm the selection.
● If applicable, enter or change a comment.
27
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Input
● Set the seam type (by pressing the appropriate symbol several times until the appropria-
te seam type is displayed).
Description of the symbols:
Sewing program with left and right seam, beginning with the right seam.
Sewing program with left seam only.
Sewing program with right seam only.
Sewing program with left and right seam, beginning with the left seam.
● Conclude the input of the basic settings and change to the seam section input, see Chap-
ter 6.01.02 Seam program input with the "Creating/adjusting a program" function or
Chapter 6.01.03 Seam program input with the "Teach in" function.
The input can also be concluded by calling up the sewing mode. In this case
the seam program input is concluded and the machine changes to programmed
sewing.
28
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Input
6.01.02
Seam program input with the "Creating/adjusting a program" functionen"
With this function the seam program is entered by entering or changing the appropriate va-
lues on the control panel. This type of seam program input is particularly suitable for adjus-
ting existing seam programs.
● Switch on the machine.
● Call up the input mode.
● Call up the "creating/adjusting a program" function.
● Carry out the basic settings and conclude with the "Enter" function, see Chapter 6.01.01
Basic settings for seam program input.
● Alter the fullness, see Chapter 4.02 Inputting fullness.
● Alter the maximum speed for the current seam section.
● These functions are used to scroll through the current seam program.
The current seam section is displayed accordingly, in addition to all the other current
values.
● Enter the seam start functions, see Chapter 6.01.04 Entering the functions at the be-
ginning of the seam during seam programming.
● Enter the functions for the end of the seam section, see Chapter 6.01.05 Entering the
end of the seam section when programming the seam.
● Select a seam type
It is only possible to select the right or left seam, if the seam type "right and left seam"
was selected in the basic setting, see Chapter 6.01.01 Basic settings for seam program
input.
29
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Input
● If necessary, insert the seam section.
The current seam section is copied and all following seam sections are set one place
back.
● If necessary, delete the current seam section.
● If necessary, conclude the input of the current seam and store the parameter for the
other seam in the reverse order (mirror seam).
● Set the seam end or program end.
If entering only one seam (only the right or only the left seam) the program end is set in
the desired seam section.
In the same way as the program end, the seam end is set when entering the right and
left seam. The seam end is set in the first seam and the program end in the second
seam.
● Conclude the input of the first seam section and change to the next seam section.
● Conclude the input and change to the input of the basic settings.
● Conclude the input and change to programmed sewing.
30
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Input
6.01.03
Seam program input with the "Creating/adjusting a program" function
With this function the seam program is entered by sewing a sample. A new program is al-
ways created, i.e. if an existing program is selected, this will be overwritten.
● Switch on the machine.
● Call up the input mode.
● Call up the "teach-in" function.
● Carry out the basic settings and conclude with the "Enter" function, see Chapter 6.01.01
Basic settings for seam program input.
Before sewing starts the following displays and functions appear on the screen.
● Enter the seam start functions, see Chapter 6.01.04 Entering the functions at the be-
ginning of the seam during seam programming.
● Enter the fullness, see Chapter 4.02 Inputting fullness.
● Enter the maximum speed for the current seam section.
● Sew the first seam section using the pedal function.
The number of stitches in the current seam section is counted and shown on the display.
After sewing starts, the following displays and functions are shown on the screen.
31
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Input
● By pressing Enter the seam section end is defined by stitch counting.
● By operating the pedal in position "-2", the seam section is ended by pedal operation
● By operating the knee switch, the seam section is ended by knee switch operation, see
Chapter 2.01 Knee switch.
● After the function has been called up, additional inputs can be made for the seam section
end or incorrect inputs can be corrected, see Chapter 6.01.05 End of seam section in-
put during seam programming.
Condensed stitches defined during the input of the functions for the end of the
seam section, will be carried out after the seam program input has been conclu-
ded. Up to 30 stitches will be sewn! Danger of injury in the needle area!
● Set the seam end or program end.
If entering only one seam (only the right or only the left seam) the program end is set in
the desired seam section.
In the same way as the program end, the seam end is set when entering the right and
left seam. The seam end is set in the first seam and the program end in the second
seam.
● Conclude the input.
● Conclude the input and change to the input of the basic settings.
● Conclude the input and change to programmed sewing.
32
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Input
6.01.04
Entering the functions at the beginning of the seam during seam programming
After the appropriate function has been called up, the menu for entering the value of the
placement stitch appears. To begin with the condensed stitches function is not activated.
PFAFF 487, 489
PFAFF 5487
● PFAFF 487, 489
Switch on the single start backtack function and call up the menu for entering the values.
(1 – 9 stitches can be entered).
or
● Switch on the double start backtack function and call up the menu for entering the values.
(1 – 9 stitches can be entered).
● PFAFF 5487
Switch on the condensed stitches function and call up the menu for entering the values.
(1 – 30 stitches can be entered).
● In each case change the number of stitches for the condensed stitches or the number of
backtack stitches with the appropriate arrow keys.
● Change the value for the maximum speed during the condensed stitches or backtacking
operation (100 – 1500 spm can be entered).
● Choose whether the condensed stitches or the backtacking operation at the beginning of
the seam should be carried out at a fixed speed (normal symbol) or at a pedal-controlled
speed (inverse symbol).
● If necessary, sew the seam section in reverse (with activated function).
● Conclude the input.
33
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Input
6.01.05
Entering the functions at the end of seam section during seam programming
After the appropriate function has been called up, the menu for entering the functions and
values for the end of the seam section without condensed stitches appears.
PFAFF 487, 489
PFAFF 5487
● PFAFF 487, 489
Switch on the single end backtack function and call up the menu for entering the values.
(1 – 9 stitches can be entered).
or
● Switch on the double end backtack function and call up the menu for entering the values.
(1 – 9 stitches can be entered).
● PFAFF 5487
Switch on the condensed stitches function and call up the menu for entering the values.
(1 – 30 stitches can be entered).
● In each case change the number of stitches for the condensed stitches or the number of
backtack stitches with the appropriate arrow keys.
● Change the value for the maximum speed during the condensed stitches or backtacking
operation (100 – 1500 spm can be entered).
● Switch the function for changing to the next seam section by pedal on or off.
● Switch the function for changing to the next seam section by knee switch on or off.
● Enter or change (with the number keys or arrow keys) the number of stitches for the
seam section.
● Execute or do not execute the automatic sewing stop function at the end of the seam
section.
● Switch the "sewing foot raised" function on or off, see Chapter 5.01 Manual Sewing.
34
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Input
● Switch the "thread trimming" function on or off, see Chapter 5.01 Manual Sewing.
● Switch the "needle raised" function on or off, see Chapter 5.01 Manual Sewing.
● Conclude the input and change to programmed sewing.
It is not possible to set every combination of functions.
All the activated functions are shown as inverse symbols.
35
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Input
6.02
6.02.01
Examples of how to create a seam program
Example of a seam program input with the "creating/adjusting a program"
function
The program to be created should
- have 3 seam sections and
- be stored under the program number "4" with the comment "PROG".
Seam area 1
Number of stitches: 40
Fullness: 0
Seam area 2
End with knee switch
Fullness: 20
Seam area 3
Without stitch count
End with pedal position "-2"
Fullness: 0
● Switch on the machine.
● Call up the input mode.
● Call up the "creating/adjusting a seam program" function and enter program number "4".
● Set the seam type (right seam) by pressing until the appropriate symbol appears.
● Call up the menu for comment input.
● Enter the comment "PROG" with the keyboard and number panel.
● Conclude the comment input.
● Change to the input of the first seam section.
36
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Input
● Enter the value "0" for the fullness.
0
● Call up the menu for the input of the end of the seam section.
● Switch on the stitch count function to change to the next seam section, and set value "40"
for the number of stitches.
● Conclude the input of the end of the seam section.
● Change to the input of the second seam section.
● Enter the value "20" for the fullness.
● Call up the menu for the input of the end of the seam section.
● Switch on the function for changing to the next seam section with the knee switch.
37
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Input
● Conclude the input of the end of the seam section.
● Change to the input of the third seam section.
● Enter the value "0" for the fullness.
● Call up the menu for the input of the end of the seam section.
● Switch on the function for changing to the next seam section by pedal.
● Switch on the "thread trimming" function.
● Switch on the "sewing foot raised" function.
● Conclude the input.
38
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Input
6.02.02
Example of a seam program input using the "teach-in" function
The program to be created should
- have 3 seam sections and
- be stored under the program number "11" with the comment "TEACH".
Seam area 1
Learn number of stitches
Fullness: 0
Seam area 2
End with knee switch
Fullness: 30
Seam area 3
Without stitch count
End with pedal position "-2"
Fullness: 0
● Switch on the machine.
● Call up the input mode.
● Call up the "teach-in" function and enter program number "11".
● Set the seam type (right seam) by pressing until the appropriate symbol appears.
● Call up the menu for comment input.
● Enter the comment "TEACH" with the keyboard and number panel.
● Conclude the comment input.
● Change to the input of the first seam section.
39
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Input
● Enter the value "0" for the fullness.
● Sew the first seam section using the pedal function.
● Change to the input of the second seam section.
● Enter the value "30" for the fullness.
● Operate the knee switch
● Conclude the input of the end of the seam section.
● Use the pedal function to sew the second seam section.
● Operate the knee switch
● Change to the input of the third seam section.
● Enter the value "0" for the fullness.
● Conclude the input.
40
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Input
6.03
Seam program administration
In the program administration the seam programs deposited in the machine memory and
the SD-Card can be deleted and copied. The left side of the display shows the programs in
machine memory. The right side of the display shows the programs on the SD-Card. Selec-
ted programs are red marked. With the MDAT-function the machine configuration can be co-
pied or deleted. The Format-function formats the SD-Card. Further actions are shown in a
dialog window.
After SD-Card insertion it takes up to 20s until the card is detected.
● Switch on the machine.
● Call up the input mode.
● Call up program administration.
● Read SD-Card and machine memory again.
Explanation of the functions
Input mode
Calls up the basic display for the input mode.
Sewing mode
Quit input mode and call up sewing mode.
Program selection
After the program administration has been selected, at least one seam program is always
marked. Using the arrow functions, the desired seam program can be selected. With the
*-function and the arrow functions a seam program block can be marked. By pressing the
*.function again, the block function is deactivated.
Copy
Selected seam programs are copied from/to SD-Card.
Delete
Selected seam programs are deleted.
41
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Input
Dialog window
The dialog window shows questions and additional buttons for the answers.
Enter button
Enter button
Yes for one seam program.
All button
Yes for one or all marked seam programs.
Esc button
No for one or all marked seam programs.
Next button
No for one seam program.
Machine configuration
With the MDAT-function the machine configuration can be copied to/from SD-Card or can be
deleted on the SD-Card (filename: MDAT).
Format SD-Card
The Format-function formats the SD-Card.
If the SD-Card is not readable, it is new formatted. If the SD-Card is readable and the direc-
tory \P487 for the 487-machine exists then all seam programs and the machine configuration
(MDAT) are deleted in this directory.
If the directory \P487 for the 487-machine does not exist, only the directory \P487 is created.
So all other files and directories on the SD-Card are not corrupted.
It is recommended to use SD-Cards with a maximum capacity of 2 GB.
42
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Adjustment
7
Adjustment differing from the basic machine
7.01
Basic setting of the differential adjustment device
Requirement
With the fullness set at "0", the stitch length at "2.5" and the adjustment gauge 5 fitted,
the roller 2 should be touching pressure sleeve 4.
2
5
1
3
4
Fig. 7 - 01
● Switch on the machine.
● Press key "0" on keyboard 1 (LED must light up).
● Switch off the machine.
● Adjust roller 2 (screw 3) according to the requirement.
43
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Adjustment
7.02
Parameter settings
7.02.01
Overview of the parameter functions
After the machine has been switched on, by pressing the appropriate function the input
mode is called up, in which the individual parameters can be called up directly. With a code it
is possible to protect all or individual parameter groups against unauthorised access.
Select parameter group
100
200
300
400
500
700
800
Operator level
Mechanic level
Sewing motor positions
Times
Counters and speeds
Sewing motor
Access rights
44
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Adjustment
7.02.02
Example of a parameter input
● Switch on the machine.
● Call up the input mode.
● e.g. call up parameter "113" (switch beep tone for section change on/off)
● e.g. switch beep tone on (value "ON").
● Conclude the input.
45
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Adjustment
7.03
List of parameters
The operator has free access to the "100" parameters. Parameters "200" - "800"
can only be changed after entering a code number and may only be changed by
authorised personnel.
1
2
102
113
114
201
Reversing
OFF - ON
OFF - ON
OFF - ON
OFF
OFF
OFF
Beep tone for section change
Max. speed forwards at each pedal positio
Machine configuration
9 = 487-918/15
10 = 5487-918/15
11 = 489-918/15
209
212
213
301
Fullness adjustment value (keyboard)
0 - 9
OFF - ON
OFF - ON
0 - 127
0
Not speed variation with change of fullness
program interruption with pedal-position -2
OFF
OFF
0
3
Position
"Needle point at top edge needle plate"
(P320ED)
302
303
Position "take-up lever t.d.c."
487, 489
5487
0 - 127
0 - 127
113
107
Position "needle lowered"
0
487, 489
5487
24
60
304
401
402
403
404
501
Reversing position
0 - 127
113
4
5
Delay time "lift foot" (s)
0,01s - 1,5s
0,01s - 1,5s
0,01s - 0,2s
0,01s - 1,5s
100 - 5500
0,02s
0,15s
0,15s
0,25s
Start delay after "lower foot" (s)
Thread cutting time (on the 5487)
Time for cleaning thread monitor (s)
Maximum speed
487, 489
5487
4800
5500
504
505
Speed soft start
100 - 5500
0 - 15
1500
0
Soft start stitches
46
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Adjustment
701
702
703
704
705
706
707
708
709
710
P-quota speed controller
7
0 - 50
16
50
40
40
25
25
15
0
I-quota speed controller
0 - 100
0 - 50
0 - 100
0 - 100
0 - 50
0 - 50
0 - 100
3 - 64
1 - 55
P-quota position controller
D-quota position controller
Time for position controller
P-quota position controller for rest brake
D-quota position controller for rest brake
Maximum moment for rest brake
Minimum machine speed
6
Maximum machine speed
0
487, 489
5487
42
55
711
Maximum motor speed
1 - 55
0
487, 489
5487
42
55
712
713
714
715
716
717
718
719
720
721
Positioning speed
Acceleration ramp
Brake ramp
3 - 25
0 - 50
0 - 50
0 - 127
0 - 255
3 - 10
1 - 10
0 - 1
18
35
30
20
40
8
Reference position
Time-out
Starting current motor
Anti-vibration filter
Rotation direction allocation
Reference position correction
6
0
0 - 127
64
Number of increments per revolution
(Read maximum value in Service and enter here)
- P323 MS
101 - 149
127
47
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Adjustment
801
802
803
804
805
806
807
808
809
810
Right of access function group 100
Right of access function group 200
Right of access function group 300
Right of access function group 400
Right of access function group 500
Right of access service
8
0 - 1
0 - 1
0
1
0 - 1
1
0 - 1
1
0 - 1
1
0 - 1
1
1
Right of access function group 700
Right of access function group 800
Right of access program creation
Enter access code
0 - 1
0 - 1
1
0 - 1
1
0 - 9999
3800
7.04
Sewing motor errors
Message
33
Description
▲
Invalid parameter value
Brake path too short *
34
▲
35
Communication error with limit control *
▲
36
Switch on sequence not ready *
▲
37
Too many commands
▲
64
Mains off during initialisation
▲
65
Overcurrent directly after mains on *
▲
66
Short circuit *
▲
68
Overcurrent during operation *
69
No increments *
▲
70
Motor stalling *
▲
71
No incremental plug *
73
Disturbed motor running *
▲
74
Incremental transmitter missing for speed increase/reduction
Regulator blocked *
75
170
171
173
175
222
Invalid transmission *
Invalid zero point *
▲
Motor blocked on first stitch
▲
Starting error *
▲
Time-out monitoring *
▲
P320 ED, * P323 MS
48
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Adjustment
7.05
Explanation of the error messages
Message
E001
Description
System error
E002
Sewing motor E002/BB/xxx
BB = 20:Time-out
02: Position forwards
03: Position in reverse
05: Position by shortest path
09: Write parameter
10: Speed
0A: Reset stitch counter
0B: Stop after xxx stitches
30: Time-out for increasing speed
31: Time-out for uncertain positioning
32: Time-out for time-out command
33: Time-out for deleting errors
34: Time-out for emergency stop
35: Time-out for writing parameters
36: Time-out for resetting stitch counter
37: Time-out for stop command after x stitches
38: Time-out for initialization
xxx = error bytes of sewing motor control unit (see list "Motor Errors")
E003
E004
E005
E006
E007
E008
Section
End of section
Pedal activated when machine switched on
Keyboard (CAN)
End of ramp
Reference for fullness adjustment not found
1: When moving towards sensor
2: When moving away from sensor
E011
E012
E014
E015
E016
E017
E018
E020
E021
E022
E023
E024
Stepping motor stepping frequency too high
not assigned
Incorrect program number (larger than 49)
Incorrect seam section number
Memory full
not assigned
not assigned
not assigned
Power supply unit overloaded (24V)
Mains voltage
Power supply 24V too low
Error at CAN interface
49
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Adjustment
7.06
Table of inputs
E1:
E2:
not assigned
not assignedi
not assigned
E3:
E4:
Start inhibitor
not assigned
E5:
E6:
Knee switch
E7:
not assigned
E8:
not assigned
E9:
not assigned
E10:
E11:
E12:
E13:
E14:
E15:
E16:
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
Reference for fullness adjustment
7.07
Table of outputs
O1:
O2:
Raise sewing foot (O1.1 and O1.2)
Thread trimmer (O2.1 and O2.2)
not assigned
O3:
O4:
not assigned
O5:
Backtacking device (only 487, 489)
Condensed stitches (only 5487)
not assigned
O6:
O7:
O8:
not assigned
O9:
not assigned
O10:
O11:
O12:
O13:
O14:
O15:
O16:
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
50
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Adjustment
7.08
Service menu
● Switch on the machine.
● Call up the input mode.
● Call up the service menu.
Explanation of the functions
Input mode
Quit the service menu and call up the input
Sewing mode
Quit the service menu and call up the sewing mode.
Set/reset outputs
Use the arrow functions to select the desired output and set "function 1" or reset
"function 2".
Cold start
See Chapter 7.09 Carry out a cold start.
Motors
After this function has been called up, the stepping motors for fullness and for the sewing
motor can be moved.
Basic position of the stepping motor
After this function has been called up, the basic position of the fullness stepping motor can
be changed.
Learning speed increase (in Motor menu)
Press this key to learn the speed increase function on machines with the control unit
P320ED. For this purpose the sewing drive sews 3 stitches at a speed of 360 min-1.
Control panel
See Chapter 4.04 Adjusting the control panel.
51
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Adjustment
7.09
Carry out a cold start
● Switch on the machine.
● Call up the input mode.
● Call up the service menu.
● Carry out a cold start.
After a cold start all programmed values are set back to their status at the time
of delivery.
All sewing programs are also deleted.
52
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Adjustment
7.10
Internet update of the machine software
The machine software can be updated with PFAFF flash programming. For this purpose the
PFP boot program and the appropriate control software for the machine type must be in-
stalled on a PC. To transfer the data to the machine, the PC and the machine control unit
must be connected with an appropriate null modem cable ( part no. 91-291 998-91 ).
The PFP boot program and the control software of the machine type
can be downloaded from the PFAFF-homepage using the following path:
To update the machine software carry out the following steps:
While the machine software is being updated, no setting up, maintenance or
adjustment work may be carried out on the machine!
● Switch off the machine.
● Connect the PC (serial interface or ap-
propriate USB-adapter) and the machine
control unit (RS232). To do so disconnect
the plug of the control panel.
● Switch on the PC and start the PFP boot
program.
● Select the machine type.
1
● Press the "programming" button.
● Hold down boot key 1 and switch on the
machine.
● Press the "OK" button.
● The software update is carried out, the
update progress is shown on the bar
display of thePFP boot program.
Fig. 7 - 08
● During the up-dating procedure the machine must not be switched off.
● When the update has been completed, switch off the machine and end the PFP boot pro-
gram.
● End the connection between the PC and the machine control unit and reconnect the con-
trol panel to the machine control unit.
● Switch on the machine.
● A plausibility control is carried out and, if necessary, a cold start.
More information and assistance is at your disposal in the file "PFPHILFE.TXT",
which can be called up from the PFP boot program by pressing the "help" but-
ton.
53
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Circuit diagrams
8
Circuit diagrams
8.01
Reference list for circuit diagrams 91-191 525-95
A1
Controller Quick P 320MS
Control panel (BDFT1)
Keyboard
A2
A3
A14
Sewing head identification (OTE)
H1
Sewing lamp
M1
M3
Sewing motor
Stepping motor fullness adjustment (SM1)
Q1
Main switch
S6
Knee switch (program switching)
Pedal speed control unit
Sychronizer PD3
S17
S18
X1
Mains plug
X1A
X1B
X3
RS232 – interface 1 Control panel BDFT1
VSS OTE (Sewing head identification)
Incremental transmitter (control unit)
Incremental transmitter (sewing motor)
Sychronizer PD3
XR3
XS3
X4B
X5
Stepping motor fullness (SM1)
Inputs
X8
Sewing motor
X11A
X11B
X13
X21
X22
X36
X46
X51
X52
X55
CAN interface (Keyboard)
Pedal speed control unit
Outputs
Stepping motor fullness (SM1) )
Keyboard
Knee switch (program switching)
Initiator reference (SM1)
Y1 -910/.. Automatic presser foot lift
Y2 -900/.. Thread trimmer
Y5 -911/.. Backtacking unit
Y1
Y2
Y5
-910/.. Automatic presser foot lift
-900/.. Thread trimmer
-911/.. Backtacking unit
54
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91-191 525-95 Part 1
Version 20.09.07
Circuit diagrams
8.01.02
Circuit diagrams 91-191 525-95
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Circuit diagrams
Version 20.09.07
91-191 525-95 Part 2
56
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91-191 525-95 Part 3
Version 20.09.07
Circuit diagrams
57
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Circuit diagrams
Version 20.09.07
91-191 525-95 Part 4
58
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Note
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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]
Hotlines:
Technical service:
+49-175/2243-101
Application consultance: +49-175/2243-102
Spare-parts hotline:
+49-175/2243-103
Printed in Germany
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