Pfaff P45 PD 2-L User manual

This Instruction Manual is valid for drives
from the following software version on:
P45 PD2-L # 4_045_05
P74 ED-L # 1_074_06
296-12-19 160/002
Betriebsanleitung engl. 04.11
INSTRUCTION MANUAL
PicoDrive P45 PD2-L
EcoDrive P74 ED-L
Industrial
®

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 Industriesysteme
und Maschinen AG
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern

Index
Contents ..................................................................................Page
3
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 Selection keys...................................................................................................................... 14
6.02.02 Function keys ....................................................................................................................... 15
7Installation and commissioning ....................................................................................... 17
8Sewing ................................................................................................................................ 18
8.01 Manual sewing..................................................................................................................... 18
8.01.01 Switching the sewing functions on / off............................................................................... 19
8.01.02 Altering the number of bartacks .......................................................................................... 19
8.01.03 Selecting the parameter input ............................................................................................. 20
8.01.04 Selecting the maximum speed ............................................................................................ 20
8.02 Programmed sewing............................................................................................................ 21
8.02.01 Switching the sewing functions on / off............................................................................... 22
8.02.02 Selecting seam program, seam segment or number of seam segment stitches................ 22
8.02.03 Selecting the speed, next program and number of seam segments................................... 23

Index
Contents ..................................................................................Page
4
8.02.04 Altering the number of bartacks .......................................................................................... 24
8.02.05 Special functions.................................................................................................................. 25
8.03 Error messages.................................................................................................................... 26
8.03.01 Description of the error messages ...................................................................................... 26
8.03.02 Error messages for sewing head recognition unit (only on EcoDrive P74 ED-L).................. 27
8.04 Bobbin thread monitor ......................................................................................................... 28
9Input .................................................................................................................................... 30
9.01 Seam programming ............................................................................................................. 30
9.01.01 Selecting the seam program number and seam segment .................................................. 31
9.01.02 Entering the speed, next program and number of seam segments.................................... 32
9.01.03 Entering bartack stitches...................................................................................................... 33
9.01.04 Entering special functions.................................................................................................... 34
9.01.05 Entering the seam segment stitches .................................................................................. 36
9.02 Example of how to enter a seam program .......................................................................... 37
9.03 Parameter input ................................................................................................................... 43
9.03.01 Example of how to enter the parameters............................................................................ 43
9.03.02 Selecting the user level........................................................................................................ 44
9.03.03 List of parameters for control unit P45 PD2-L ..................................................................... 45
9.03.04 List of parameters for control unit P74 ED-L........................................................................ 52
10 Service functions................................................................................................................ 63
10.01 Resetting the control unit..................................................................................................... 63
10.01.01 Calling up the reset function................................................................................................ 63
10.01.02 Resetting the set parameter values ..................................................................................... 64
10.01.03 Deleting all seam programs ................................................................................................. 65
10.01.04 Cold start ............................................................................................................................. 66
10.02 Display of software version and current machine class for
PicoDrive P45 PD2-L............................................................................................................67
10.03 Display of software version for EcoDrive P74 ED-L ............................................................. 68
10.04 Hardware test for the PicoDrive P45 PD2-L......................................................................... 69
10.05 Hardware test for the EcoDrive P74 ED-L............................................................................ 72

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 P45 PD2-L and P74 ED-L 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: ..................................................................................................................50/60 Hz
Current for drive: ...............................................................................................................5.0 A
Current for control unit: .....................................................................................................0.6 A
Power output: .................................................................................................................550 W
Speed: ...................................................................................................................... 4000 min-1
Torque: ...........................................................................................................................1.2 Nm
Moment of inertia of motor (without belt pulley): .....................................................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: .................................................................................................. 4500 min-1
Max. torque (short time): ............................................................................................... 7.0 Nm
Max. power output (short-time): ...................................................................................1500 W
Moment of inertia of machine (reduced to motor shaft): ..........................................9.0 kg cm²
Before connecting the sewing machine drive make sure that the mains voltage
is in the specified rated voltage range.
Operating requirements
Ambient temperature: .......................................................................................... +5 to +45° C
Average ambient temperature (over 24 hours): .............................................................<35° C
Relative humidity: ................................................................................................85% at 30° C
External control elements
Voltage with engine idling: ................................................................................................. 25 V
Voltage under load: ......................................................... 24 V at 4A / 20 V at 10 A (short-time)
Output:
P45 PD2-L .........................................................................................96W / 200 W (short-time)
P74 ED-L ........................................................................................ 192 W / 400 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.

Control elements
13
6 Control elements
6.01 Main switch
●Turn main switch 1to switch the power
supply of the sewing machine drive on
or off.
Fig. 6 - 01
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 operating and display elements:
●The display 1consists of a one-line display with an 8-figure LCD-matrix and is used to
show appropriate information and selection parameter.
●The selection keys 2are used to change the screen display, to switch the function keys
and to select the operating mode (manual / programmed sewing).
●The function keys 3below the display are used to switch the appropriate functions on or
off, depending which key is selected, or to change the values of the appropriate setting
range (A, B, C or D).
Fig. 6 - 03
1
2
3

Control elements
14
PM / operating mode
●Press this selection key to switch between manual sewing and programmed sewing.
When the LED is illuminated, the programmed sewing mode is activated.
TE / input off TE / input on
6.02.01 Selection keys
The functions of the selections keys 2are described in detail below:
Scrolling
●This selection key is used to change between the different menus shown on the display.
The selection of the menu and the setting values shown depend on the selection of the
operating mode, also see Chapter 9.01 Manual sewing or Chapter 9.02 Programmed
sewing.
●Press this selection key to acknowledge the correction of an error,
see Chapter 8.03 Error messages.
TE / input
●This selection key is used to switch the function keys 3, also see Chapter 6.03.02 Func-
tion keys:
When this function is switched off (LED off), the appropriate sewing function can be
switched on or off with the function keys 3.
When this function is switched on (LED on), the set values of the appropriate setting
ranges (A, B, C and D) can be altered.

Control elements
15
6.02.02 Function keys
The function keys 3described below generally have two basic functions:
●To switch the sewing function on or off (LED in the "TE/Input" key is off)
An activated function is always shown by the corresponding illuminated LED.
●To alter the set values shown on the display (LED in the "TE/Input" key is on)
Press and hold the appropriate function key to slowly change the set value shown above
it. If the function key is pressed longer, the set value changes more quickly.
Description of the individual functions:
Start bartack / A+
●If the "TE / Input" key is switched off, the bartacks at the beginning of the seam (start
bartacks) are switched on or off, see Chapter 9.01.03 Entering bartack stitches.
●If the "TE / Input key" is switched on, this function key serves as a plus function for the
setting range (A).
End bartack / A-
●If the "TE / Input" key is switched off, the bartacks at the end of the seam (end bartacks)
are switched on or off, see Chapter 9.01.03 Entering bartack stitches.
●If the "TE / Input key" is switched on, this function key serves as a minus function for the
setting range (A).
Raised needle position after sewing stop / B+
●If the "TE / Input" key is switched off, the "raised needle position after sewing stop" func-
tion is switched on or off. If the function is switched on, the needle positions in t.d.c.
take-up lever after sewing stops
●If the "TE / Input key" is switched on, this function key serves as a plus function for the
setting range (B).
Thread trimming / B-
●If the "TE / Input key" is switched off, the thread trimmer is switched on or off.
●If the "TE / Input key" is switched on, this function key serves as a minus function for the
setting range (B).
Raised foot position after sewing stop / C+
●If the "TE / Input key" is switched off, 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 sew-
ing stops.
●If the "TE / Input key" is switched on, this function key serves as a plus function for the
setting range (C).
Raised foot position at end of seam sector / C-
●If the "TE / Input key" is switched off, 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.
●If the "TE / Input key" is switched on, this function key serves as a minus function for the
setting range (C).

Control elements
16
Sewing with light barrier / D+
●If the "TE / Input key" is switched off, the sewing with light barrier functions is switched
on or off. When sewing with light barrier, the number of stitches entered corresponds to
the light barrier compensation stitches.
●If the "TE / Input key" is switched on, this function key serves as a plus function for the
setting range (D).
F1 / D-
●If the bobbin thread is monitored by stitch counting, the counter is reset after "Bobbin" is
displayed on the monitor. Afterwards the next counting operation begins.
●If the "TE / Input key" is switched on, this function key serves as a minus function for the
setting range (D-).
●For control unit P45 PD2-L other functions can be allocated to this key with parameter
"488" (see Chapter 9.03 Parameter input).

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, set values for the most
important parameters can be altered directly.
The "PM" selection key is used to choose between manual sewing (LED in the selection key
is off) and programmed sewing (LED in the selection key is on).
8.01 Manual sewing
●Switch on the machine.
●Select manual sewing (LED in the selection key is off) by pressing the "PM" key.
●By pressing the "scroll" key it is possible to choose one of the following display diagrams:
Start and end tacks
3 3 3 3
111a 8
Parameters
3000
Speed
When the machine is switched on, the display diagram, which was activated
before the machine was switched off, always appears.

Sewing
19
8.01.01 Switching the sewing functions on / off
●When the "TE / input" selection key is switched off, the sewing functions for manual
sewing can be switched on or off. If a function is activated, the LED in the corresponding
key is illuminated:
Start tacks on/off Foot position raised after sewing
stops on/off
End tacks on/off Foot position raised at end of seam
sector on/off
Needle position raised
on/off Light barrier on/off
Thread trimming on/off Function on/off
8.01.02 Altering the number of bartacks
●Call up the display diagram for the start and end bartacks
(if necessary, press key several times).
●Switch on the "TE / input" function (LED is illuminated).
3 3 3 3
The number of bartack stitches are shown on the display, which can be altered as follows
when the machine has stopped:
Increase the number of
forwards stitches for start
bartack (A+)
Increase the number of reverse
stitches for the end bartack (C+)
Reduce the number of
forwards stitches for start
bartack (A-)
Reduce the number of reverse
stitches for the end bartack (C-)
Increase the number of
reverse stitches for start
bartack (B+)
Increase the number of forward
stitches for the end bartack (D+)
Reduce the number of
reverse stitches for start
bartack (B-)
Reduce the number of forward
stitches for the end bartack (D-)
●Enter the set values for the start and end bartacks.

Sewing
20
8.01.03 Selecting the parameter input
●Call up the display diagram for the parameters (if necessary, press the key several times).
●Switch on the "TE / input" function (LED is illuminated).
111a 8
The first parameter with the corresponding set value is shown on the display.
The parameter selection and the alteration of the value can be carried out as follows:
Selecting the hundred fi-
gure of the parameter (A+)
Selecting the ten and unit figure of the
parameter (B-)
Selecting the hundred fi-
gure of the parameter (A-)
Increase the set value of the
parameter (D+)
Selecting the ten and unit
figure of the parameter (B+)
Reduce the set figure of the
parameter (D-)
●Select the parameter and alter the set value, see Chapter 9.03 Parameter input.
8.01.04 Selecting the maximum speed
●Call up the display diagram for the speed (if necessary, press the key several times).
●Switch on the "TE / input" function (LED is illuminated).
4000
When the machine stops, the maximum speed is displayed and can be altered with the
function keys in hundred steps.
When the value for parameter "605" is set at "1", the actual machine speed
appears on the display after sewing starts.