Pfaff PicoDrive P40PD User manual

Instruction manual 08.2008
296-12-18 xxx/xxx
Instruction Manual
QuickPicoDrive P40,41,42,43,44PD
Part 2
Control panel Pico Top

The reprinting, copying or translation of PFAFF Manuals, whether in whole or in part, is only
permitted with our previous authorization and with written reference to the source.
PFAFF Industrie Maschinen AG
Postfach 3020
D-67653 Kaiserslautern
Königstr. 154
D-67655 Kaiserslautern

Table of Contents Part 2
Chp. Contents Page
7. DescriptionofthePicoDrivedrivesystem 7.1 - 7.8
7.1 MotorQE3760/QE5540
7.2ControlunitP4xPD
7.3 Speed controlunitSCU2
7.4 ExternalPicoTop control panel
7.5 Usingthedrive
8.Application8.1 - 8.18
8.1 Displays on the PicoTop control panel
8.2 Sewingprograms
8.3 Sewingwith an external PicoTop control panel
8.4 Sewingwithasewing program based on a program example
8.5 Specialdarningprogram
8.6 Errormessages(troubleshooting)
9. Parameterprogramming 9.1 - 9.10
9.1 Programminglevel"a"(operatorlevel)
9.2Programminglevel "b" (mechaniclevel)
9.3 Programminglevel"c" (special level)
9.4 Resetting
9.5Startinhibitor device (Error 9)
9.6 Treadle(speedcontrol unit)
10. Startof operation 10.1 - 10.8
10.1 Checkingthedirectionofrotation and reference position of the needle bar
(needleposition NP0)
10.2 Teach process for the gear ratio
10.3 CheckingneedlepositionsNP1/NP2
10.4 Checking the maximum speed
10.5 Sewingheadsynchronisation
10.6 Hardwaretest
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Technical modifications reserved!

7. Description of the PicoDrive drive system
The PicoDrive drive system is an electronically commutated, brushless DC motor.
The drive system comprises the following main assemblies:
Fig. 7.1 Fig. 7.2
Motor QE3760orQE5540(Fig.7.1)withanintegratedopto-electronicangularrotationsensorfor
commutationandpositioning.CertifiedaccordingtoCCC.
Control unit (Fig. 7.2) with
-integratedmainsswitch
-mainsconnectionwithinterferencesuppression circuit
-electronicallycontrolled switched mode power supply (SMPS)
-d.c. link
-motor-guidedinverter
-control electronics for the motor control unit and machine-specific functions
Speed control unit SCU2 (Fig. 7.3)
Control panel (Fig. 7.4) PicoTop.
7.1 Motor QE3760/QE5540
Themotor is a synchronous motor. Ithas a permanent-magnet rotor, an opto-electronic commutation
transmitter (rotor position sensor) that is mounted on the fan side, and a stator with three-phase
winding.
The rated output of the motor (shaft output) is 375W (QE3760) / 550W (QE5540) in S5 mode. The
rated speed of the motor is 6000 rpm (QE3760) / 3700 rpm (QE5540); the maximum speed is 9000
rpm(QE3760)/4000 rpm (QE5540).
Themotor has two connection cables
a) four-conductorwith four-contactAMPspecial plug (X1) for connecting the statorwindings to the
control system
b) six-conductorshieldedwithnine-contactD-subconnector(X2)forconnectingthecommutation
transmitter to the control system.
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Fig. 7.3 Fig. 7.4

7.2Control unit P4xPD
Fig. 7.5 Fig. 7.6
The control system casing is suspended from below and screwed to the table top with four screws
whichareincludedwith delivery.
The mains connection is single-phase via the three-conductor cable exiting from the back by means of
a locally used plug with earthing contact.
The control unit has peripheral function controls
on the front (Fig. 7.5):
external mains switch
X0 mains switch
on the back (Fig. 7.6):
the connection sockets and plugs
X1 four-contact socket for connecting the stator windings of the motor
X2 nine-contact D-sub socket for connecting the incremental encoder of the motor
X3 nine-contactD-sub connector for connecting the speed control unit SCU2
X4 nine-contactD-sub connector for connecting the PicoTopcontrol panel
X5 37-contact D-sub socket for connecting process controls
(keys, switches, magnets, solenoid valves) to the machine
X7 optionalexternalsynchroniser
X8 western socket for connecting a light barrier
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X0 X1
X5
X3
X2
X7
X4
X8

7.3 Speed control unit SCU2
The SCU2 is secured beneath the machine table using the bracket included and is mechanically
connected to the machine treadle by means of a pitman rod.
The SCU2 is connected electrically via the nine-connector coupling to the X3 connector on the back of the
control unit.
TheSCU2isananalogue,mechanical-electricalconverterthatconvertsthetreadlepathintoananalogue
control voltage. This analogue output voltage of the SCU2 is digitalised in the control unit so that the
treadle path is subdivided into 26 stages (-2, -1, 0, 1D to 22D).
Contact assignment of the connecting plug (X3) on the SCU2 (Fig. 7.13)
+3.3V
0...5V control voltage (setpoint) / optional 0...10V control voltage
0V
1
2
3
4
5
6
7
8
9
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Fig. 7.13

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7.4 External PicoTop control panel
The PicoTop control panel(Fig. 7.14) has the following components
-a single line display with an 8-digit LCD matrix
-4setting ranges: A+ / A-, B+ / B-, C+ / C-, D+ / D- (when TE on)
-the T11 key (PM) for choosing the mode
"manualsewing"or "programmedsewing".
-the T10 key (TE) for switching on the "Alter set values" mode
such as backtack stitches, parameters values.
-the T9 key (paging) to change the function type
such as backtack stitches, parameters values and speed.
-8keys(T1...T8) for machine functions (when TE off)
Function of keys T1 … T8 for machine functions
-T1 frontbacktack (on / off)
-T2 end backtack (on / off)
-T3 needle position at sewing stop (up / down)
-T4 threadtrimming(on / off)
-T5 presser foot position at sewing stop (up / down)
-T6 presserfootposition after end of seam section (up / down)
-T7 sewingwithlight barrier (on / off)
-T8 function key F1
The keys T1…T8, T10 and T11each have a signal light (LED).
The T9 key has no signal light (LED).
Each LED gives an optical response regarding the switch status of the function allocated to the respective key.
If the function is switched on,If the function is switched off,
the LED lights up! thentheLEDis off!
Fig. 7.14
T1 T2 T3 T4 T6 T5 T8 T7
T9
T10
T11

Functionof the T11key for choosing modes
-T11(PM)unlit,manual sewing
-T11(PM)lit, programmed sewing
Function of the PM key in "Manual sewing" mode (Fig. 7.15)
T11 key (PM) unlit, T10 key (TE) lit.
-A+ /A- SetstitchnumberAfront backtack forward
-B+ /B- Set stitch number Bfront backtack backward
-C+ /C- Set stitch number Cend backtack backward
-D+ /D- Set stitch number Dend backtack forward
Function of the programming key in "Programmed sewing" mode
T11 key (PM) lit, T10 key (TE) lit.
Setting for T9key (paging) is on mode 2(Fig. 7.16): used to select
the speed of the sewing program, program number and seam section:
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Fig. 7.16
-A+ /A- Set speed nx in program x
-B+ /B- Set speed nx in program x
-C+ /C- Selectprogram number orthesubsequentprogram
-D+ /D- Set for the number of seam sections
Pagingkey
TE key
(Entermode)
PM key
(Programmode)
Pagingkey
TE key
(Entermode)
PM key
(Programmode)

Setting for T9key (paging) is on mode 3(Fig. 7.17): used to select
frontandend backtack stitchesfortheselected program:
-A+ /A- SetstitchnumberAfront backtack forward
-B+ /B- Set stitch number Bfront backtack backward
-C+ /C- Set stitch number Cend backtack backward
-D+ /D- Set stitch number Dend backtack forward
Setting for T9key (paging) is on mode 4(Fig. 7.18): used to select
program number and seam section, special function: stop at the end of the seam,
special function: constant speed (or treadle-controlled), special function: feed reverse and
special function: manual seam:
-A+ /A- Selectthe program number
-B+ /B- Set the seam section for which the following settings apply
-C+ Stop at the end of the seam, I = on 0 = off
-C- Constantspeed (ortreadle-controlled) I = constant speed 0= treadle-controlled
-D+ Feedreverseatthe end of the seam I = on 0 = off
-D- Manualseamsection I = on 0 = off
Fig. 7.17
Fig. 7.18
Pagingkey
TE key
(Entermode)
PM key
(Programmode)
Pagingkey
TE key
(Entermode)
PM key
(Programmode)
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Setting for T9key (paging) is on mode 1(Fig. 7.19): used to select the
display program number, display seam section number and the seam section stitches:
-A+ /A- Setthe program number
-B+ /B- Set the seam section number
-D+ /D- Set the seam section stitches
Function of the programming key in "Parameter programming" mode (Fig. 7.20)
T11 key (PM) unlit, T10 key (TE) lit.
-A+ /A-Changethe hundreds digitofthe parameter number
-B+ /B-Changethe parameter numberinthe selected hundredsrange
-C+ /C- Programthe parameter valueofthe set parameternumber
-D+ /D- Programthe parameter valueofthe set parameternumber
Fig. 7.19
Pagingkey
TE key
(Entermode)
PM key
(Programmode)
Fig. 7.20
Pagingkey
TE key
(Entermode)
PM key
(Programmode)
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7.5 Using the drive
ThePicoDrivedrive system can be used for variousmanufacturers.
Each machine class requires a specific control unit program.
Activation (switching on) of the machine-specific control unit program is
viaparameter<799> (see Chp. 9 Parameter programming).
Thefollowing applies:
For the P45PD drive system
Parameter <799> to 1 = machine class 1
for: 1 = PFAFF machine class 1163
2 = PFAFF machine class 1180
3 = PFAFF machine class 1122
4 = PFAFF machine class 591
5 = PFAFF machine class 1525S
6 = PFAFF machine class 574

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8. Application
The PicoDrive drive system can only be operated with an external PicoTop control panel!
Switching on
The on/off switch (mains switch) S1 is located on the front of the control unit.
When switched on, the S1 switch lights up if there is mains voltage.
8.1 Displays on the PicoTop control panel
After switching on the control unit, the control field name (Fig. 8.1) is displayed for approx. 3 sec.
If, when switching on, the T9 key (paging) is simultaneously pressed, the software number
(Fig. 8.2) is displayed. The display remains until any key is pressed.
Fig. 8.1
Fig. 8.2
Pagingkey

Then the current machine class (Fig. 8.3) is displayed for approx. 3 sec.
Depending on the setting, manual mode(PM off) will then display the set backtack stitch numbersfor the front and end
backstitch (Fig. 8.4), the set maximum speed (Fig. 8.5) or the parameter menu (Fig. 8.6).
Fig. 8.3
Fig. 8.4 Fig. 8.5 Fig. 8.6
Backtack stitch numbers for front and end backtack
For setting the backtack stitch numbers (Fig. 8.7) see Chp. 8.2.1 Sewing without a sewing program
(manualsewing).
Fig. 8.7
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8.2 Sewing programs
a) Numberofsewing programs: 5
b) Seamsectionsper sewing program: 9
c) Stitch number per seam section: max. 250
d) Assignment of sewing functions to the seam section (see also Chp. 7.7):
- T1 front backtack (on / off)
- T2 end backtack (on / off)
- T3 needle position at sewing stop (up / down)
- T4 thread trimming (on / off)
- T3 presser foot position at sewing stop (up / down)
- T6 presser foot position after end of seam section (up / down)
- T7 sewing with light barrier (on / off)
- T8 function key F1
e) Interrupting the stitch count:
The stitch count in a seam section can be interrupted using treadle position "-2" (fully back). This
status is signalled by an "M" on the display. Sewing can continue without stitch count (manually). By
pressing treadle position "-2" again, the seam section is finished and switched to the next seam
section.
f) Seam section without stitch count:
Seam sections can also be sewn without stitch count (manually). The stitch count is switched off
using key T4.
Manual seam sections are signalled by an "m" on the display.
For a seam section without stitch count, the set stitch number on the display must be ≥1.
Using treadle position "-2", the seam section is finished and switched to the next seam section.
g) Seam section with light barrier control:
The target stitch numbers saved for this seam section are light barrier compensation stitches.
h) Sewingspeed:
Thesewingspeedisseparatelyprogrammableforeach program in the lower line of the display before
startof operation. The maximum programmable sewing speed is limited by parameter<607>
i) Linkingsewingprograms:
Thereistheoption of having different sewing programsrunoneafter the other.
During programming, the subsequent sewing program is displayed on the lower line by digits 6 and 7
and is set using keys D+ or D−.
01-00 means that only the current program is running; at the end of this sewing program it will
switch back to the start of the same program again.
j) The programs can be used as backtack/darning programs
Change-overis viaparameter<313>

8.3 Sewing with an external PicoTop control panel
Sewing without a sewing program (manual sewing)
Precondition: Key 11 (P/M) is unlit
Shownon the display (Fig.8.8)
target stitches forfront backtack target stitches forend backtack
Thetargetstitchnumbers for the front and end backtacks can only be set when the machine is at standstill:
forfront backtack with key A+ or B+ or
keyA- or B-,
for end backtack with key C+ or D+ or
key C - or D-.
Shown on the display during sewing (Fig. 8.9)
-after starting if parameter <605> = 1 actual speed
Fig. 8.8
Fig. 8.9
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8.4 Sewing with a sewing program based on a program example:
3 programs that are linked to each other with the following functions
Program 1, with constant speed of 1000 revolutions, 3 seam sections, 5 stitches per seam section
andlinkedwith program 2,
Program 2, with constant speed of 1500 revolutions, 5 seam sections, 7 stitches per seam section
andlinkedwith program 3,
Program 3, with constant speed of 1800 revolutions, 4 seam sections, 10 stitches per seam section
andlinkedwith program 1,
Thread trimming to be carried out at the end of the third seam section in the third program,
then it should start again with program 1 and seam section 1.
Note:The followingfunctionscanbeprogrammed for every seam section:
frontandendbacktack, needle position, thread trimming
andpresser foot lift!
8.4.1 Program 1:
Entering the number of stitches you want for seam section 1
1.1 To enter the desired number of stitches for seam section 1 in "Program 1"
press the PM key, (LED on) and press the TE key, (LED on)
1.2 Press the paging key until the display Fig. 8.1 appears
1.3Set "Program number 1" using keys A+ / A-, (TE on)
1.4Set "Seam section number 1" using keys B+ / B-, (TE on)
1.5 Use the D+ / D- keys to set the desired number of stitches for seam section 1 e.g. "5 stitches"
Note:
The other desired seam sections 2, 3 etc. with the assigned number of stitches per seam
segment can be entered as described under 1.4 and 1.5.
To enter other functions, continue working in programming mode.
To finish your entry
press the PM key, (LED off) and press the TE key, (LED off)
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Programnumber Number of stitches (1-250)
for seam section 1
Seamsectionnumber
Fig. 8.1

8.4.2 In program 1:
Entering the program speed you want
Precondition: Program 1 has been preselected as described under 1.2 to 1.3!
2.1 To enter thedesiredprogramspeed in "Program 1"
press the PM key, (LED on) and press the TE key, (LED on)
2.2 Press the paging key until the display Fig. 8.2 appears
2.3 Using the A+ / A- keys, set the desired program speed for sewing program 1.
Note:
The desired program speed for sewing program 2 can be entered as described under 2.3 and 2.4.
However, this presupposes that program 2 has been preselected as described under 1.2 to 1.3!
The desired program speed for sewing program 3 can be entered as described under 2.3 and 2.4.
However, this presupposes that program 3 has been preselected as described under 1.2 to 1.3!
To enter other functions, continue working in programming mode.
To finish your entry
press the PM key, (LED off) and press the TE key, (LED off)
Fig. 8.2
Program speed
of sewing program 1 Numberofseamsections forsewing program1
Subsequentprogramnumber
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8.4.3 In program 1:
Entering the desired number of seam sections
Precondition: Program 1 has been preselected as described under 1.2 to 1.3!
3.1 To enter thedesiredprogramspeed in "Program 1"
press the PM key, (LED on) and press the TE key, (LED on)
3.2 Press the paging key until the display Fig. 8.3 appears
3.3 Using the D+ / D- keys, set the desired number of seam sections, e.g. "3 seam sections" for
sewing program 1,
Note:
The desired number of seam sections for sewing program 2 can be entered as described under 3.3.
However, this presupposes that program 2 has been preselected as described under 1.2 to 1.3!
The desired number of seam sections for sewing program 3 can be entered as described under 3.3.
However, this presupposes that program 3 has been preselected as described under 1.2 to 1.3!
To enter the following functions, continue working in programming mode.
To finish your entry in "Program 1"
press the PM key, (LED off) and press the TE key, (LED off)
Fig. 8.3
Speedof sewing program1 Number of seam
sections for sewing
program 1
Subsequentprogramnumber
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8.4.4 In program 1:
Entering the desired backtack stitches for front and end backtacks
Precondition: Program 1 has been preselected as described under 1.2 to 1.3!
4.1 To enter the desired backtack stitches for front and end backtacks in "Program 1"
press the PM key, (LED on) and press the TE key, (LED on)
4.2 Press the paging key until the display Fig. 8.4 appears
4.3 Using theA+ /A- keys, set the desired number of front backtack stitches for the forward section,
4.4 Using the B+ / B- keys, set the desired number of front backtack stitches for the backward section,
4.5 Using the C+ / C- keys, set the desired number of end backtack stitches for the backward section,
4.6 Using the D+ / D- keys, set the desired number of end backtack stitches for the forward section,
Note:
The desired backtack stitches for the front and end backtacks of sewing program 2 can be entered as
describedunder4.3 to4.6.
However, this presupposes that program 2 has been preselected as described under 1.2 to 1.3!
The desired backtack stitches for the front and end backtacks of sewing program 3 can be entered as
describedunder4.3 to4.6.
However, this presupposes that program 3 has been preselected as described under 1.2 to 1.3!
To enter other functions, continue working in programming mode.
To finish your entry in "Program 1"
press the PM key, (LED off) and press the TE key, (LED off)
Front backtack stitches
forthe forward section
Fig. 8.4
Front backtack stitches
forthebackward section End backtack stitches
forthebackward section End backtack stitches forthe forward section
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8.4.5 In program 1:
Entering the desired special functions for the intended seam sections
Precondition: Program 1 has been preselected as described under 1.2 to 1.3!
5.1 To enter the desired special functions in "Program 1"
press the PM key, (LED on) and press the TE key, (LED on)
5.2 Press the paging key until the display Fig. 8.5 appears
5.3 Using the C+ key = special function stop at end of seam section,
I = stop on (standard), 0 = stop off
5.4 Using the C- key = special function programmed speed or treadle-controlled speed,
I = program speed (standard), 0 = treadle-controlled speed
5.5 Using the D+ key = special function feed reverse off / on,
I = feed reverse on, 0 = feed reverse off (standard)
5.6 Using the D- key = special function manual sewing off / on,
I = manual sewing on, 0 = manual sewing off (standard)
Note:
The desired special functions of sewing program 2 can be entered as
describedunder5.3 to5.6.
However, this presupposes that program 2 has been preselected as described under 1.2 to 1.3!
The desired special functions of sewing program 3 can be entered as
describedunder5.3 to5.6.
However, this presupposes that program 3 has been preselected as described under 1.2 to 1.3!
To finish your entry
press the PM key, (LED off) and press the TE key, (LED off)
Fig. 8.5
Stop at end
of the seam section Programmedspeed or
treadle-controlled
speed
Feedreverse
off/on Manualsewing
off/on
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