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Pfaff 2481-980/30 PLUSLINE, Instruction Manual, Page: 2 / 112

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Pfaff 2481-980/30 PLUSLINE Instruction Manual Download Page 2

This Instruction Manual is valid for all models and subclasses listed in the  
chapter "

Specifications

 ".

The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or 
in part, is only permitted with our previous authorization and with written reference to the 
source.

PFAFF Industriesysteme 
und Maschinen AG

Hans-Geiger-Str. 12  -  IG Nord

D-67661 Kaiserslautern

Summary of Contents for 2481-980/30 PLUSLINE

Page 1: ...TION MANUAL 296 12 18 760 002 Betriebsanleitung engl 03 10 This instruction manual applies to machines from the following serial numbers 2 216 531 and software version 0307 001 onwards 2481 980 30 Ind...

Page 2: ...eci cations The reprinting copying or translation of PFAFF Instruction Manuals whether in whole or in part is only permitted with our previous authorization and with written reference to the source PF...

Page 3: ...5 1 5 02 Transport within the customer s premises 5 1 5 03 Disposal of the packaging 5 1 5 04 Storage 5 1 6 Explanation of the symbols 6 1 7 Controlelements 7 1 7 01 On offswitch 7 1 7 02 Keys on mach...

Page 4: ...s 10 4 11 Input 11 1 11 01 Inputmode 11 1 11 02 Entering the seam program 11 2 11 02 01 Selecting the seam types 11 4 11 02 02 Entering the seam depth 11 6 11 03 Example of how to enter a seam program...

Page 5: ...3 06 01 Adjusting the solenoid preliminary adjustment of the control cam 13 23 13 06 02 Lateral alignment of the thread catcher 13 24 13 06 03 Knifeposition 13 25 13 06 04 Front point of reversal of t...

Page 6: ...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 adheredto When exch...

Page 7: ...d and safety devices Before threading changing bobbin and needle cleaning etc switch off main switch I 1 04 Important points for the user This Instruction Manual is an integral part of the machine and...

Page 8: ...hanges in the machine which may limit its safety 1 05 02 Specialist personnel Specialist personnel are persons with a specialist education in the fields of electrics electronics and mechanics They are...

Page 9: ...inhibitor 3 Danger of injury if the machine is started accidentally 1 06 Danger A working area of 1 meter is to be kept free both in front of and behind the machine while it is in operation so that it...

Page 10: ...stry for sewing lockstitch seams 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...

Page 11: ...Needle bar stroke 30 or 36 mm Connection data Operating voltage 230 V 10 50 60 Hz Max power consumption 400 VA Fuse protection 1 x 16 A inert Leakage current 5 mA Ambient temperature 85 rel humidity c...

Page 12: ...Specifications 3 2 3 02 Work aids for the various models Model A for sewing with fine materials Model B for sewing medium weight materials Work aids Sub class 909 04 Thread wiping device...

Page 13: ...various plastics The electrical equipment consists of plastics and copper The machine is to be disposed of in accordance with the locally valid environmental protection regulations If necessary a spec...

Page 14: ...of use Make sure that the machines are always transported upright 5 03 Disposal of the packaging The packaging of these machines consists of paper cardboard and VCE fiber The proper disposal of the pa...

Page 15: ...this Instruction Manual certain tasks or important pieces of information are accentuated by symbols The symbols used have the following meanings Note information Cleaning care Lubrication greasing Se...

Page 16: ...lever as far as possible The machine can be switched on or off by turning the on off switch 1 77 005 1 7 02 Keys on machine head By operating the respective keys the following functions are carried o...

Page 17: ...lifting the presser foot The presser foot is raised by turning lever 1 Fig 7 04 1 7 03 Pedal 0 Neutralposition 1 Sewing 2 Raise presser foot 3 Cut thread reset bobbin thread monitor or bobbin rest th...

Page 18: ...7 3 7 05 Knee switch When the knee switch 1 is operated one stitch is sewn with a reduced stitch length The value for the reduced stitch length is set with parameter 835 see Chapter 13 11Parameterset...

Page 19: ...re 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...

Page 20: ...iently sturdy even during sewingoperations 8 01 Mounting The necessary electricity supply must be available at the machine s location Also a stable and horizontal surface as well as adequate lighting...

Page 21: ...8 02 Connect plugs 1 7 as labelled to the control box Screw the earth cable from the sewing head to earth point A Fasten the earth cable 8 from the motor to earth point B Connect earth point C to ear...

Page 22: ...hines delivered without a table the plate 1 from the accessories should be mounted so that it is on a level with the bottom edge of the table top and with the left edge of the table top cutout Set the...

Page 23: ...ioning Before commissioning the machine remove plug 1 from the oil tank 2 Danger of damage to the machine Plug 1 serves as a safety device for transportation and should not be used during sewingoperat...

Page 24: ...50 0 2 9 8 0 2 9 8 0 2 1 7 17 4 1 5 0 2 4 1 5 0 2 12 85 40 71 5 0 1 339 6 0 3 28 0 2 8 5 50 1 5 1 5 4 5 4 5 1 5 15 5 18 30 R 1 0 2 x R 1 9 2 x 0 5 R 3 0 R 3 0 R 10 R 10 R 10 R 1 0 R 10 R 1 0 R 10 R 1...

Page 25: ...be separated from the electricity supply by removing the plug from the mains or switching off the On Off switch 9 01 Inserting the needle Switch off the machine Danger of injury due to unintentionalst...

Page 26: ...r 3 simultaneously The bobbin fills up during sewing If the machine is only run for bobbin winding without sewing a hook base must be fitted in the hook Otherwise a jammed thread may damage the hook T...

Page 27: ...g the bobbin case Press bobbin case 2 until you feel it snap into the bobbin case base Return the machine to its upright position usingboth hands Danger of injury by crushing between the machine and t...

Page 28: ...he needle thread Adjusting the needle thread tension Fig 9 05 Switch off the machine Danger of injury due to unintentional starting of the machine Thread the machine as shown in Fig 9 05 Adjust the ne...

Page 29: ...ch length can be entered or altered directly Switch on the machine Call up the stitch length input menu Enter the stitch length with the number keys Or Alter the stitch length step by step Conclude th...

Page 30: ...ion can be entered or altered directly Switch on the machine Call up the edge guide position input menu Enter the edge guide position with the number keys Or Alter the edge guide position step by step...

Page 31: ...end backtack the corresponding symbol is shown as an inverse symbol Select the desired value for the number of forward stitches A of the start backtack Select the desired value for the number of reve...

Page 32: ...hich will be sewn after the recognition of the material edge till the machine stops Switch on the machine Switch on the edge sensor and call up the compensating stitches input menu Enter the number of...

Page 33: ...been used up there is still an amount of remaining thread on the bobbin Switch on the machine Call up the input mode Call up parameter 660 Switch on the bobbin thread monitoring function Value 1 Expla...

Page 34: ...760 Set the number of remaining stitches which can still be sewn after the signal from the bobbin thread monitor depends on the thread size Concludetheinput The number of remaining stitches can be alt...

Page 35: ...the machine Call up the seam program selection menu Enter the seam program number with the number keys Or Scroll through the seam program numbers Conclude the input and change to the programmed sewin...

Page 36: ...9 12 Adjusting the control panel Switch on the machine Call up the input mode Select user lever C see Chapter 13 11 02 Selecting the user level Call up the service menu Call up the control panel func...

Page 37: ...Preparation 9 13 Change the display contrast Switch the key tone on or off Never reduce the display contrast to such an extent that the display can no longerberead...

Page 38: ...ameters necessary for the sewing operation can be changed directly The manual sewing mode is selected with the program number selection function see Chapter 9 11 Selecting the seam program The selecti...

Page 39: ...ensor compensating stitches Opens the menu for entering the compensating stitches see Chapter 9 09 Entering the number of compensating stitches When this function is switched on the seam end is initia...

Page 40: ...Selecting the seam program Explanation of the functions and displays Seam program selection Opens the menu for entering the seam program number or for selecting the manual sewing mode see Chapter 9 1...

Page 41: ...er of remaining stitches is shown and when the speed display function is activated the current speed is shown see Chapter 13 11 03 List of parameters Sewing is carried out with the pedal functions see...

Page 42: ...tions Sewing mode Quit the input mode and call up the sewing mode Parameterselection Select the hundred and unit figures of the desired parameters see Chapter 13 11 01 Example of a parameter input Alt...

Page 43: ...function Explanation of the functions Seam program selection Opens the menu for entering the seam program number or for selecting the manual sewing mode see Chapter 9 11 Selecting the seam program Edg...

Page 44: ...ion When this function is activated the corresponding seam section is sewn in reverse Sewing stop When this function is activated sewing stops automatically at the send of the seam section Seam sectio...

Page 45: ...and values in the individual seam sections can be altered The seam types are divided into groups for flaps cuffs collars and shoulder flaps In additions one free description space is available if it...

Page 46: ...he desired seam type When a seam type has been selected the machine switches to the seam program input function Overview of the seam groups with their corresponding seam types Free seam Flap Cuffs Col...

Page 47: ...les to the edge have to be sewn a correction value must be entered Switch on the machine Select a program number see Chapter 9 11 Selecting a seam program Call up the seam program input function Call...

Page 48: ...alue input menu and enter the correction value Or Place the workpiece on the angle outline on the display and adjust the angle The correction value is calculated automatically from the adjusted angle...

Page 49: ...ine Call up the seam program number input menu and select program number 16 see Chapter 9 11 Selecting the seam program Call up the seam program input function 3 mm 3 mm Program number 16 45 Stitchlen...

Page 50: ...tion and enter the edge guide position 3 0 see Chapter 9 07 Entering the edge guide position Call up the seam depth input menu and enter the seam depth 3 0 Select first seam section Call up the correc...

Page 51: ...workpiece on the angle outline on the display and adjust the angle The correction value is calculated automatically from the adjusted angle Conclude the input and take over the correction value Switch...

Page 52: ...eam section Call up the stitch length input menu and enter the stitch length 0 see Chapter 9 06 Entering the stitch length The fifth seam section is then recognised as the last seam section Conclude t...

Page 53: ...ation If the machine is operated more than this shorter intervals arerecommended 12 01 Cleaning the machine Switch off the machine Danger of injury due to unintentionalstartingofthe machine Tilt back...

Page 54: ...sewing head support Fill oil through hole 1 into the reservoir 2 up to the level of the front edge see arrow Return the machine to its upright position usingboth hands Danger of injury by crushing be...

Page 55: ...e 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...

Page 56: ...d c Turn the balance wheel until the needle bar is approximately in the required position Insert adjustment pin 1 in the hole Move the balance wheel fractionally to and fro until adjustment pin 1 enga...

Page 57: ...positioned 0 6 mm past b d c the markings 3 and 4 should be in alignment Fig 13 02 Bring needle bar to 0 6 mm past b d c Adjust the toothed belt wheel 1 according to the requirement and slide on tooth...

Page 58: ...above BDC the mark on the needle bar 1 must be flush with the bottom edge of the needle bar frame 3 Fig 13 03 Set needle bar at 1 8 mm past b d c and block machine with blocking pin see Chapter 13 04...

Page 59: ...motion of the bottom feed dog when the balance wheel is turned Fig 13 04 Switch on the machine On the control panel set the stitch length at 0 and turn the balance wheel until the stitch length contro...

Page 60: ...e bar when the balance wheel is turned Switch on the machine On the control panel set the stitch length at 0 and turn the balance wheel until the stitch length control motor reacts Make sure that para...

Page 61: ...With the needle bar positioned 0 6 mm past b d c the bottom feed dog should not move when shaft 3 is turned backwards and forwards Fig 13 06 Position the needle bar at 0 6 mm past b d c Adjust eccentr...

Page 62: ...Requirement With the needle bar positioned 0 6 mm past b d c the needle should not move when shaft 3 is turned backwards and forwards Fig 13 07 Position the needle bar at 0 6 mm past b d c Adjust ecc...

Page 63: ...ts stroke and 2 The control cam 3 should be resting on the feed lifting eccentric 1 Switch on the machine Set the stitch length at 0 and bring the needle bar to 0 6 mm past b d c Turn the balance whee...

Page 64: ...whole length Fig 13 09 Switch on the machine and set the stitch length at 0 Turn the balance wheel until the stitch length control motor reacts Bring the bottom feed dog 1 to the top of its stroke Rai...

Page 65: ...ch on the machine On the control panel set the stitch length at 0 and turn the balance wheel until the stitch length control motor reacts By turning the balance wheel position the needle in the needle...

Page 66: ...d belt should be tightened so that when the gauge is placed on it the marking in the gauge window should match the marking on the bushing 1 3 Fig 13 11 Align the hook bearing shaft 1 screw 2 in accord...

Page 67: ...seconds a mark should be made by a fine stripe of oil on the strip of paper placed over the needle plate cutout The adjustment is only necessary if the wick has been replaced When replacing the wick m...

Page 68: ...the clearance cut of the needle and 2 the top edge of the needle eye must be 0 8 mm below the hook point 3 Between the projection of the bobbin case position finger 4 and the bottom of the retaining...

Page 69: ...sition the needle bar at 1 8 mm after BDC Adjust the hook according to requirement 1 Tighten screw 1 Move needle bar 2 screw 3 without turning it according to requirement 2 Align bobbin case position...

Page 70: ...e the slack thread regulator 3 screw 4 toward the more thread or toward the less thread Fig 13 14 13 05 13 Thread check spring and slack thread regulator Requirement 1 The motion of the thread check s...

Page 71: ...sed the clearance between the presser foot and the needle plate should be 5 mm Adjust solenoid 1 screw 2 in accordance with requirement 1 Raise the hand lever and place adjustment gauge 3 part no 61 1...

Page 72: ...issible values in accordance with the requirement The permissible values for parameter 834 are 1 0 or 1 If the zero point of the feed regulator cannot be set by selecting one of the permissible values...

Page 73: ...ustment of the reverse stitch length is carried out as described in the above work steps under parameter 847 with the reverse feed key pressed see Chapter 7 02 Keys on the machine head More informatio...

Page 74: ...n winder Adjust pin 3 screw 4 in accordance with requirement 2 and turn it in accordance with requirement3 13 05 17 Bobbin winder Requirement 1 With the bobbin winder on the drive wheel 1 must engage...

Page 75: ...earance of 0 3 mm to the corresponding metal edge Fig 13 19 Switch on the machine and set parameter 849 in accordance with requirement 1 see Chapter 13 11 Parameter settings Select the maximum stitch...

Page 76: ...nt 13 22 Fig 13 20 1 13 05 19 Presser foot pressure Requirement The material must be fed reliably In the process pressure marks on the material must not be made Turn screw 1 in accordance with the req...

Page 77: ...etely extended roller lever 4 should be at the lowest point of the control cam 2 When the needle bar is positioned at 1 8 mm after b d c needle rise position roller lever 4 should engage in the approp...

Page 78: ...d catcher 5 must be horizontal It must not graze anything when it is operating Remove knife 1 screw 2 Move needle bar to its BDC Loosen stop 3 screws 4 Position thread catcher 5 screw 6 manually in fr...

Page 79: ...the right edge of the thread catcher see arrow Bring the needle bar to BDC Slide knife 1 under the locking tab and align according to requirement 1 Tighten screw 2 lightly Adjust thread catcher carrie...

Page 80: ...front point of reversal of thread catcher 4 the tip of the thread catcher cutout should be 1 mm in front of the bobbin case position finger 5 Fig 13 24 Position roller lever 1 at the lowest point of t...

Page 81: ...1 by hand to its front point of reversal Double the thread and insert into catcher cutout Carry out trimming operation manually If the threads are not cut according to the requirement align thread ca...

Page 82: ...stroke should be 1 5 mm 2 When the solenoid 5 is operated by hand there should be a distance of at least 0 5 mm between the tension disks 6 Fig 13 26 Adjust disk 1 nuts 2 in accordance with requiremen...

Page 83: ...9 028 Fig 13 27 13 06 07 Readjusting the control cam Requirement When the take up lever is in its t d c control cam 1 should have moved thread catcher 3 Adjust control cam 1 screws 2 according to the...

Page 84: ...oned the transmitters PS2 and PS1 should display the same value same receiving power Switch on the machine Call up the input mode Call up the service menu Call up the sensor menu Adjust light transmit...

Page 85: ...the adjustment without material End the adjustment without material Start the adjustment with material e g cuff Move the cuff to and fro under the sensors for a short time End the adjustment for with...

Page 86: ...ssion of the incoming signal of the bobbin thread sensor Place the bobbin in the bobbin case and the bobbin case in the hook Switch on the machine Call up the input mode Call up the service menu Call...

Page 87: ...cted using the control panel guide unit 3 should be at a distance of approximately 0 1 mm from sewing foot 4 Switch on the machine Set the edge guide position at 1 0 mm see Chapter 9 07 Entering the e...

Page 88: ...r 660 bobbin thread control 0 660 Switch on the bobbin thread control value 1 Conclude the parameter input 13 11 Parameter settings 13 11 01 Example of a parameter input Switch on the machine Call up...

Page 89: ...A 100 100 By selecting the appropriate value for parameter 798 the user level is determined and shown in the display in front of the current parameter 0 Operator level A 1 Mechanic level B 11 Service...

Page 90: ...with param 105 C ON OFF OFF 107 Pedal controlled speed start backtacks ON limited with parameter 105 OFF limited with parameter 607 C ON OFF OFF 108 End backtacks in reverse C 0 9 3 109 End backtacks...

Page 91: ...min 1 10 mm B 10 50 10 325 Edge guide position max 1 10 mm B 165 185 185 4 419 Bartacks ON inverted OFF suppressed C ON OFF ON 478 Corner stitch ON accurate OFF fast C ON OFF ON 492 Number of seam pro...

Page 92: ...mp 2 off 0 B 0 2 2 7 700 Logical zero mark increments B 0 127 0 702 Needle position needle lowered B 0 30 15 703 Needle position take up lever raised B 100 127 113 705 Needle position end of cutting s...

Page 93: ...end backtack ms C 0 2550 60 760 Stitch count to bobbin thread monitor machine stop in needle lowered position A 0 50000 1000 761 Extension thread tension release pull thread ms B 0 2550 0 791 Stitch c...

Page 94: ...63 32 863 Current for current reduction of stepping motor axis 1 A 8 63 32 864 Proportional amplification of the speed control general B 0 2500 20 880 Starting current main drive C 1 10 8 881 Filter p...

Page 95: ...ing motor axis 2 B 30 63 56 957 Current for current reduction of stepping motor axis 2 B 15 48 39 958 Current reduction time stepping motor axis 2 B 0 2500 2000 978 Delay power off stepping motor 2 C...

Page 96: ...thread monitoring E062 Short circuit 24V E063 Overload switch power supply E064 Network monitoring E065 Extint low in operation E066 Short circuit E067 Power off E068 Extint low in operation E069 No...

Page 97: ...n E158 Stepping motor frequency E170 Incorrect main drive transmission E171 Logical zero mark invalid E172 Communication error main drive E175 Main drive start E200 Brake path too short E201 Main driv...

Page 98: ...ode Quit the service menu and call up the sewing mode Set resetoutputs Using the arrow functions select the desired output and set function 1 or reset function 2 Parameterreset All parameters are rese...

Page 99: ...ction Plugmarking Signalmarking X15 1 Sensors current source UFW P7 3 X15 2 Sensors DLS outside LS2 P5 3 analog X15 3 Sensors DLS inside LS1 P5 6 analog X15 4 Sensors ZZ Sensor 2438 E9 E9 Port_E9 X15...

Page 100: ...ADTC X3 5 incr transm 5V X3 6 incr transm 5V X3 7 incr transm Gnd X3 8 incr transm Ext SyMa 180 EXTSM_MINI X3 9 incr transm Gnd Stepping motor 1 edge guide Pin No Comment Function Plugmarking Signalm...

Page 101: ...9 SN solenoid Y2 24V 24V X13 20 WI solenoid Y3 24V 24V X13 21 24V 24V X13 22 RAFI LED H1 24V 24V X13 23 24V 24V X13 24 A13 O13 X13 25 A12 O12 Inputs Pin No Comment Function Plugmarking Signalmarking X...

Page 102: ...achine Switch off the machine Connect the PC serial interface or appropriateUSB adapter andthe machine control unit RS232 To do so disconnect the plug of the control panel Switch on the PC and start t...

Page 103: ...t for the complete machine under parts number296 12 18760 91 262 250 91 99 262 376 91 99 137 187 15 2x 99 137 186 05 99 137 189 05 4x 99 137 188 15 99 137 190 05 3x 91 262 377 91 99 137 192 05 99 137...

Page 104: ...Wearing parts 14 2 99 137 151 45 91 171 049 05 91 171 042 05 11 108 087 15 91 262 235 15 91 171 853 15 91 108 222 15 91 264 240 15 11 108 084 15 2x...

Page 105: ...tch included in A4 S11 Backtacking by hand backtack included in A4 S12 Needle position included in A4 S13 Knee switch single stitch S14 Startinhibitor S15 2nd knee switch H1 Sewing lamp H10 Bobbin thr...

Page 106: ...15 2 View Version 27 01 03...

Page 107: ...15 3 91 191 441 95 Part 1 Version 24 01 02 Circuit diagram...

Page 108: ...15 4 Circuit diagram Version 24 01 02 91 191 441 95 Part 2...

Page 109: ...15 5 91 191 441 95 Part 3 Version 24 01 02 Circuit diagram...

Page 110: ...15 6 Circuit diagram Version 24 01 02 91 191 441 95 Part 4...

Page 111: ...Note...

Page 112: ...ger Str 12 IG Nord D 67661 Kaiserslautern Phone 49 631 200 0 Fax 49 631 17202 E mail info pfaff industrial com Hotlines Technical service 49 175 2243 101 Application consultance 49 175 2243 102 Spare...

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