Pfaff 3819 -20/02, Instruction Manual

Page 1: ... instruction manual applies to machines from the following serial numbers onwards 2 808 742 and software version 0441 001 3819 296 12 19 290 002 Instruction Manual engl 10 15 INSTRUCTION MANUAL 20 02 40 01 ...

Page 2: ...ed only with our prior approval and listing of sources PFAFF Industriesysteme und Maschinen GmbH Hans Geiger Str 12 IG Nord D 67661 Kaiserslautern The adjustment manual for the machine can be downloaded at no charge at www pfaff industrial de de service support downloads technical As an alternative to the Internet download the adjustment manual can also be ordered under order no 296 12 19 291 002 ...

Page 3: ...rage 12 5 01 Transport to the customer s premises 12 5 02 Transport within the customer s premises 12 5 03 Disposal of the packaging materials 12 5 04 Storage 12 6 Work Symbols 13 7 Operating Controls 14 7 01 Main switch 14 7 02 Light barrier 14 7 03 Treadle 15 7 04 Control panel 16 7 04 01 Symbols on the display 17 7 04 02 Plus minus keys 17 7 04 03 Function keys 18 8 Set up and Initial Commissio...

Page 4: ...nserting and removing the SD memory card 40 10 10 02 Displaying the machine directory 41 10 10 03 Displaying the SD card directory 42 10 10 04 Copying program s to the SD card 43 10 10 05 Copying program s from the SD card 44 10 10 05 Deleting program s in the machine memory 45 10 10 06 Deleting program s on the SD card 46 10 10 07 Formatting the SD card 47 10 10 08 Error messages 48 11 Maintenanc...

Page 5: ...in switch or pulling out the mains plug when sewing tools are replaced such as the needle sewing foot needle plate feed dog etc and when threading leaving the workstation or performing maintenance The daily maintenance work may only be carried out by suitably qualified personnel Repairs and special maintenance work may only be carried out by technical staff or peo ple with appropriate training Unl...

Page 6: ...tor This instruction manual is a part of the machine and must be made available to the operating personnel at all times The instruction manual must have been read before the initial start up The operating personnel and technical staff must be instructed about the machine s safety covers and about safe working methods The owner operator may only operate the machine in a flawless condition The owner...

Page 7: ...air its safety must be reported to the owner operator immediately 1 05 02 Technical staff Technical staff are persons with technical training in electricity electronics and mechanics They are responsible for lubricating servicing repairing and adjusting the machine The technical staff are obligated to comply with the following points The safety instructions provided in the instruction manual must ...

Page 8: ... be placed on the table during the adjustment work The objects could become jammed or be slung away Risk of injury from parts flying around Danger of hands being crushed Do not operate the machine without the finger guard 1 Risk of injury from the needle Do not operate the machine without the take up lever guard 2 Risk of injury due to movement of the take up lever Do not operate the machine witho...

Page 9: ...ng on trouser waistbands Any usage not approved by the manufacturer is deemed misuse The manufacturer shall assume no liability for damage caused by misuse Proper use also includes compliance with the operating maintenance adjustment and repair measures specified by the manufacturer ...

Page 10: ...4000 stitches min Stitch length max 4 5 mm Noise data Noise emission level at workplace with a sewing speed of n 2400 min 1 LpA 75 dB A Noise measurement in accordance with DIN 45 635 48 A 1 ISO 11204 ISO 3744 ISO 4871 Motor data see motor instruction manual Air consumption per switching cycle 0 146 Nl Net weight of sewing head with stand approx 128 kg Gross weight of sewing head with stand approx...

Page 11: ...arious plastics The electrical equipment consists of plastics and copper The machine must be disposed of in accordance with the locally valid environmental protection regulations with a specialised company being contracted if necessary Please ensure that parts coated with lubricants are disposed of separately in accordance with the locally valid environmental protection regulations ...

Page 12: ...e ensure that the machines are only transported in a vertical position 5 03 Disposal of the packaging materials The packaging materials of these machines consists of paper cardboard and VCI fleece It is up to the customer to dispose of the packaging properly 5 04 Storage The machine can be stored for up to 6 months when not in use It must then be protected from dirt and moisture For longer storage...

Page 13: ...rmed or important information in this instruction manual are emphasised by symbols The symbols used have the following meaning Note information Cleaning care Lubrication Maintenance repairs adjustment service work only to be carried out by technical staff ...

Page 14: ... green Reception indica tor If there is no sewing material below it LED flashes green or yellow Setting aid soiling indicator LED lights up yellow Output indicator If there is sewing material below it 7 Operating Controls 7 01 Main switch Fig 7 01 1 Turning the main switch 1 switches the machine on and off Fig 7 02 1 ...

Page 15: ...Operating Controls 15 7 03 Treadle With the main switch turned on 0 Neutral position 1 Manual sewing or start sewing cycle 1 Raise sewing foot and top needle bar position Fig 7 03 0 1 1 ...

Page 16: ...ng and display controls The display 1 comprises a two line alphanumerical LCD display with 16 characters per line and is used to display corresponding information and selection parameters The plus minus keys 2 are used for selecting or altering the functions and parameters shown on the display The function keys 3 are used for turning the corresponding function on and off Switched on functions are ...

Page 17: ... length SD memory card Machine memory 7 04 02 Plus minus keys The corresponding set values are selected and altered using the appropriate plus minus keys At the same time the set value shown above is changed slowly at first by pressing and holding the corresponding plus or minus key If the key is held pressed for longer the set value changes more quickly Plus minus keys The displayed values can be...

Page 18: ... This key corresponds to number 3 when entering the code number Tape cutter on off This key corresponds to number 4 when entering the code number Tape cutter at seam start on off This key corresponds to number 5 when entering the code number Skip stitch system at seam start on off This key corresponds to number 6 when entering the code number Skip stitch system at seam end on off This key correspo...

Page 19: ...ff Cutting puller on off Free Raise lower presser foot This is raised if the presser foot is lowered and lowered if the presser foot is raised Coded via parameter 813 Free Free sewing You can sew with treadle control and the machine does not react to a photo cell This key corresponds to number 0 when entering the code number 00 0 ...

Page 20: ...may only be set up and started up by qualified personnel All of the relevant safety regulations must always be complied with in this process Adequate stability of the stand must be guaranteed even during the sewing operations 8 01 Set up Suitable electrical and pneumatic supply connections must be provided at the erection site see Chapter 3 Technical Data The erection site must have a firm and lev...

Page 21: ...p and Initial Commissioning 21 Fig 8 02 8 01 02 Mounting the reel stand Assemble the reel stand as shown in Fig 8 02 Then insert the stand into the hole in the table top and secure it with the enclosed nuts ...

Page 22: ...Securely attach the ground cable from the sewing head 1 to ground point A Securely attach the ground cable from the control point 8 to ground point B Securely attach the ground cable from the main switch 3 to ground point C Securely attach the ground cable from the stand 4 to ground point D Securely attach the ground cable 5 from the motor to ground point E Fig 8 03 X15 Fadenwächter X11 A CAN BUS ...

Page 23: ...chnical staff check whether the machine s motor may be operated at the existing mains voltage Never operate the machine if there are any differences Before the initial commissioning have technical staff verify that parameter 201 machine class is set to 1 The machine must only be connected to a grounded socket Connect the machine to the compressed air system The manometer should display a pressure ...

Page 24: ...ity mains for all set up work by operating the main switch or by removing the mains plug 9 01 Inserting the needle Switch off the machine Risk of injury due to accidental machine start up Only use needles of the system intended for the machine see Chapter 3 Technical Data Bring the needle bar to the top position and loosen the screws 1 Insert the needles 2 up to the stop while doing so the long ne...

Page 25: ...eading the needle adjusting the needle thread Switch off the machine Risk of injury due to accidental machine start up Thread the needle as shown in Fig 9 02 Adjust the needle thread tension by turning the knurled thumb screw 1 1 ...

Page 26: ...k room cover and side cover Slide the lever 4 to the left this unlocks the hook bracket and it can be swivelled out Thread the looper thread as shown in Fig 9 03 Use tweezers to thread in the thread on the hook 2 Slide the lever 4 to the left swivel the hook bracket back in until it engages Adjust the looper thread tension by turning the knurled thumb screw 3 3 4 2 ...

Page 27: ...perator Cut the beginning of the tape 3 sharply 1 3 2 Fig 9 05 9 05 Threading the tape into the pleating attachment Feed the tape through the tape smoother 1 Insert the tape tip 2 into the pleating attachment 3 and slide the tape completely through the pleating attachment 3 with the aid of scissors Fold the tape in the pleating attachment 3 and feed it to the sewing position 1 2 3 ...

Page 28: ...1 99 Stitch length e g 3 5 mm it can be changed using the corresponding plus minus key The electronically set stitch length here must be identical to the mechanically set stitch length on the sewing head See the Stitch length chapter in the adjustment manual to set the stitch length Coded via parameter 810 Piece counter e g 2000 The function of the other keys is explained in the Operating Controls...

Page 29: ...ly lowers when you press the treadle and the machine sews at a fixed speed set in P08 and possibly with the skip stitch system switched on until the start cut is made Tape cutter photo cell and the clearance programmed in P01 Switch on the skip stitch system after reaching the appropriate clearance P02 After cutting the tape sew with treadle control until the Skip stitch photo cell light up again ...

Page 30: ...ion Press the Insert tape key The needle and puller move to the top dead centre position Feed the tape manually to below the puller rollers Press the Insert tape key again The needle and puller move to the working position Press the Free sewing key Press the Tape cutter tape end key and trim the tape Now stop the machine with the needle down and raise the presser foot The next piece can be sewn on...

Page 31: ... minus key The upper key is and the lower key is The selected function group is taken over by pressing the plus minus key under the Enter symbol and the machine jumps to the Enter parameter status after entering the code This display does not appear if the access code has already been entered or the function group is not code protected If the TE key is pressed the machine changes to production mod...

Page 32: ...Service coded 700 Sewing motor coded 800 Access rights coded Access rights for the individual function groups and for the functions accessible via the keys can be changed in the function group 800 The access code for coded functions can also be changed status on delivery 3819 Coded functions can only be accessed after entering the code Specific keys as interpreted as numeric keys for input purpose...

Page 33: ...Parameter 403 the tape cutter switch on time has been selected in the example above The displayed parameter value is 0 03 s The values above can be changed using the plus minus keys The parameter values are taken over by advancing to another parameter number If the TE key is pressed the values are also taken over and the machine switches to sewing mode 00 0 No 403 0 03 VAL ...

Page 34: ...responding plus minus key The upper key is and the lower key is The selected function group is taken over by pressing the plus minus key under the Enter symbol and the machine switches to enter the 8 program parameters P01 P08 The entered values are taken over by pressing the Program key and the machine switches back to the initial status of input mode The entered values are taken over by pressing...

Page 35: ...to the right Example The maximum program speed is limited to 4000 rpm The programmable parameter numbers P01 P02 P08 can be changed with the corresponding plus minus key The entered values are taken over by pressing the Sew Enter key and the machine switches to input mode The entered values are taken over by pressing the Program key and the machine switches back to the initial status of input mode...

Page 36: ...irst skip stitch after start of seam at seam start in mm P04 Start clearance of final skip stitches in mm P05 Clearance of final cut at seam end in mm P06 Length after which the cutting puller moves down at seam start in mm P07 Length for which the cutting puller stays down after the start cut in mm P08 Constant speed during the tape cutting Fig 10 07 ...

Page 37: ...nce position needle at top edge of needle plate 302 Position of cover thread carrier t d c 153 0 191 303 Position of needle at bottom position 81 0 191 Function group 400 Times 0 01 2 00 s 401 Delay time before raising presser foot 0 01 s 402 Start time after lowering presser foot 0 02 s 403 Tape cutter switch on time 0 10 s 404 Tape cutter travel time 0 03 s 405 Needle thread monitor hide stitche...

Page 38: ...3 D Skip stitch light barrier E14 X5 8 E Tape cutter light barrier E15 X5 6 F free E16 X5 7 603 Outputs 1 Presser foot X13 1 and X13 2 1 up 0 down 2 Tape cutter X13 3 and X13 4 1 down 0 up 3 Needle cooling X13 5 4 Thread tension X13 6 1 open 0 close 5 Skip stitch generation X13 7 1 on 0 off 6 Raise transport puller X13 8 1 up 0 down 7 Raise cutting puller X13 9 1 up 0 down 8 free X13 10 9 free X13...

Page 39: ... ramp 30 715 Reference position 43 716 Dead man time 40 717 Motor starting current 7 718 Anti rank filter 3 719 Rotation direction assignment 1 720 Positioning technique 1 time optimised 2 path optimised Function group 800 Access rights 801 Access rights for function group 100 802 Access rights for function group 200 803 Access rights for function group 300 804 Access rights for function group 400...

Page 40: ...s are Display the machine directory Display the SD card directory Copy program s to the SD card Copy program s from the SD card Delete program s in the machine memory Delete program s on the SD card Format the SD card 10 10 01 Inserting and removing the SD memory card Inserting the SD card Open the cover 1 Insert the SD card 2 into the card slot with the label facing forwards Close the cover 1 aga...

Page 41: ...010 The contents of the machine memory are displayed after pressing the key under the En ter symbol You can scroll through within the display by pressing the right keys You can switch to the next previous menu item by pressing the left keys 00 0 DIR 00 0 DIR 01 02 40 42 END ...

Page 42: ...ig 10 12 The contents of the SD card are displayed after pressing the key under the Enter symbol You can scroll through within the display by pressing the right keys You can switch to the next previous menu item by pressing the left keys 00 0 DIR 00 0 DIR 02 40 END 01 ...

Page 43: ...y in the machine memory and on the SD card can be selected with the buttons under the values The MD machine data can only be copied to the machine data file If the complete machine contents ALL are selected all programs are copied to the SD card If a program is already present on the SD card a prompt for confirmation will be displayed The right key confirms that the data will be overwritten The ri...

Page 44: ...he machine memory and on the SD card can be selected with the keys under the values The MD machine data can only be copied to the machine data file If the complete machine contents ALL are selected all programs are copied to the ma chine memory If a program is already present in the machine memory a prompt for confirmation will be displayed The right key confirms that the data will be overwritten ...

Page 45: ...an switch to the program number of the program in the machine memory that you want to delete using the keys If the complete machine contents ALL are selected all programs are deleted The MD machine data cannot be deleted A prompt for confirmation is displayed before deleting the data The right key confirms that the data will be overwritten The right key cancels the overwriting process 00 0 DEL 00 ...

Page 46: ...ou can select the program number of the program on the SD card that you want to de lete using the keys under the value If the complete machine contents ALL are selected all programs on the SD card are deleted A prompt for confirmation is displayed before deleting the data The right key confirms that the data will be overwritten The right key cancels the overwriting process 00 0 DEL 00 0 DEL ALL ...

Page 47: ...s that the card will be formatted The right key cancels the formatting process The card will be completely formatted if it cannot be read All files in this directory will be deleted if it can be read and the directory P3819 for the 3819 exists If the directory P3819 for the 3819 does not exist only the directory is created This is to ensure that programs from other machines and other files are not...

Page 48: ...ergency stop 35 Timeout for writing parameters 36 Timeout for resetting stitch counter 37 Timeout for stop command after x stitches 38 Timeout for initialisation xxx sewing motor control unit error see Motor errors 39 Establishing contact when turned on Error 3 Ramp memory too small Error 4 free Error 5 Treadle activated when machine turned on Error 6 free Error 7 Stepping motor movement 1 Ramp X ...

Page 49: ...d 2 Incorrect card does not fit 3819 3 Card incorrectly inserted 4 Card is write protected 5 Data error on SD card 6 Formatting failed 7 File does not fit 3819 8 Incorrect file size 9 Transfer error 10 File could not be deleted Error 28 free Error 29 1 CAN error Timeout 2 Incorrect answer 4 Lost data Error 30 free All error messages are acknowledged with the key If the key is pressed the error is ...

Page 50: ...mmand overrun 64 Mains off during initialisation 65 Excess current directly after mains on 66 Short circuit 68 Excess current during operation 70 Motor blocked 71 No incremental plug 74 Incremental encoder missing for transmission reduction 173 Motor blocked in 1st stitch 175 Internal starting error 222 Dead man monitoring ...

Page 51: ...y shutting off the main switch or removing the mains plug Risk of injury due to accidental machine start up The following tasks are recommended during a single shift operation to avoid operational errors Open the hook area cover 1 Daily clean the hook area 2 more frequently during continuous operation Close the gripper area cover Only operate the machine when the hook room cover is closed Risk of ...

Page 52: ... oil level must not drop below the min marking and rise above the max marking The oil level must always be visible in the sight glass 1 Add oil to the container through the hole 2 as needed Only use oil with a centre viscosity of 22 0 mm2 s at 40 C and a density of 0 865 g cm3 at 15 C We recommend PFAFF sewing machine oil part no 280 1 120 144 2 min max 1 ...

Page 53: ... before every machine start up The oil level must always be visible in the sight glass 1 if no air bubble is visi ble then the oil level is too high Remove the screw 2 as needed and add only enough oil for an air bubble to remain visible Replace the screw 2 Only use oil with a centre viscosity of 22 0 mm2 s at 40 C and a density of 0 865 g cm3 at 15 C We recommend PFAFF sewing machine oil part no ...

Page 54: ... 06 Emptying cleaning the maintenance unit s water tank Switch the machine off Detach the compressed air tube on the maintenance unit Empty the water tank The water tank 1 empties itself automat ically after the compressed air tube for the maintenance unit has been removed Clean the filter Unscrew the water tank 1 and take out the filter 2 Clean the filter with compressed air or isopropyl alcohol ...

Page 55: ...e support downloads technical As an alternative to the Internet download the parts list can also be requested as a hard copy under order no 296 12 19 290 System 62 x 57 11 173 174 15 11 108 171 15 2x 11 174 089 15 11 108 171 15 2x 91 264 154 25 2x 11 174 173 25 11 330 082 15 2x 11 174 089 15 4x 91 172 843 05 2x 91 100 348 15 95 352 068 05 95 352 070 25 11 225 223 25 4x 95 352 069 25 ...

Page 56: ...an authorized licensee of the PFAFF trademark PFAFF Industriesysteme und Maschinen GmbH Hans Geiger Str 12 IG Nord D 67661 Kaiserslautern Telefon 49 6301 3205 0 Telefax 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 ...