Pfaff 3511-2/01 User manual

3511-2/01
Instruction manual
296-12-19 010/002
Betriebsanleitung engl. 11.06
This instruction manual applies to machines from software
version 1-912-19 and serial number 2 736 439 onwards

Reprinting, copying or translation of PFAFF instruction manuals, whether in whole or in
part, is not permitted without our prior permission and not without written indication of the
source.
PFAFF Industrie Maschinen AG
Postfach 3020
D-67653 Kaiserslautern
Königstr. 154
D-67655 Kaiserslautern

Index
Contents ..................................................................................Page
1Safety .................................................................................................................................... 6
1.01 Directives .............................................................................................................................. 6
1.02 General notes on safety......................................................................................................... 6
1.03 Safety symbols ...................................................................................................................... 7
1.04 Important points for the user................................................................................................. 7
1.05 Operating and specialist personnel........................................................................................ 8
1.05.01 Operating personnel .............................................................................................................. 8
1.05.02 Specialist personnel............................................................................................................... 8
1.06 Danger warnings.................................................................................................................... 9
2Proper use .......................................................................................................................... 10
3Specifications ......................................................................................................................1!
4Disposal of Machine .......................................................................................................... 12
5Transportation, packing and storage................................................................................ 13
5.01 Transportation to customer‘s premises ............................................................................... 13
5.02 Transportation inside the customer‘s premises................................................................... 13
5.03 Disposal of packing materials ..............................................................................................13
5.04 Storage ................................................................................................................................ 13
6Explanation of symbols..................................................................................................... 14
7Controls .............................................................................................................................. 15
7.01 On/off switch ....................................................................................................................... 15
7.02 Lever for lifting the presser foot........................................................................................... 15
7.03 Pedal .................................................................................................................................... 16
7.04 Photo sensor........................................................................................................................ 16
7.05 Control panel........................................................................................................................ 17
7.05.01 Screen displays .................................................................................................................... 17
7.05.02 Symbole im Display ............................................................................................................. 17
7.05.03 Function keys ....................................................................................................................... 18
8Installation and commissioning ....................................................................................... 21
8.01 Installation............................................................................................................................ 21
8.01.01 Adjusting the table height.................................................................................................... 21
8.01.02 Mounting the spool holder .................................................................................................. 22
8.01.03 Connecting the plug-in connections and earth cables ......................................................... 23
8.02 Commissioning .................................................................................................................... 24
8.03 Switching the machine on/off ..............................................................................................24
8.04 Basic position of the machine drive unit .............................................................................. 25
9Preparation ........................................................................................................................ 26
9.01 Inserting the needle............................................................................................................. 26
9.02 Winding the bobbin thread, adjusting the thread tension.................................................... 27
9.03 Removing / Inserting the bobbin case ................................................................................ 28
9.04 Inserting the bobbin case / Adjusting the bobbin thread tension......................................... 28
9.05 Threading the needle thread / Adjusting the needle thread tension .................................... 29

Index
Contents ..................................................................................Page
9.06 Entering the stitch length..................................................................................................... 30
9.07 Entering the start and end backtacks................................................................................... 30
9.08 Inserting and removing the SD-memory card...................................................................... 31
9.09 Inserting the workpiece ....................................................................................................... 32
9.09.01 Loading the sewing jig ......................................................................................................... 32
9.09.02 Inserting the sewing jig........................................................................................................ 33
10 Sewing ................................................................................................................................ 34
10.01 Manual sewing .................................................................................................................... 35
10.02 Programmed sewing............................................................................................................ 36
10.03 Creating / altering seam patterns......................................................................................... 37
10.03.01 Creating a seam pattern in the "teach in mode" ................................................................... 37
10.03.02 Altering seam patterns......................................................................................................... 41
10.03.03 Switch on edge trimmer with delay (waistband extension) ................................................. 42
10.04 Program management .........................................................................................................43
10.04.01 Calling up the program management .................................................................................. 43
10.04.02 Displaying programs in the machine memory ..................................................................... 44
10.04.03 Displaying programs on the SD-memory card ..................................................................... 45
10.04.04 Copying individual programs to the SD-memory card ......................................................... 46
10.04.05 Copying all programs to the SD-memory card..................................................................... 47
10.04.06 Copying individual programs to the machine memory......................................................... 48
10.04.07 Copying all programs to the machine memory ................................................................... 49
10.04.08 Deleting programs in the machine memory ........................................................................ 50
10.04.09 Deleting programs on the SD-memory card ........................................................................ 51
10.04.10 Formatting the SD-memory card .........................................................................................52
10.05 Error messages.................................................................................................................... 52
11 Care and maintenance....................................................................................................... 53
11.01 Maintenance intervals.......................................................................................................... 53
11.02 Cleaning the machine .......................................................................................................... 53
11.03 Topping up the oil tank......................................................................................................... 54
11.04 Checking/regulating the air pressure ................................................................................... 54
11.05 Emptying/cleaning the water bowl of the air filter/regulator................................................ 55
12 Adjustment ......................................................................................................................... 56
12.01 Notes on adjustment ........................................................................................................... 56
12.02 Tools, gauges and other accessories for adjusting ............................................................. 56
12.03 Abbreviations ...................................................................................................................... 56
12.04 Checking and adjusting aids................................................................................................. 57
12.05 Adjusting the basic machine ................................................................................................58
12.05.01 Basic position of the machine drive .....................................................................................58
12.05.02 Preadjusting the needle height ............................................................................................ 59
12.05.03 Needle in needle hole center............................................................................................... 60
12.05.04 Hook shaft bearing and toothed belt tension....................................................................... 61
12.05.05 Hook lubrication .................................................................................................................. 62
12.05.06 Needle rise, hook-to-needle clearance, needle height and bobbin case position finger ...... 63
12.05.07 Thread check spring and slack thread regulator ................................................................... 64
12.05.08 Bobbin winder...................................................................................................................... 65
12.05.09 Presser foot pressure .......................................................................................................... 66
12.06 Adjusting the edge trimmer.................................................................................................67
12.06.01 Zero position of the knife ..................................................................................................... 67
12.06.02 Cutting motion ..................................................................................................................... 68

Index
Contents ..................................................................................Page
12.06.03 Knife height.......................................................................................................................... 69
12.06.04 Knife position in sewing direction ........................................................................................ 70
12.06.05 Cutting angle of the knife..................................................................................................... 71
12.06.06 Knife position crosswise to sewing direction ...................................................................... 72
12.07 Adjusting the thread trimming device.................................................................................. 73
13.0.01 Adjusting the solenoid / preliminary adjustment of the control cam ................................... 73
12.07.02 Lateral alignment of the thread catcher ............................................................................... 74
12.07.03 Knife position ....................................................................................................................... 75
12.07.04 Front point of reversal of the thread catcher........................................................................ 76
12.07.05 Manual trimming check........................................................................................................ 77
12.07.06 Needle thread tension release............................................................................................. 78
12.07.07 Readjusting the control cam ................................................................................................ 79
12.08 Adjusting the automatic presser foot lift.............................................................................. 80
12.09 Adjusting the jig drive ......................................................................................................... 81
12.09.01 Position of the jig drive in the sewing direction ................................................................... 81
12.09.02 Position of the jig drive crosswise to the sewing direction.................................................. 82
12.09.03 Jig drive contact pressure.................................................................................................... 83
12.09.04 Adjusting the support roller.................................................................................................. 84
12.10 Adjusting the retainer .......................................................................................................... 85
12.11 Adjusting the photo sensor and jig stop .............................................................................. 86
12.12 Parameter settings............................................................................................................... 87
12.12.01 Selecting the user level........................................................................................................ 87
12.12.02 Example of parameter input ................................................................................................ 88
12.12.03 List of parameters................................................................................................................ 89
12.13 Explanation of the error messages ...................................................................................... 93
12.13.01 Sewing motor errors............................................................................................................ 93
12.13.02 Error SD memory card ......................................................................................................... 93
12.14 Hardware-Test...................................................................................................................... 94
12.14.01 Carry out the hardware test................................................................................................. 94
12.14.02 Test block 1 – inputs ............................................................................................................ 94
12.14.03 Test block 2 – outputs .......................................................................................................... 95
12.14.04 Test block 3 – Set value sender and actual value sender ..................................................... 95
12.14.05 Test block 4 – photo sensor and thread monitor.................................................................. 96
12.15 Reset .................................................................................................................................. 96
12.16 Internet update of the machine software ............................................................................ 97
13 Wearing parts ..................................................................................................................... 98
14 Circuit diagram................................................................................................................. 100

Safety
6
1 Safety
1.01 Directives
This machine is constructed in accordance with the European regulations contained in the
conformity and manufacturer’s declarations.
In addition to this Instruction Manual, also observe all generally accepted, statutory and
other regulations and legal requirements and all valid environmental protection regulations!
The regionally valid regulations of the social insurance society for occupational accidents or
other supervisory organizations are to be strictly adhered to!
1.02 General notes on safety
This machine may only be operated by adequately trained operators and only after having
completely read and understood the Instruction Manual!
All Notes on Safety and Instruction Manuals of the motor manufacturer are to be read be-
fore operating the machine!
The danger and safety instructions on the machine itself are to be followed!
This machine may only be used for the purpose for which it is intended and may not be
operated without its safety devices. All safety regulations relevant to its operation are to
be adhered to.
When exchanging sewing tools (e.g. needle, roller presser, needle plate and bobbin),
when threading the machine, when leaving the machine unattended and during mainte-
nance work, the machine is to be separated from the power supply by switching off the
On/Off switch or by removing the plug from the mains!
Everyday maintenance work is only to be carried out by appropriately trained personnel!
Repairs and special maintenance work may only be carried out by qualified service staff
or appropriately trained personnel!
Work on electrical equipment may only be carried out by appropriately trained personnel!
Work is not permitted on parts and equipment which are connected to the power supply!
The only exceptions to this rule are found in the regulations EN 50110.
Modifications and alterations to the machine may only be carried out under observance
of all the relevant safety regulations!
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 which are not supplied by us have
not been tested and approved by us. The installation and/or use of any such products can
lead to negative changes in the structural characteristics of the machine. We are not liable
for any damage which may be caused by non-original parts.
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Safety
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1.04 Important points for the user
This Instruction Manual is an integral part of the machine and must be available to the
operating personnel at all times.
The Instruction Manual must be read before operating the machine for the first time.
The operating and specialist personnel is to be instructed as to the safety equipment of
the machine and regarding safe work methods.
It is the duty of the user to only operate the machine in perfect running order.
It is the obligation of the user to ensure that none of the safety mechanisms are removed
or deactivated.
It is the obligation of the user to ensure that only authorized persons operate and work
on the machine.
Further information can be obtained from your PFAFF agent.
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1.03 Safety symbols
Danger!
Points to be observed..
Danger of injury for operating and specialist personnel!
Caution
Do not operate without finger guard and safety devices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.
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Safety
8
1.05 Operating and specialist personnel
1.05.01 Operating personnel
Operating personnel are persons responsible for the equipping, operating and cleaning of
the machine as well as for taking care of problems arising in the sewing area.
The operating personnel is required to observe the following points and must:
always observe the Notes on Safety in the Instruction Manual!
never use any working methods which could adversely affect the safety of the machine!
not wear loose-fitting clothing or jewelery such as chains or rings!
also ensure that only authorized persons have access to the potentially dangerous area
around the machine!
always immediately report to the person responsible any changes in the machine which
may limit its safety!
1.05.02 Specialist personnel
Specialist personnel are persons with a specialist education in the fields of electrics, electro-
nics and mechanics. They are responsible for the lubrication, maintenance, repair and adjust-
ment of the machine.
The specialist personnel is obliged to observe the following points and must:
always observe the Notes on Safety in the Instruction Manual!
switch off the On/Off switch before carrying out adjustments or repairs, and ensure that
it cannot be switched on again unintentionally!
wait until the luminous diode on the control box is no longer blinking or on before begin-
ning adjustment or repair work.
never work on parts which are still connected to the power supply! Exceptions are explai-
ned in the regulations EN 50110.
replace the protective coverings and close the electrical control box afer all repairs or
maintenance work!
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Safety
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1.06 Danger warnings
A working area of 1mmust be kept free both in front of and behind the machi-
ne, so that easy access is possible at all times.
Never put your hands or fingers in the sewing area during sewing!
Danger of injury by the needle!
While setting or adjusting the machine do not leave any objects on the table nor
in the needle plate area! Objects may be trapped or flung out of the machine!
Do not run the machine without take-up lever guard 1!
Danger of injury by moving take-up lever!
Do not operate the machine without covers 2 and 3!
Danger of injury from moving parts!
Do not operate the machine without start inhibitor 4!
Danger of injury if the machine is started accidentally!
Fig. 1 - 01
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Proper use
10
2 Proper use
The PFAFF 3511-2/01 is an ultra-high-speed, single-needle lockstitch sewing machine for stit-
ching and turning small parts.
Any and all uses of this machine which have not been approved of by the
manufacturer are considered to be inappropriate! The manufacturer cannot be
held liable for any damage caused by the inappropriate use of the machine!
The appropriate use of the machine includes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!

11
Specifications
3 Specifications ▲
Stitch type:......................................................................................................... 301 (lockstitch)
Needle system:...............................................................................................................134 KK
Needle size in 1/100 mm: .............................................................................................. 80 -100
Max. stitch length: .........................................................................................................3,5 mm
Max. speed: ......................................................................................................... 3000 Sti/min◆
Trimming margin (depends on version)............................................................... 3.5 or 5.0 mm
Bed-plate dimensions: ........................................................................................ 476 x 177 mm
Dimensions of machine:
Length:........................................................................................................... approx. 1250 mm
Width: ..............................................................................................................approx. 800 mm
Height (above table): ........................................................................................approx. 300 mm
Electrical data
Power supply:: ..................................................................................... 230 V ± 10 %, 50/60 Hz
Max. output: ...................................................................................................................400 VA
Fuse protection: ................................................................................................... 1 x 16 A, inert
Working air pressure:......................................................................................................... 6 bar
Air consumption:................................................................................... approx. 25 l/work cycle
Noise data:
Noise emission level at workplace with a sewing speed of 2000 spm: .......... LpA = 78 dB(A) ■
(Noise measurement in accordance with DIN 45 635-48-B-1, ISO 11204, ISO 3744, ISO 4871)
Net weight: ........................................................................................................approx. 105 kg
Gross weight ...................................................................................................... approx. 176 kg
▲Subject to alterations
◆The max. speed is reduced automatically depending on the stitch length.
■K
pA = 2,5 dB

Disposal of Machine
12
4 Disposal of Machine
Proper disposal of the machine is the responsibility of the customer.
The materials used for the machine are steel, aluminium, brass and various plastic
materials. The electrical equipment comprises plastic materials and copper.
The machine is to be disposed of according to the locally valid pollution control regula-ti-
ons; if necessary, a specialist ist to be commissioned.
Care must be taken that parts soiled with lubricants are disposed of separately
according to the locally valid pollution control regulations!
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Transportation, packing and storage
13
5 Transportation, packing and storage
5.01 Transportation to customer‘s premises
The machines 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
nor to other operating locations. It must be ensured that the machines are only transported
in an upright position.
5.03 Disposal of packing materials
The packing materials of this machine comprise paper, cardboard and VCE fibre. Proper dis-
posal of the packing material is the responsibility of the customer.
5.04 Storage
If the machine is not in use, it can be stored as it is for a period of up to six months, but It
should be protected against dust and moisture.
If the machine is stored for longer periods, the individual parts, especially the surfaces of
moving parts, must be protected against corrosion, e.g. by a film of oil.

Explanation of symbols
14
6 Explanation of symbols
In this instruction manual, work to be carried out or important information is accentuated by
symbols. These symbols have the following meanings:
Note, information
Cleaning, care
Lubrication
Maintenance, repairs, adjustment, service work
(only to be carried out by technical staff)

Controls
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77
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005
1
7 Controls
7.01 On/off switch
Switch the machine on or off by turning
main switch 1.
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Fig. 7 - 01
7.02 Lever for lifting the presser foot
The presser foot is raised by turning
lever 1.
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Fig. 7 - 02
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Controls
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0 +1
-1 -2
7.03 Pedal
The pedal functions depend on the selected
operating mode, see Chapter 10 Sewing.
In manual sewing:
+ 1 = sewing
0 = neutral position
-1 = raise sewing foot
-2 = cut thread
In programmed sewing:
+ 1 = start sewing cycle
0 = neutral position
-1 = no function
-2 = seam stop.
Fig. 7 - 03
7.04 Photo sensor
The LED 1 in the photo sensor indicates the
following status:
- LED shows green light = indicates
reception
- LED shows green flashing light =
adjustment aid / indicates soiling
- LED shows yellow light = indicates ready
status
Button 2 on the photo sensor is used to
adjust the photo sensor, see Chapter
12.11 Adjusting the photo sensor.
Fig. 7 - 04
1
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Controls
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7.05 Control panel
The control panel is used to call up machine functions for setting up the machine and for
sewing operation, for entering parameter values and for reading error messages and service
settings.
The control panel consists of display screen 1 with the function keys described below. The
display 1 consists of a two-row alphanumerical LCD display with 16 symbols per row. The
function keys 2 are located below and to the right of the display screen. The status of the
function keys and the machine operating modes are shown with LEDs in the corresponding
keys. Every time the function keys 2 are operated, a key tone sounds as confirmation of the
input. If the input required is invalid, e.g. because the max. permissible value for the
parameter input has been reached, a double tone is audible. An SD-card reader for data
transfer is integrated.
7.05.01 Screen displays
In the sewing mode all relevant sewing data is displayed and can be changed directly, de-
pending on the status of the machine, see also Chapter 10 Sewing.
During the parameter input the selected parameter number with the corresponding value
is displayed, see Chapter "12.12 Parameter settings".
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Fig. 7 - 06
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7.05.02 Symbole im Display
Program
Machine memory
SD-memory card
Enter
Program with corners

Controls
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7.05.03 Function keys
The functions keys described below are used essentially to switch machine functions on and
off. When the function is switched on, the diode in the key is illuminated.
If a corresponding value has to be fixed for the activated function, this can be carried out
with the corresponding +/- keys 3.
By pressing and holding the corresponding +/- key, firstly the numerical value displayed abo-
ve it is altered slowly. If the +/- key is pressed longer, the numerical value changes more
quickly. The respective +/- keys shown opposite are described below.
Start backtacks
If this key is pressed, the backtack function at the beginning of the seam (start backtacks)
is switched on or off. In manual sewing the number of forward stitches (A) or reverse stit-
ches (B) for the start backtacks can be changed respectively by pressing the +/- key un-
derneath. To convert from double backtack to single backtack, reset the number of stit-
ches for the corresponding seam section.
End backtacks
If this key is pressed, the backtack function at the end of the seam (end backtacks) is
switched on or off. In manual sewing the number of reverse stitches (C) or forward stit-
ches (D) can be changed respectively by pressing the +/- key underneath. To convert from
double backtack to single backtack, reset the number of stitches for the corresponding
seam section.
Edge trimmer
Press this key to switch the edge trimming knife on or off.
Jig drive
Press this key to switch the jig drive unit on or off.
Foot position after trimming
If this key is pressed the "foot raised after thread trimming" function is switched on or off.
When the function is switched on, the presser foot is raised after thread trimming.
Thread trimmer
If this key is pressed the thread trimming function is switched on or off.
Alternate sewing
If this key is pressed, it is possible to switch between the linked programs.
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Controls
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Sewing / correcting seam programs
If this key is pressed, the sewing/correcting seam programs function is switched on. By
operating the pedal, the individual seam sections of a program can be sewn after each
other and corrected if necessary.
PM
Press this key to switch the sewing of programmed seam patterns on or off. The specific
program parameters are shown in the alphanumerical section of the display.
Line selection
If this key is pressed, the activated line in the display is selected. Parameter alterations
can only be made in the current active line. If this function is switched on, the top line of
the display is active.
TE
If this key is pressed in the sewing mode, the machine changes to the parameter input
function.
If this key is pressed during the seam pattern input the "teach in mode" is selected.
If this key is pressed during the parameter input, the altered values are stored and the se-
wing mode is called up.
Press this key twice to call up the program management function, see Chapter 10.04
Program Management.
Piece Counter
Press this key to switch the piece counter on or off. When the function is switched on the
actual value is shown on the display.
Support roller
If this key is pressed during seam programming, the support roller function for the corre-
sponding section of the seam pattern is switched on or off. In programmed sewing with
the seam pattern the support roller retracts in the appropriate seam section.
Corner programming
If this key is pressed, the corresponding function is switched on or off. If the function is
switched on, the corner programming function is carried out for the appropriate section
of the seam pattern.
Turning the corner
If this key is pressed, the corresponding function is switched on or off. If the function is
switched on, the "turning the corner" function for the current seam section is carried out
for the segment shown on the display.
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Controls
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F1 (cycle time)
If this key is pressed, the display function for the cycle time (duration of a seam
sequence) is switched on or off.
F2 (adjustment aid for the edge trimmer)
If this key is pressed, the corresponding function is switched on or off. If the function is
switched on in the manual sewing mode, the edge trimmer moves to the cutting positi-
on.
F3
After the corresponding "PC" (piece counter) function has been selected, press the key
to reset the piece counter, see Chapter 10.03.03 Switch on edge trimmer with delay
(waistband extension)
Start inhibitor
Press this key to switch the start inhibitor on or off. When the function is switched on,
sewing or the seam sequence cannot be started.
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