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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