Pfaff 2481-3/01-980/30 User manual

2481
296-12-19 272/002
Instruction Manual engl. 05.16
This instruction manual applies to machines
from the serial number 2809 573 and
software version 0307/010 onwards.
INSTRUCTION MANUAL
-3/01-980/30

Reprinting, reproduction and/or translation of PFAFF instruction manuals (including parts
thereof) is only permitted with our prior agreement and citation of the source.
PFAFF Industriesysteme
und Maschinen GmbH
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
This instruction manual applies for all models and subclasses listed in chapter 3
Technical Data.
The adjustment manual for the machine can be downloaded at no charge
under www.pfaff-industrial.de/de/service-support/downloads/technical.
As an alternative to the Internet download, the adjustment manual can also be
ordered as a hard copy under order no. 296-12-19 273/001.

Table of Contents
Contents ..................................................................................Page
1Safety .................................................................................................................................... 6
1.01 Directives............................................................................................................................... 6
1.02 General safety instructions .................................................................................................... 6
1.03 Safety symbols ...................................................................................................................... 7
1.04 Special points of attention for the owner-operator ................................................................ 7
1.05 Operating personnel and technical staff ................................................................................ 8
1.05.01 Operating personnel .............................................................................................................. 8
1.05.02 Technical staff........................................................................................................................ 8
1.06 Danger warnings.................................................................................................................... 9
2Proper Use.......................................................................................................................... 10
3Technical Data s................................................................................................................ 11
3.01 PFAFF 2481-980/30.............................................................................................................. 11
4Disposal of the Machine.................................................................................................... 12
5Transport, Packaging and Storage ................................................................................... 13
5.01 Transport to the customer's premises ................................................................................ 13
5.02 Transport within the customer's premises.......................................................................... 13
5.03 Disposal of the packaging materials .................................................................................... 13
5.04 Storage ................................................................................................................................ 13
6Work Symbols.................................................................................................................... 14
7Operating Controls ............................................................................................................ 15
7.01 Main switch ......................................................................................................................... 15
7.02 Keys on the machine head .................................................................................................. 15
7.03 Pedal .................................................................................................................................... 16
7.04 Hand lever to raise the sewing foot..................................................................................... 16
7.05 Knee switch ......................................................................................................................... 17
7.06 Control panel........................................................................................................................ 17
8Set-up and Initial Commissioning .................................................................................... 19
8.01 Set-up .................................................................................................................................. 19
8.01.01 Setting the table height ....................................................................................................... 19
8.01.02 Inserting the sewing machine into the stand ...................................................................... 20
8.02 Connecting the plug-in connections and ground cable ........................................................ 22
8.03 Assembling the reel stand ................................................................................................... 23
8.04 Initial start-up ....................................................................................................................... 24
8.05 Switching the machine on / off............................................................................................ 24
8.06 Checking the start inhibitor function.................................................................................... 24

Table of Contents
Contents ..................................................................................Page
9Set-up.................................................................................................................................. 25
9.01 Inserting the needle ............................................................................................................ 25
9.02 Winding the bobbin thread, adjusting the thread tension.................................................... 26
9.03 Removing / inserting the bobbin case ................................................................................. 27
9.04 Inserting the bobbin case / adjusting the bobbin thread tension ......................................... 27
9.05 Threading the needle thread / adjusting the needle thread tension .................................. 28
9.06 Entering the stitch length .................................................................................................... 29
9.07 Entering the edge guide position......................................................................................... 30
9.08 Entering the start and end backtacks .................................................................................. 31
9.09 Entering the number of compensation stitches .................................................................. 32
9.10 Setting the number of remaining stitches for the bobbin thread monitor ........................... 33
9.11 Selecting the seam program................................................................................................ 35
9.12 Setting the control panel...................................................................................................... 36
9.13 Inserting and removing the SD memory card...................................................................... 38
10 Sewing ................................................................................................................................ 39
10.01 Manual sewing .................................................................................................................... 39
10.02 Programmed sewing ........................................................................................................... 41
10.03 Error messages.................................................................................................................... 42
11 Input .................................................................................................................................... 43
11.01 Input mode .......................................................................................................................... 43
11.02 Entering seam programs ..................................................................................................... 44
11.03 Example for seam program input ........................................................................................ 50
11.04 Parameter settings .............................................................................................................. 54
11.04.01 Overview of parameter functions ........................................................................................ 54
11.04.02 Example of a parameter entry ............................................................................................. 55
11.04.03 List of parameters................................................................................................................ 56
11.05 Error messages and description .......................................................................................... 62
11.06 Sewing motor errors............................................................................................................ 63

Table of Contents
Contents ..................................................................................Page
12 Maintenance and Care....................................................................................................... 64
12.01 Maintenance intervals.......................................................................................................... 64
12.02 Cleaning the machine .......................................................................................................... 64
12.03 Topping up the oil tank ........................................................................................................ 65
12.04 Cleaning the blower air filter................................................................................................ 65
13 Table Top............................................................................................................................ 66
13.01 Table top cutout................................................................................................................... 66
13.02 Table top assembly.............................................................................................................. 67
14 Wearing Parts..................................................................................................................... 68

Safety
6
1 Safety
1.01 Directives
The machine was built in compliance with the European regulations specified in the declara-
tion of conformity and declaration of incorporation.
As a supplement to this instruction manual, please also observe the generally applicable,
legal and other regulations and legislation – also in the country of use – and the valid
environmental protection regulations! Always comply with the locally applicable regulations
of the professional associations and other supervisory authorities!
1.02 General safety instructions
OThe machine may only be operated after you have become acquainted with the associ-
ated instruction manual and only by operating personnel who have received appropriate
training!
OAlways read the safety instructions and the instruction manual of the motor manufactur-
er before starting up the machine!
OAlways follow the hazard and safety instructions attached to the machine!
OThe machine may only be operated for its intended purpose and only with the associated
safety covers, while adhering to all the relevant safety requirements.
OThe machine must always be disconnected from the power supply by pressing the main
switch or pulling out the mains plug when sewing tools are replaced (such as the needle,
sewing foot, needle plate and bobbin) and when threading, leaving the workstation, or
performing maintenance!
OThe daily maintenance work may only be carried out by suitably qualified personnel!
ORepairs and special maintenance work may only be carried out by technical staff or peo-
ple with appropriate training!
OWork on electrical equipment may only be carried out by qualified technical staff!
OWork on parts and equipment under voltage is not permitted!
OExceptions are regulated by the EN 50110 standards.
OModifications and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
OOnly those replacement parts approved by us for usage may be used for repairs! We
warn you expressly that spare parts and accessories that are not supplied by us are also
not tested and approved by us.
Fitting or using these products may therefore have negative effects on features which
depend on the machine design. We are not liable for any damage caused by the use of
non-Pfaff parts.

Safety
7
1.03 Safety symbols
Hazard point!
Special points of attention.
Risk of injury to operating personnel or technical staff!
Electric voltage!
Danger to operating personnel or technical staff
Caution!
Do not operate without finger guard and safety covers!
Turn off the main switch before threading, changing the
bobbin or needle, cleaning, etc.!
1.04 Special points of attention for the owner-operator
OThis 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.
OThe operating personnel and technical staff must be instructed about the machine’s
safety covers and about safe working methods.
OThe owner-operator may only operate the machine in a flawless condition.
OThe owner-operator must ensure that no safety covers are removed or disabled.
OThe owner-operator must ensure that only authorised persons work on the machine.
Additional information can be requested from the responsible sales centre.

Safety
8
1.05 Operating personnel and technical staff
1.05.01 Operating personnel
Operating personnel are persons responsible for equipping, operating and cleaning the ma-
chine and for fault clearance in the sewing area.
The operating personnel are obligated to comply with the following points:
OThe safety instructions provided in the instruction manual must be followed for all work!
OAny work method jeopardising machine safety must be refrained from!
OTight-fitting clothing must be worn. The wearing of jewellery such as chains and rings is
prohibited!
OCare must be taken to ensure that no unauthorised persons are located in the machine’s
hazard zone!
OAny changes occurring on the machine which impair 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:
OThe safety instructions provided in the instruction manual must be followed for all work!
OTurn off the main switch and secure it against reactivation before starting any adjustment
and repair work!
ONever work on live parts and equipment!
Exceptions are regulated by the EN 50110 standards.
OReattach the safety covers following repair and maintenance work!

Safety
9
Fig. 1 - 01
1.06 Danger warnings
A work area of 1mmust be kept free in front of and behind the machine to en-
sure unobstructed access at all times.
Do not reach into the needle range during the sewing operation!
Risk of injury from the needle!
Do not allow any objects to 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!
Do not operate the machine without the take-up lever guard 1!
Risk of injury due to the motion of the take-up lever!
Do not operate the machine without the finger guard 2!
Risk of injury from the needle!
Do not operate machines with an integrated motor without the start inhibitor 3!
Risk of injury due to accidental machine start-up!
Do not operate the machine without the support 4! Risk of damage due to the
top-heavy sewing head!
Machine can tip over backwards when moving it!
1
2
3
4

Proper Use
10
2 Proper Use
The PFAFF 2481-980/30 is an ultra high-speed, single-needle seamer with a needle and drop
feed as well as a seam-program controlled edge guide and edge sensor.
The machines are used for sewing lockstitch seams in the clothing industry.
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!

Technical Data
11
3 Technical Data s
3.01 PFAFF 2481-980/30
Stitch type:.........................................................................................................301 (lockstitch)
Needle system:...............................................................................................................134 KK
Model BN3.5:............................................................... for the machining of medium materials
Needle size in 1/100 mm .............................................................................................. 90 - 110
Thread thickness max.:........................................................................................................ 120
Stitch length max:..........................................................................................................3.5 mm
Needle bar stroke: ..........................................................................................................30 mm
Speed max.:............................................................................................... 4500 stitches/min l
Clearance beneath the sewing foot:............................................................................4 - 6 mm
Passage width: .............................................................................................................300 mm
Clearance height: ..........................................................................................................125 mm
Bed plate dimensions: ............................................................................................... 516 x 177
Sewing head dimensions:
Length:.............................................................................................................approx. 580 mm
Width: ..............................................................................................................approx. 180 mm
Height (above table):........................................................................................approx. 300 mm
Ambient temperature
85% rel. humidity (condensation not permitted) ......................................................... 5 - 40 °C
Connection data:
Operating voltage: ................................................................................ 230 V ± 10%, 50/60 Hz
Max. input power:...........................................................................................................400 VA
Fuse protection:...................................................................................................1 x 16 A, inert
Leakage current: .......................................................................................................... < 5 mAu
Noise data:
Emissions sound pressure level in the workplace at n = 2700 min-1:.............. LpA = 80 dB(A) n
(Noise measurement in accordance with DIN 45 635-48-A-1,ISO 11204, ISO 3744,
ISO 4871)
Net weight of sewing head: ................................................................................ approx. 52 kg
Gross weight of sewing head:............................................................................. approx. 62 kg
sSubject to alterations
lDepending on the material, workstep and stitch length
uDue to the use of network filters there is a nominal leakage current of < 5 mA.
nKpA = 2,5 dB

Disposal of the Machine
12
4 Disposal of the Machine
OIt is up to the customer to dispose of the machine properly.
OThe materials used for the machine include steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
OThe machine must be disposed of in accordance with the locally valid environmental pro-
tection 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!

Transport, Packaging and Storage
13
5 Transport, Packaging and Storage
5.01 Transport to the customer's premises
All machines are completely packed for delivery.
5.02 Transport within the customer's premises
The manufacturer assumes no liability for transport within the customer's premises or to
the individual usage sites. Please 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 6months when not in use. It must then be protected
from dirt and moisture. For longer storage periods, the machine's single components,
especially its sliding surfaces, must be protected against corrosion, e.g. by an oil film.

Work Symbols
14
6 Work Symbols
Activities to be performed 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)

Operating Controls
15
7.02 Keys on the machine head
OThe following functions are carried out
by operating the respective keys.
Key 1: Reverse sewing
Key 2: Raise the needle without thread
trimming
Key 3: Carry out a single stitch
Fig. 7 - 02
7 Operating Controls
7.01 Main switch
Before switching on the
machine, raise the take-up lever
as far as possible.
OTurning the main switch 1switches the
machine on and off.
Fig. 7 - 01
1
BA-P-114_Fig-7-01
1
2
3

Operating Controls
16
7.03 Pedal
OWith the main switch turned on
0 = Neutral position
+1= Sewing
-1= Raise sewing foot
-2= Trim thread/reset bobbin
thread monitor or bobbin rest
thread count function
0
-2
-1
Fig. 7 - 03
+1
Fig. 7 - 04
7.04 Hand lever to raise the sewing foot
OTurning the hand lever 1raises the
sewing foot.
1

Operating Controls
17
7.05 Knee switch
OWhen the knee switch 1is operated,
one stitch is sewn with a reduced stitch
length (standard).
The value for the reduced stitch
length is set with parameter
"835", see chapter 11.04
Parameter settings.
OIf the edge guide connector is inserted
into the bushing X47, the edge guide can
be moved back using the knee switch.
Fig. 7 - 05
1
Fig. 7 - 06
2 GB
max.
7.06 Control panel
The current operating statuses are indicated on the control panel 1. The machine
is operated with constant dialogue between the control unit and the operator; different
pictograms and / or texts are displayed for this purpose according to the operating status of
the machine. Pictograms or texts with a border represent
12

Operating Controls
18
functions that can be called up by pressing on the respective point on the monitor. Pressing
the respective function causes its immediate actuation or activation/deactivation or another
menu will appear, e.g. for entering a value. Activated functions are indicated by pictograms
shown inversely. Apart from the bobbin change function, the pictograms and texts without
border are only for display purposes and cannot be called up by pressing them.
SD card 2in the control panel can be used to import seam programs.
Presentation of functions
Normal pictogram = Function deactivated (inactive)
Inverse pictogram = Function activated (active)

Set-up and Initial Commissioning
19
8 Set-up and Initial Commissioning
The machine 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!
If the machine was delivered without a table, then the stand and the table top
provided must safely support the weight of the machine and its motor.
Adequate stability of the stand must be guaranteed, even during the sewing
operations.
8.01 Set-up
Suitable electrical supply connections must be provided at the erection site, see chapter 3
Technical Data. The erection site must also have a firm and level subsurface and adequate
lighting.
The table top is lowered for packaging purposes.
The adjustment of the table height is described below.
8.01.01 Setting the table height
Fig. 8 - 01
OLoosen the screws 1and 2.
OMove the table top to the desired working height by pulling it out and pushing it in and
align the table top horizontally.
Adjust the stand on both sides evenly to prevent it tilting.
OThe stand must have all four feet firmly on the ground to make sure it is positioned
securely.
OFirmly tighten the screws 1.
OAdjust and tighten the desired pedal position on the screws 2.
1
1
2

Set-up and Initial Commissioning
20
Fig. 8 - 02
8.01.02 Inserting the sewing machine into the stand
OThe hinge 1is screwed to the sewing head base plate.
OInsert the sewing machine into the table top.
OInsert the sewing head support 2into the table top hole.
1
Do not operate the machine without the support 2! Risk of damage due to the
top-heavy sewing head!
Machine can tip over backwards when moving it!
2
1