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Pfaff PLUSLINE 2483-3/03-980 Series, Adjustment Manual, Page: 2 / 58

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Pfaff PLUSLINE 2483-3/03-980 Series Adjustment Manual Download Page 2

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thereof) is only permitted with our prior agreement and citation of the source.

PFAFF Industriesysteme  
und Maschinen GmbH

Hans-Geiger-Str. 12  -  IG Nord

D-67661 Kaiserslautern

Summary of Contents for PLUSLINE 2483-3/03-980 Series

Page 1: ...296 12 19 275 002 adjustment Manual engl 05 16 This instruction manual applies to machines from the serial number 2 809 573 and software version 0307 010 onwards ADJUSTMENT MANUAL 2483 3 03 980 ...

Page 2: ...or translation of PFAFF instruction manuals including parts thereof is only permitted with our prior agreement and citation of the source PFAFF Industriesysteme und Maschinen GmbH Hans Geiger Str 12 IG Nord D 67661 Kaiserslautern ...

Page 3: ...ar rise hook to needle clearance needle height and bobbin case position finger 16 15 06 11 Thread check spring and slack thread regulator 18 15 06 12 Passage under sewing foot 19 15 06 13 Adjusting feed regulator zero position 20 15 06 14 Stitch length adjustment forwards and backwards 21 15 06 15 Bobbin winder 22 15 06 16 Mechanical stitch length limitation 23 15 06 17 Sewing foot pressure 24 15 ...

Page 4: ...y 36 15 11 03 Selecting user level 37 15 11 04 List of parameters 38 15 12 Error messages and description 44 15 13 Sewing motor errors 45 15 14 Service menu 46 15 15 Internet update of machine software 48 16 Circuit Diagrams 49 16 01 Block diagram of PFAFF 2483 with control unit P322 ED 49 16 02 Circuit diagrams 50 16 03 Plug connections 55 ...

Page 5: ...logical work sequence for machines that have to be completely adjusted Both the preceding and following chapters must be ob served if only specific individual work steps are carried out Screws and nuts indicated in brackets are fastenings for machine parts which must be loosened before any adjustment and tightened again afterwards 15 02 Tools gauges and other accessories O O 1 set of screwdrivers ...

Page 6: ...Turn the handwheel until the needle bar is approximately in the required position O O Push the adjustment pin 1 into the hole O O Move the handwheel gently back and forwards until the adjustment pin 1 engages in the crank 2 Needle bar positioned 0 6 mm after b d c O O Move the needle bar approximately into the required position O O Fit the adjustment gauge 3 to the studs 4 and 5 ensuring the right...

Page 7: ... be aligned if the needle bar is positioned 0 6 mm after b d c O O Move the needle bar to 0 6 mm after b d c O O Turn the toothed belt wheel 1 according to the rule and slide on the toothed belt 2 Make sure that the shaft flange shock absorber and motor flange are in the right position when installing the motor The second toothed belt wheel screw 1 is a balance cup screw Fig 15 02 3 4 1 2 ...

Page 8: ...h the lower edge of the needle bar frame 3 when the needle bar is positioned 1 8 mm after b d c Fig 15 03 O O Move the needle bar to 1 8 mm after b d c and fix with the adjustment pin see chapter 15 05 Checking and adjustment aid O O Adjust the needle bar 1 screw 2 without twisting according to the rule 2 1 3 ...

Page 9: ...ould not move when turning the handwheel Fig 15 04 O O Switch the machine on O O Set the stitch length to 0 using the control panel and turn the handwheel until the feed regulator motor responds O O Make sure that parameter 834 is set to 0 see chapter 15 11 Parameter settings O O Adjust the toothed segment 1 screws 2 without the gear wheel 3 according to rule 1 O O Turn the crank 4 screws 5 accord...

Page 10: ...le bar is positioned 0 6 mm after t d c the bottom transporter should not move when the shaft 3 is rotated back and forth Fig 15 05 O O Move the needle bar to a position 0 6 mm after t d c O O Turn the eccentric 1 screws 2 without moving it sideways according to the rule 3 1 2 2 ...

Page 11: ...ng point and 2 the control cam 3 should abut the feed lifting eccentric 1 O O Switch the machine on O O Set the stitch length to 0 and move the needle bar to a position 0 6 mm after t d c O O Turn the handwheel until the feed regulator motor responds O O Turn the eccentric 1 screws 2 according to rule 1 O O Adjust the control cam 3 screws 4 according to rule 2 and switch off the machine Fig 15 06 ...

Page 12: ...e stitch length to 0 O O Turn the handwheel until the feed regulator motor responds O O Move the bottom transporter 1 to its upper turning point O O Raise the sewing foot move the feed dog setting gauge 2 over the needle plate cut out with the arrow in the sewing direction and the front edge flush with the needle plate edge and lower the sewing foot O O Adjust the bottom transporter carrier 3 scre...

Page 13: ... O O Insert the needle into the needle hole by turning the handwheel O O Loosen the screws 1 2 and 3 O O Adjust the needle bar frame 4 according to the rule O O Tighten the screw 2 and gently tighten the screw 3 O O Use the screw 1 to pull the internal guide pin up to the eye of the needle bar frame 4 and tighten it O O Turn the handwheel a few turns so that the needle bar frame 4 is not under ten...

Page 14: ... be minimal yet noticeable play between the plastic pinion 3 and the steel wheel 4 This play should be approximately the same for a 360 turn 3 The steel wheel 4 should align with the plastic pinion 3 3 Fig 15 09 O O Align the hook shaft bearing 1 screw 2 according to rule 1 O O Set the steel wheel 4 with the eccentric bush of the hook shaft bearing 1 according to rule 2 and tighten the screw 2 O O...

Page 15: ...d over the needle plate cutout after ap proximately 10 seconds when the machine is running at full speed The setting is only required if the wick is replaced Make sure that the new wick is impregnated with oil when replacing the wick O O Adjust the centrifugal disc 1 screw 2 according to rule 1 O O Check rule 2 and adjust the centrifugal disc 1 if necessary Fig 15 10 1 5 mm 2 1 3 ...

Page 16: ...rom the fillet of the needle and 2 The upper edge of the eye of the needle should be 0 8 mm under the tip of the hook 3 There should be a clearance of 0 5 mm between the lug of the bobbin case position finger 4 and the base of the stop groove O O Switch the machine on O O Set the stitch length to 0 using the control panel and turn the handwheel until the feed regulator motor responds O O Switch th...

Page 17: ...ve the needle bar to 1 8 mm after b d c O O Adjust the hook according to rule 1 O O Tighten the screws 1 O O Adjust the needle bar 2 screw 3 without twisting according to rule 2 O O Align the bobbin case position finger 4 screw 5 according to rule 3 ...

Page 18: ...ld have moved approx 1 mm when forming the maxi mum thread loop while passing the thread around the hook O O Turn the thread tension 1 screw 2 according to rule 1 O O Adjust the slack thread regulator 3 screws 4 according to rule 2 It may be necessary to deviate from the specified spring deflection for reasons relating to the sewing technology Adjust the slack thread regulator 3 screw 4 by more th...

Page 19: ...rance between the sewing foot and needle plate should be should be 5 mm Fig 15 13 2 1 7 mm O O Adjust the solenoid 1 screw 2 according to rule 1 O O Raise the hand lever and place the adjustment gauge 3 order no 61 111 639 73 under the sewing foot according to rule 2 O O Move the presser bar lifting lever 4 so that it touches the lift piece 5 Make sure that the needle is positioned in the middle o...

Page 20: ...e permissible values according to the rule The permissible values for parameter 834 are 1 0 or 1 If the feed regulator zero position cannot be set by selecting the permissi ble values the mechanical setting must be checked or corrected see chapter 15 06 03 Bottom transporter zero position The zero position of the feed regulator is always identifiable in a range of 3 val ues The middle value must b...

Page 21: ...sing the formula O O Select the determined value for parameter 846 and switch off the machine The stitch length adjustment backwards is performed under parameter 847 according to the work steps mentioned above the key for reverse sewing must be pressed see chapter 7 02 Keys on the machine head Further information about selecting and changing parameters and explanations functions about the individu...

Page 22: ...winder should switch off automatically if the thread fill is approx 1 mm away from edge of the bobbin 3 The eccentric stud 3 should be at the centre of the large bobbin chamber 1 2 5 81 043 3 4 1 mm Fig 15 15 3 O O Adjust the drive wheel 1 screw 2 according to rule 1 O O Place a bobbin on the bobbin winder thread the bobbin and switch on the bobbin winder O O Adjust the stud 3 screw 4 according to...

Page 23: ...clearance of 0 3 mm to the corresponding cast edge O O Turn on the machine and adjust parameter 849 according to rule 1 see chapter 15 11 Pa rameter settings O O Select the maximum stitch via the control panel O O Turn the stop 1 screw 2 according to rule 2 O O Sew stitches with the key for reverse sewing 2 pressed see chapter 7 02 Keys on the machine head O O Turn the stop 3 screw 4 according to ...

Page 24: ...ustment 24 15 06 17 Sewing foot pressure Rule The material should be transported properly at all times no pressure marks should appear on the material Fig 15 17 1 O O Turn the screw 1 according to the rule ...

Page 25: ... the roller lever 4 should be at the lowest point of the control cam 2 When the needle bar is positioned 1 8 mm after b d c needle rise position the roller lever 4 should engage in the corresponding control cam cutout Fig 15 18 O O Move the solenoid carrier 1 screws 2 according to rule 1 O O Turn the control cam 5 screws 6 according to rule 2 2 3 1 4 4 6 5 ...

Page 26: ...zontal and not touch at any position as it moves O O Remove the knife 1 screw 2 O O Move the needle bar to b d c O O Loosen the stop 3 screws 4 O O Manually position the thread catcher 5 in front of the needle O O Align the thread catcher 5 screws 6 according to the rules The knife 1 remains dismantled and the stop 3 remains loosened for other set tings Fig 15 19 6 5 3 1 2 5 6 ...

Page 27: ...f the thread catcher see arrow 3 O O Move the needle bar to b d c O O Slide the knife 1 under the locking tab and align according to rule 1 O O Gently tighten the screw 2 O O Manually adjust the thread catcher carrier 3 until the cutting tip in the thread catcher is positioned just in front of the knife edge O O Align the knife 1 according to rule 2 and tighten the screw 2 Fig 15 20 1 1 2 4 mm ...

Page 28: ...e front turning point the tip of the thread catcher cutout should be 1 mm in front of the bobbin case position finger 5 Fig 15 21 O O Swivel the roller lever 1 to the lowest point of the control cam O O Turn the lever 2 screws 3 according to the rule 1 2 3 5 4 1 mm 1 15 07 05 Manual cutting control 31 ...

Page 29: ...ning point O O Pull a double up length of thread and hook it in the thread catcher cutout O O Carry out the cutting operation manually O O If the threads are not cut according to the rule align the thread catcher 1 screws 2 to the knife 3 accordingly O O Move the stop 4 until it abuts the thread catcher 1 and tighten the screws 5 O O Chapter 15 07 02 Aligning thread catcher laterally check and adj...

Page 30: ...gnet lift should be 1 5 mm 2 When the solenoid 5 is operated manually there should be a clearance of at least 0 5 mm between the tension discs 6 O O Turn the disc 1 nuts 2 according to rule 1 O O Turn the screw 3 nut 4 according to rule 2 Fig 15 23 3 4 5 2 1 0 5 mm 6 ...

Page 31: ... 31 15 07 07 Re calibrating control cam Rule When the needle bar is at t d c the control cam 1 should have controlled the thread catcher 3 O O Turn the control cam 1 screws 2 according to the rule Fig 15 24 1 2 3 ...

Page 32: ...show the same value same signal strength when the sewing material is in place O O Switch the machine on O O Call up function PS from the service menu see chapter 15 14 Service menu O O Adjust the transmitted light transmitter 1 screw 2 according to the rule O O Switch the machine off Fig 15 25 2 1 ...

Page 33: ...nd forth under the sensors O O Press using the corresponding key to end the adjustment for the single material layer O O Place a double material layer under the sensors O O Press using the corresponding key to start the adjustment for the double materi al layer O O Briefly move the material layers back and forth under the sensors O O Press using the corresponding key to end the adjustment for the ...

Page 34: ... sensor receiving signal O O Insert the bobbin into the bobbin case and insert the bobbin case into the hook O O Switch the machine on O O Call up function TM from the service menu see chapter 15 14 Service menu O O Remove the thread by hand and check the rule O O Increase or decrease the transmission power if necessary using the corresponding key O O Switch the machine off Fig 15 26 Tx ...

Page 35: ...r groups or also indi vidual ones can be protected by a code against unauthorised access Select parameter group 100 Operator level 200 Mechanic level 300 Sewing motor functions 400 Times 500 Counter and revolution speed 600 Service 700 Sewing motor 800 Access rights To call up the seam program input see chapter 11 02 Entering seam programs For a more detailed description of parameter functions see...

Page 36: ...to prevent an accidental start up of the machine O O Select the desired parameter e g 660 bobbin thread monitor by pressing the corre sponding keys O O Set the desired value for the parameter e g 0 to switch off the bobbin thread monitor by pressing the corresponding key No VAL 2 x O O The value is taken over and the machine switches to sewing mode by pressing the TE Speed key No VAL 101 on TE No ...

Page 37: ...vel A Select the desired user level by pressing the corresponding keys 0 Operator level A 1 Mechanic level B 11 Service level C The user level chosen is shown by the parameter number O O Conclude the parameter input The changed values are saved and the control unit switch es to sewing mode After turning the main switch off and on again it will automatically change back to operator level A No VAL 7...

Page 38: ... 107 Pedal controlled start backtack speed C OFF ON OFF ON limited with parameter 105 OFF limited with parameter 607 108 End backtack stitches in reverse C 0 9 3 109 End backtack stitches forwards C 0 9 3 110 End backtack speed B 100 1500 1000 111 Stitch count of bright light barrier to A 1 255 6 seam end in manual sewing 113 Start with light barrier B OFF ON ON ON only when light barrier is dark ...

Page 39: ...ick up time in 10 ms B 0 100 20 349 Bobbin changer hold bobbin activate B 0 100 10 in 10 ms 350 Bobbin changer hold bobbin deactivate B 0 100 10 in 10 ms 4 419 Bartacks C OFF ON ON ON inverted OFF suppressed 478 Corner stitch C OFF ON ON ON accurate OFF quick faster cycle time at the expense of accuracy 492 Number of seam programs B 1 99 99 493 Number of seam sections per seam program B 1 15 25 49...

Page 40: ...ON ON on OFF off 660 Bobbin thread monitor A 0 2 1 0 off 1 on 2 bobbin thread reverse counter on 668 Thread wiper 1 B 0 2 2 Thread clamp 2 0 off 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 signal B 80 127 98 706 Needle position start of cutting signal B 40 80 68 7...

Page 41: ...simple end backtack ms 733 Holdoff time from C 0 200 30 switch on feed reverse to speed start ms 739 Holdoff time for speed C 0 2550 200 after start backtack or stitch condensation ms 740 Stitch count delay for end backtacks ms C 0 2550 60 760 Stitch count to bobbin thread monitor A 0 50000 1000 machine stop in needle lowered position 761 Extension of B 0 2550 0 thread tension release thread tensi...

Page 42: ...1 10 mm 844 Distance sensor 1 to needle 2 10 mm B 80 300 200 845 Speed controlled B 0 3 1 stitch length adjustment pro 1000 min 1 846 Feed regulator characteristic line A 80 110 s adjustment for forward stitch length 847 Feed regulator characteristic line A 80 110 s adjustment for reverse stitch length 849 Maximum stitch length 1 10 mm A 0 60 25 862 Current for stepping motor axis 1 C 16 63 32 863...

Page 43: ...of higher ranking speed controller for standstill brake rest brake 891 Proportional amplification C 1 50 20 of subordinate speed controller for standstill brake rest brake 9 901 Cutting release speed C 180 500 400 956 Current for stepping motor axis 2 B 30 63 56 957 Current for current reduction B 15 48 39 of stepping motor axis 2 958 Current reduction time B 0 2500 2000 stepping motor axis 2 978 ...

Page 44: ... on BDF P1 ERROR 27 SD card ERROR 40 Transmitted light sensors ERROR 45 Bobbin thread monitor ERROR 46 Bobbin changer if timeout ERROR 47 Bobbin changer empty if magazine is empty ERROR 48 Bobbin changer error with can node suberror ERROR 60 Power supply 24 V too low ERROR 61 Power supply 24 V too high ERROR 62 Short circuit 24 V ERROR 63 Overload switch power supply ERROR 92 Start inhibitor when ...

Page 45: ...RROR 66 Short circuit ERROR 67 Mains off ERROR 68 Excess current during operation ERROR 69 No increments ERROR 70 Motor blocked ERROR 71 No incremental encoder connector ERROR 73 Faulty motor operation ERROR 75 Control locked ERROR 170 Transmission invalid ERROR 171 Zero mark invalid ERROR 173 Motor blocked in 1st stitch ERROR 175 Internal starting error ERROR 222 Dead man monitoring ...

Page 46: ...ce functions are displayed under FCT and can be selected using the corresponding key Overview of the service functions FCT No VAL 01 OFF SERVICE X05 P01 FKT IN FCT Explanation IN Read inputs The number of the input No can be selected using the corresponding key OUT Set reset outputs The number of the output No can be selected and set accordingly VAL ON OFF using the corresponding keys PED Read ped...

Page 47: ...e SPD and entering the desired value using the corresponding keys The value for the stitch count is changed accordingly by selecting the type SC and entering the desired value using the corresponding keys RES Perform a reset The values for all parameters are reset master reset by selecting the type PAR and confirming the selection using the corresponding keys All seam programs are deleted by selec...

Page 48: ...tween the PC serial interface or corresponding USB adapter and the machine control unit RS232 by loosening the control pan el connector Switch on the PC and start the PFP boot program O O Select the machine type O O Press the Programming button O O Press and hold the boot key 1 and switch on the machine O O Press the OK button The software update is conducted and the progress of the update can be ...

Page 49: ... Circuit Diagrams 49 16 Circuit Diagrams 16 01 Block diagram of PFAFF 2483 with control unit P322 ED ...

Page 50: ...n A4 S11 Hand operation front bartack included in A4 S12 Needle position included in A4 S13 Knee switch single stitch S14 Starting lock out S15 Knee switch 2 H1 Sewing lamp H10 Bobbin thread alarm included in A4 Q1 Main switch M1 Sewing motor M10 Stepping motor feed regulator M11 Stepping motor edge guide B10 Forked light barrier included in M10 Y2 900 Thread trimmer Y3 WI Thread wiper device Y4 P...

Page 51: ...4 95 Part 1 Version 11 05 2016 Circuit diagram Control panel BDFS3 RS232 interface Speed control unit CAN interface Sewing motor Incremental encoder Motor Motor Rotor position sensor Sewing lamp Speed control unit Control device A1 ...

Page 52: ...Circuit Diagrams 52 Circuit diagram Version 11 05 2016 91 191 454 95 Part 2 Step motors Control device A1 Forked light barrier SM position SM stitch setter Optional SM straight edge ...

Page 53: ... Circuit Diagrams 53 91 191 454 95 Part 3 Version 11 05 2016 Circuit diagram Control device A1 Outputs Presser foot Optional thread wiper Thread trimmer Thread tension ventilation Key field ...

Page 54: ...rt 4 Control device A1 Inputs Bartack Single stitch Single stitch Knee switch Bobbin thread monitor Transmitted light sensor Transmitter Transmitted light sensor Receiver Optional Second knee switch Bobbin thread alarm Start inhibitor Needle position change over Key field ...

Page 55: ...s Pin no Comment Function Connector name Signal name X15 1 Sensors Power source UFW P7 3 X15 2 Sensors DLS external LS2 P5 3 analog X15 3 Sensors DLS internal LS1 P5 6 analog X15 4 Sensors Zig zag sensor 2438 E9 E9 Port_E9 X15 5 Sensors Power source DLS A10 PortA10 O10 X15 6 Sensors 5V 5V X15 7 Sensors UFW Out UFW_MESS X15 8 Sensors 24V 24V X15 9 Sensors 0V 0V RS232 Pin no Comment Function Connect...

Page 56: ...ect ADTC X3 5 IncrEncod 5V X3 6 IncrEncod 5V X3 7 IncrEncod Gnd X3 8 IncrEncod Ext SyMa 180 EXTSM_MINI X3 9 IncrEncod Gnd Stepping motor 1 edge guide Pin no Comment Function Connector name Signal name X4B 1 SM1 FSL Phase A 2 A11 X4B 2 SM1 FSL Phase A 1 A12 X4B 3 SM1 Phase B 2 A21 X4B 4 SM1 Phase B 1 A22 X4B 5 SM1 X4B 6 SM1 X4B 7 SM1 5V with 120R X4B 8 SM1 Reference SM1 SM_REF1 SM_REF1 X4B 9 SM1 Gn...

Page 57: ...d 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 Connector name Signal name X5 01 TUM switch key S1 E1 E7 X5 02 NPW switch key S2 E2 E8 X5 03 EST switch key S2 E3 E2 X5 04 ANLSP switch S14 E4 E4 X5 05 EST knee switch S13 E5 E5 X5 06 Knee switch 2 E15 E15 X5 07 E16 E16 X5 08 E14 E14 X5 09...

Page 58: ... is an authorised licensee of the PFAFF trademark PFAFF Industriesysteme und Maschinen GmbH Hans Geiger Str 12 IG Nord D 67661 Kaiserslautern Tel 49 6301 3205 0 Fax 49 6301 3205 1386 E mail info pfaff industrial com Gedruckt in der BRD Printed in Germany Imprimé en la R F A Impreso en la R F A ...

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