Pfaff EcoDrive P40 ED User manual

Instruction Manual
EcoDrive P40 ED
P70 ED
296-12-18 970/002
Betriebsanleitung engl. 08.08
This Instruction Manual is valid for drives
from the following software version on:
P40 ED # 1_040_14
P70 ED # 1_023_09
Control panel BDF S3

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 Industrie Maschinen AG
Hans-Geiger-Str. 12
D-67661 Kaiserslautern

Index
Contents ..................................................................................Page
1Safety .................................................................................................................................... 5
1.01 Directives............................................................................................................................... 5
1.02 General notes on safety......................................................................................................... 5
1.03 Safety and work symbols....................................................................................................... 6
1.04 Important notes for the user.................................................................................................. 6
1.05 Operating and technical staff ................................................................................................. 7
1.05.01 Operating staff ....................................................................................................................... 7
1.05.02 Technical staff ........................................................................................................................ 7
1.06 Notes on danger .................................................................................................................... 8
2Proper use............................................................................................................................. 9
3Specifications ..................................................................................................................... 10
4Disposal ...............................................................................................................................11
5Transportation packing and storage................................................................................. 12
5.01 Transportation to the customer’s premises ......................................................................... 12
5.02 Transportation inside the customer’s premises ................................................................... 12
5.03 Disposal of packing materials ..............................................................................................12
5.04 Storage ................................................................................................................................ 12
6Control elements................................................................................................................ 13
6.01 Main switch ......................................................................................................................... 13
6.02 Control panel........................................................................................................................ 13
6.02.01 Symbols on the display ........................................................................................................ 14
6.02.02 Plus-minus keys ................................................................................................................... 14
6.02.03 Function keys ....................................................................................................................... 14
7Installation and commissioning ....................................................................................... 17
8Sewing ................................................................................................................................ 18
8.01 Manual sewing..................................................................................................................... 18
8.01.01 Altering the number of bartacks .......................................................................................... 19
8.01.02 Piece counter....................................................................................................................... 19
8.01.03 Set bobbin thread control by stitch counting ....................................................................... 20
8.01.04 Bobbin thread monitoring on sub-class -926/06 (optional)................................................... 20
8.02 Programmed sewing............................................................................................................ 21
8.02.01 Example of a seam program input by entering the number of stitches............................... 23
8.02.02 Example of a seam program input by sewing the seam sectors (teach-function) ............... 27
8.03 Malfunctions ........................................................................................................................ 30

Index
Contents ..................................................................................Page
8.03.01 Error messages.................................................................................................................... 30
8.03.02 Description of the error messages ...................................................................................... 30
9Input .................................................................................................................................... 32
9.01 Parameter input ................................................................................................................... 32
9.01.01 Example of how to enter the parameters............................................................................ 32
9.01.02 Selecting the user level........................................................................................................ 33
9.01.03 List of parameters for control unit P40 ED .......................................................................... 34
9.01.04 Machine types and control panel combinations P70 ED...................................................... 44
9.01.05 List of parameters for control unit P70 ED ......................................................................... 46
10 Service functions................................................................................................................ 56
10.01 Reset / Cold start ................................................................................................................. 56
10.02 Hardware-test ...................................................................................................................... 57
10.02.01 Test block 1 – inputs ............................................................................................................ 57
10.02.02 Test block 2 – outputs .......................................................................................................... 58
10.02.03 Test block 3 – speed control unit ......................................................................................... 58
10.02.04 Test block 4 – actual value transmitter .................................................................................59
10.02.05 Test block 5 – light barrier .................................................................................................... 59
10.02.06 Test block 6 – thread monitor (only on subclass -926/06) .................................................... 60
10.02.07 Test block 7 – data transfer ............................................................................................... 60
10.03 Connection plan for connector X5........................................................................................ 61
10.04 Description of the solenoids or solenoid valves and key switches ...................................... 62

Safety
5
1 Safety
1.01 Directives
This sewing machine drive was built in accordance with the European regulations stated in
the Conformity and Manufacturer’s Declaration.
In addition to this Instruction Manual, please also observe all generally accepted, statutory
and other regulations and legal requirements – also those of the country of operation – and
all valid environmental protection regulations! The applicable local regulations of the social in-
surance society for occupational accidents or other supervisory organisations must also be
strictly adhered to!
1.02 General notes on safety
Before unpacking and commissioning the sewing machine drive this Instruction Manual●
must be read carefully. Please become familiar with the safety, assembly, operating and
maintenance regulations before you set the sewing machine drive, its accessories and at-
tachments into operation for the first time.
All work on an with the sewing machine drive may only be carried out in compliance with●
the following general and special safety notes in this Instruction Manual!
All persons concerned must be aware of these safety notes and must comply with them.●
Non-compliance with the safety notes can lead to personal injury, damage to objects or
to defects and damage to the sewing machine drive.
The danger and safety warnings attached to the sewing machine drive must be obser-●
ved!
The sewing machine drive may only be operated with a protective earth conductor which●
is connected to a functioning protective system in accordance with all local provisions
and regulations.
The installation and commissioning of the sewing machine drive must be carried out ca-●
refully by properly trained personnel. The accident prevention regulations valid in the re-
spective user country and the rules for safe and professional work must be observed.
To reduce the risk of burns, fire, electric shock or injuries, the alteration or rebuilding of●
the sewing machine drive are not permitted under any circumstances.
If additional equipment or appliances are attached to the control unit of the sewing machi-●
ne drive, these may only be operated with low voltage produced by a safety transformer!
The sewing machine drive may only be used for the purpose for which it is intended and●
must not be operated without its safety devices. All applicable safety regulations must be
observed.
Before the removal of covers, the fitting of additional attachments or accessories, such as●
speed control unit, light barrier etc., the sewing machine drive must be switched off and
disconnected from the mains, and the sewing machine drive must have come to a stand-
still. The case of the control unit may only be opened after 10 minutes!
Before leaving the workplace, the machine must be switched off at the main switch. If●
the machine will be out of operation for a longer period, the mains switch should be dis-
connected, to protect the sewing machine drive from being switched on accidentally.

Safety
6
Work is not permitted on parts and equipment which are connected to the power supply!●
Exceptions to this are contained in the regulations EN 50110.
Repair work and special maintenance work must only be carried out by specialists or●
appropriately trained personnel!
Only spare parts which have been approved by us are to be used for repairs! We express-●
ly point out that any replacement parts or accessories not supplied by us have not been
tested and approved by us. The installation and /or use of such products may result in
negative changes to the constructional characteristics of the machine. We are not liable
for any damage caused by non-original parts.
1.03 Safety and work symbols
Danger!
Points for particular attention
Danger of injury to operating or technical staff!
Dangerous voltage!
Danger of death for operating and technical staff!
Note, information
1.04 Important notes for the user
This instruction manual belongs to the equipment of the sewing machine drive and must●
be available to the operating staff at all times. The instruction manual must be read before
the equipment is operated for the first time.
Both operating and technical staff must be instructed on the safety devices of the sewing●
machine drive and on safe working methods.
It is the duty of the user to operate the sewing machine drive in perfect running order●
only.
The user must ensure that none of the safety devices are removed or put out of working●
order.
The user must ensure that only authorized persons work on the sewing machine drive.●
For further information please contact your PFAFF agency.

Safety
7
1.05 Operating and technical staff
1.05.01 Operating staff
Operating staff are the persons responsible for setting up, operating and cleaning the machi-
ne and for eliminating any malfunctions in the sewing area.
The operating staff is obliged to observe the following points:
For all work the notes on safety in this Instruction Manual must always be observed!●
Any working methods, which adversely affect the safety o the machine, must be avoided!●
Any changes occurring ton the sewing machine drive, which may affect its safety, must●
be reported to the user immediately!
1.05.02 Technical staff
Technical staff are persons who have been trained in electrical engineering/electronics and
mechanical engineering. They are responsible for servicing, repairing and adjusting the ma-
chine.
The operating staff is obliged to observe the following points:
For all work the notes on safety in this Instruction Manual must always be observed!●
Before carry out any repair work, the main switch must be switched off and measures●
taken to prevent it from being switched on again!
Never work on parts or equipment still connected to the power supply! Exceptions are●
only permissible in accordance with the regulations EN 50110.
All safety covers must be replaced after the completion of maintenance and repair work!●

Safety
8
1.06 Notes on danger
Only operate the sewing machine drive with a protective earth conductor con-
nected to a functioning protective system in accordance with all local regulati-
ons and directives! Danger of electric shocks!
Do not disconnect the protective earth conductor!
Do not neutralize the protection by using extension lines without a protective
earth conductor!
Danger of electric shocks!
Never operate the sewing machine drive if the air vents are clogged!
Danger of damage to the sewing motor!
Remove threads, fluff, dust etc. from the air vents.
Do not stick or drop any objects, e.g. needles, in the openings!
Danger of damage to the sewing machine drive!
Do not place fingers near moving parts! Danger of injury!
Do not operate the sewing machine drive if aerosols (sprays) or oxygen have
been used! Danger of explosions!

Proper use
9
2 Proper use
The sewing machine drives P40 ED and P70 ED are not machines which are ready for use.
They are intended for installation in machines for the sewing thread processing industry,
which are operated in clean, dry rooms.
Any and all uses of this machine, e.g. use outdoors or in a wet environment,
or where there is a risk of explosion, which have not been approved by the
manufacturer, are considered to be inappropriate! The manufacturer cannot be
held liable for any damage caused by inappropriate use! The appropriate use
includes the observance of all operational, adjustment, maintenance and repair
measures specified by the manufacturer!

Specifications
10
3 Specifications▲
Rated values
Voltage: ........................................................................................................230 V, single-phase
Frequency: ....................................................................................................................50/60Hz
Current for drive ED QE3760 / EDL QE5540:......................................................... 3,5 A / 5,0 A
Current for control unit:......................................................................................................0,6 A
Power output ED QE3760 / EDL QE5540: ......................................................... 375 W / 550 W
Speed: ED QE3760 / EDL QE5540: .......................................................6000 min-1 / 4000 min-1
Torque: ED QE3760 / EDL QE5540:.............................................................. 0,63 Nm / 1,2 Nm
Moment of inertia of motor (without belt pulley):
ED QE3760 / EDL QE5540:..................................................................... 0,5 kgcm² / 1,0 kgcm²
Operating mode:...........................................................S5 (40% rel. on-time for 2.5 s runtime)
Protection system: .............................................................................................................IP40
Insulation class: ......................................................................................................................E
Limit values
Rated voltage range: ..........................................................................180 - 260 V, single-phase
Max. motor speed: ED QE3760 / EDL QE5540: ................................... 9000 min-1 / 4500 min-1
Max. torque (short time): ED QE3760 / EDL QE5540:.......................................... 3 Nm / 7 Nm
Max. power output (short-time): ED QE3760 / EDL QE5540:........................1000 W / 1500 W
Moment of inertia of machine (reduced to motor shaft):
ED QE3760 / EDL QE5540:..................................................................... 4,5 kgcm² / 9,0 kgcm²
Operating requirements
Ambient temperature: .......................................................................................... +5 to +45° C
Average ambient temperature (over 24 hours): .............................................................<35° C
Relative humidity: ................................................................................................85% at 30° C
Control voltage for external control elements
Voltage with engine idling:.................................................................................................. 25 V
Voltage under load: ......................................................24 V bei 4 A / 20 V bei 10 A (short-time)
Output:.............................................................................................. 96 W / 200 W (short-time)
Load current:.........................................................................................................................4 A
Max. load current (short-time):............................................................................................ 10 A
The sum of the load currents of all simultaneously activated control elements
must not continuously exceed 4A .
Weights
Net weight (drive complete with all accessories): .................................................approx. 9 kg
Gross weight: ....................................................................................................... approx. 11 kg
▲Subject to alteration

Disposal
11
4 Disposal
Proper disposal of the sewing machine drive is the responsibility of the customer.●
The materials used for the sewing machine drive are steel, aluminium, brass and various●
plastic materials. The electrical equipment comprises plastic materials and copper.
The sewing machine drive must be disposed of according to the locally valid pollution●
regulations. If necessary, a specialised company should be commissioned.
Care must be taken to see that parts soiled with lubricants are disposed of
separately in accordance with the locally valid pollution control regulations!

Transportation packing and storage
12
5 Transportation packing and storage
The sewing machine drive can be transported and stored at temperatures in the
range from -25 to +55 ° C. For a period of less than 24 hours temperatures up
to +70° C are permitted.
5.01 Transportation to the customer’s premises
The sewing machine drives are delivered completely packed.
5.02 Transportation inside the customer’s premises
The manufacturer cannot be made liable for transportation inside the customer’s premises
or to the other operating locations.
5.03 Disposal of packing materials
The packing materials for this sewing machine drive comprise PVC, cardboard and
styrofoam. Proper disposal of the packing material is the responsibility of the customer.
5.04 Storage
When the machine is not in use, it can be stored in its packing in a dry environment. If the
sewing machine drive is stored for longer periods, the individual parts, in particular the sur-
faces of moving parts, must be protected against corrosion, e.g. with a film of oil.

13
Control elements
Fig. 6 - 01
6 Control elements
6.01 Main switch
Turn main switch●1to switch the power
supply of the sewing machine drive on
or off.
77-005
1
6.02 Control panel
The control panel is used to display and call up the machine functions for setting up and for
sewing operation, for entering parameter values and for reading error messages and service
settings.
The control panel has the following control and display elements:
The display screen●1consists of a two-line, alphanumerical LCD display with 16 symbols
per line and is used to show relevant information and selection parameters.
The plus-minus keys●2are used to select or alter the functions and parameters shown on
the display.
The function keys●3are used to switch the relevant function on or off. Activated functions
are shown in each case by an illuminated LED.
Fig. 6 - 02
1
3
2

14
Control elements
The relevant plus-minus keys are used for the selection and alteration of the set values con-
cerned (e.g. when entering bartack stitches). In this case the relevant plus or minus key
is pressed and held while the set value shown above the key slowly changes. If the key is
pressed longer, the set value changes more quickly.
6.02.03 Function keys
The activated function is always shown by the relevant illuminated LED.
Description of the individual functions:
Start bartack
If this key is pressed, the securing stitches at the beginning of the seam (start bartacks)●
are switched on or off. The number of forward stitches (A) or reverse stitches (B) for the
start bartack can be changed in each case by pressing the +/- key underneath. To change
from double tacks to single tacks set the forward stitches (A) at zero.
End bartack
If this key is pressed, the securing stitches at the end of the seam (end bartacks) are●
switched on or off. The number of reverse stitches (C) or forward stitches (D) can be
changed in each case by pressing the +/- key underneath. To change from double tacks to
single tacks set the forward stitches (D) at zero.
A B C D
3 3 3 3
6.02.01 Symbols on the display
In addition to texts and set values, the following symbols are shown on the display. The sym-
bols only appear in the programmed sewing mode, see Chapter 8.02 Programmed Sewing.
Current program number
Current seam sector
Number of stitches in current seam sector
Maximum speed in current seam sector
Number of seam sectors in current seam program
Program number of the seam program to be linked
6.02.02 Plus-minus keys

15
Control elements
Raised needle position after sewing stop
If this key is pressed, the "raised needle position after sewing stop" function is switched●
on or off. If the function is switched on, the needle positions in t.d.c. after sewing stops
Raised foot position after sewing stop
If this key is pressed, the "raised foot position after sewing stop" function is switched on●
or off. If the function is switched on, the sewing foot is raised after sewing stops.
Raised foot position at end of seam sector (in programmed sewing)
If this key is pressed, the "raised foot position at end of seam sector" function is switched●
on or off. If the function is switched on, the sewing foot is raised at the end of the seam
sector.
Thread trimming
If this key is pressed, the "thread trimming" function is switched on or off.●
Program speed (only in programmed sewing)
If this key is pressed, the relevant function is switched on or off.●
If the function is activated, the pedal forwards function is used to select the program
speed as a fixed speed. The pedal setting for stopping the fixed speed is chosen with
parameter 206.
If the function is switched off, the speed is regulated with the pedal until program speed●
is reached.
Reverse sewing direction (only in programmed sewing)
If this key is pressed, the relevant function is switched on or off. If the function is activa-●
ted during programmed sewing, the relevant seam sector is sewn in reverse.
Manual sewing sector (only in programmed sewing)
If this key is pressed, the relevant function is switched on or off.●
If the function is activated, switching to the next seam sector is not carried out by stitch
counting or sensor, but manually with the pedal setting "-2".
Programmed sewing stop (only in programmed sewing)
If this key is pressed, the relevant function is switched on or off.●
If the function is activated, the machine stops at the end of the seam sector.
Sewing with light barrier
In the manual sewing mode with light barrier, the number of stitches entered with para-●
meter 111 corresponds to the light barrier compensation stitches. In the programmed se-
wing mode, the number of stitches in the seam sector is used as the number of compen-
sation stitches.
Stitch counting (only in programmed sewing)
If this key is pressed, the relevant function is switched on or off.●
If the function is activated, in the programmed sewing mode the machine switches to●
the next seam sector after the number of stitches entered have been sewn.

16
Control elements
TE/Speed
If this key is pressed once while in the manual sewing mode, the menu for entering the●
maximum speed is selected. If no input is made within 5 seconds, the sewing mode is
selected again.
If this key is pressed twice (within 5 seconds) while in the manual sewing mode, the ma-●
chine changes to the parameter input function.
If this key is pressed while in the parameter input function, the altered set values are sto-●
red and the sewing mode is called up.
If this key is pressed three times (within 5 seconds) while in the manual sewing mode,●
the piece counter display is called up (only if parameter 180 is set at "ON").
Scroll
Press this key to scroll through the sub-menus of the program.●
PM / Operating mode
If this key is pressed, the machine switches between manual and programmed sewing. If●
the LED is illuminated, programmed sewing is active.
F1
No function at present.
F2
No function at present..
F3
No function at present.
F4 / reset piece counter
If this key is pressed, the piece counter is reset, when the piece counter menu is called up,
see Chapter 8.01.02 Piece counter.

Installation and commissioning
17
7 Installation and commissioning
Only operate the sewing machine drive with a protective earth conductor
connected to a functioning protective system in accordance with all local
regulations and directives! Danger of electric shocks!
Do not disconnect the protective earth conductor!
Protection is neutralized by the use of extension lines without a protective earth
conductor! Danger of electric shocks!
Before connecting the sewing drive make sure that the mains voltage is within
the specified rated voltage range, see Chapter 3Specifications.
If the sewing machine drive was stored at temperatures below +5° C, it must
reach ambient temperature before being operated.
The sewing machine drive many only be operated after establishing that the
machine in which this sewing machine drive is to be installed, complies with
the regulations of the EC-machine directives.
Never operate the sewing machine drive if the air vents are clogged!
Danger of damage to the sewing motor!
Remove threads, fluff, dust etc. from the air vents.
During installation and commissioning the appropriate Instruction or Set-up Manual for the
sewing machine must be observed!

Sewing
18
8 Sewing
In the sewing mode all settings, which are relevant for the sewing operation, are shown on
the display. Functions can be switched on or off by pressing a key.
The "PM" function key is used to choose between manual sewing (LED off) and programmed
sewing (LED on).
8.01 Manual sewing
Switch on the machine.●
Press the "TE/Speed" key once to call up the current speed.●
4000
If necessary, change the maximum speed by pressing the relevant plus-minus key.●
Other functions in the manual sewing mode, also see Chapter 6.02.03 Function keys:
Start tacks on/off Foot position raised at end of seam
sector on/off
End tacks on/off Thread trimming on/off
Needle position raised
when sewing stops on/off Sewing with light barrier on/off
Foot position raised when
sewing stops on/off
Sewing is carried out with the pedal functions.●

Sewing
19
8.01.01 Altering the number of bartacks
Switch on the machine.●
A B C D
3 3 3 3
Press the relevant plus-minus key to select the desired value for the number of forward●
stitches (A) of the start bartack.
Press the relevant plus-minus key to select the desired value for the number of reverse●
stitches (B) of the start bartack.
Press the relevant plus-minus key to select the desired value for the number of reverse●
stitches (C) of the end bartack.
Press the relevant plus-minus key to select the desired value for the number of forward●
stitches (D) of the end bartack.
8.01.02 Piece counter
The piece counter display can only be called up if parameter 180 is set at "ON".
Switch on the machine.●
Press the "TE/speed" key three times, to call up the piece counter menu (LED on).●
Reset the piece counter by pressing the "F●4/reset piece counter" key.
Press the relevant plus-minus keys to change the piece counter value.
3x
PieceCnt 36

Sewing
20
8.01.03 Set bobbin thread control by stitch counting
Switch on the machine.●
Press the "TE/Speed" key twice to call up the parameter input function (LED on).●
Press the relevant plus-minus keys to select parameter●760.
2x
Set the number of remaining stitches, which can still be sewn after recognition through●
the bobbin thread monitoring function, by pressing the relevant plus-minus key. The
selected value is multiplied by 200, in this way showing the number of stitches.
Example:
Display●5(x 200) = 1000 stitches. The setting depends, among other things, on the thread
size.
Press the "TE/speed" key to take over the value and change to the manual sewing mode.●
The remaining bobbin thread counter can only be used, if parameter 660 is set
at value "1" or "2".
8.01.04 Bobbin thread monitoring on sub-class -926/06 (optional)
Setting the bobbin thread monitor function, see Instruction Manual -926/06
(part no. 296-12-18 770/001).
No VAL
A 101 ON
No VAL
A 760 5