Pfaff 3519-5/01 User manual

INSTRUCTION MANUAL
3519-5/01
296-12-19 384/002
Instruction manual engl. 12.17
This instruction manual applies to machines
from the serial number 2 814 134 and
software version 0361/021 onwards.

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

Table of Contents
Contents ..................................................................................Page
1Safety .................................................................................................................................... 7
1.01 Directives............................................................................................................................... 7
1.02 General safety instructions .................................................................................................... 7
1.03 Safety symbols ...................................................................................................................... 8
1.04 Special points of attention for the owner-operator ................................................................ 8
1.05 Operating personnel and technical staff ................................................................................ 9
1.05.01 Operating personnel .............................................................................................................. 9
1.05.02 Technical staff........................................................................................................................ 9
1.06 Danger warnings.................................................................................................................. 10
2Proper Use.......................................................................................................................... 11
3Technical Data................................................................................................................. 12
4Disposal of the Machine.................................................................................................... 13
5Transportation, Packaging and Storage .......................................................................... 14
5.01 Transport to the customer's premises ................................................................................ 14
5.02 Transport within the customer's premises.......................................................................... 14
5.03 Disposal of the packaging materials .................................................................................... 14
5.04 Storage ................................................................................................................................ 14
6Work Symbols.................................................................................................................... 15
7Operating Controls ............................................................................................................ 16
7.01 Main switch ......................................................................................................................... 16
7.02 Push-buttons on the machine control unit........................................................................... 16
7.03 Switch for the suction air blower (option)............................................................................ 17
7.04 Emergency stop push-button .............................................................................................. 17
7.05 Control panel........................................................................................................................ 18
7.06 Pedal .................................................................................................................................... 18
7.07 Start keys............................................................................................................................. 19
7.08 Key for small parts stacker .................................................................................................. 19
8Set-up and Initial Start-up ................................................................................................. 20
8.01 Set-up .................................................................................................................................. 20
8.01.01 Aligning the machine ........................................................................................................... 20
8.01.02 Removing the transit support on the infeed table ............................................................... 21
8.01.03 Removing the sewing machine transit support ................................................................... 21
8.01.04 Removing the loading clamp transit support ....................................................................... 22
8.01.05 Assembling the reel stand ................................................................................................... 23
8.01.06 Connecting the pedal........................................................................................................... 23
8.02 Initial start-up ....................................................................................................................... 24
8.03 Switching the machine on / off............................................................................................ 25
8.04 Setting the control panel (only for the control panel BDF T1).............................................. 26

Table of Contents
Contents ..................................................................................Page
9Set-up.................................................................................................................................. 27
9.01 Inserting the needle............................................................................................................. 27
9.02 Threading the needle thread / adjusting the needle thread tension .................................... 28
9.03 Winding the bobbin thread / adjusting the bobbin thread tension ....................................... 29
9.04 Changing the bobbin / adjusting the bobbin thread tension ................................................ 30
9.05 Changing the insert for darts ............................................................................................... 31
9.06 Adjusting the ironing compensation strip feeder................................................................. 32
9.07 Selecting a program number ............................................................................................... 33
9.08 Selecting / compiling program groups ................................................................................. 34
9.08.01 Selecting a program group................................................................................................... 34
9.08.02 Compiling a program group ................................................................................................. 35
10 Sewing ................................................................................................................................ 36
10.01 Inserting the workpiece ....................................................................................................... 37
10.01.01 Inserting the workpiece using the positioning tube............................................................. 37
10.01.02 Inserting the workpiece using the infeed table ................................................................... 39
10.02 Sewing in automatic mode .................................................................................................. 40
10.03 Sewing in manual mode ...................................................................................................... 41
10.04 Error messages.................................................................................................................... 43
11 Input .................................................................................................................................... 44
11.01 Overview of the functions in input mode ............................................................................ 44
11.02 Creating / altering seam programs....................................................................................... 46
11.02.01 Creating / altering single-point darts .................................................................................... 48
11.02.02 Creating / altering double-point darts................................................................................... 49
11.02.03 Creating / altering tapered darts .......................................................................................... 50
11.02.04 Entering a comment ............................................................................................................ 51
11.02.05 Entering correction values ................................................................................................... 52
11.02.06 Concluding seam programming........................................................................................... 53
11.03 Program management ......................................................................................................... 54
11.04 Rights of access .................................................................................................................. 56
12 Maintenance and Care....................................................................................................... 59
12.01 Maintenance intervals.......................................................................................................... 59
12.02 Cleaning the entire machine ................................................................................................ 59
12.03 Cleaning the needle area and hook area.............................................................................. 60
12.04 Cleaning the blower air filter................................................................................................ 61
12.05 Cleaning the maintenance unit air filter ............................................................................... 61
12.06 Checking / setting the air pressure ...................................................................................... 62
12.07 Checking the oil level........................................................................................................... 63
12.08 Lubricating the trimmer ....................................................................................................... 64
12.09 Lubricating the stacker drive................................................................................................ 65
13 Adjustment ......................................................................................................................... 66
13.01 Notes on adjustment ........................................................................................................... 66

Table of Contents
Contents ..................................................................................Page
13.02 Tools, gauges and other accessories .................................................................................. 66
13.03 Abbreviations ....................................................................................................................... 66
13.04 Sewing head service position .............................................................................................. 67
13.05 Adjusting the sewing head .................................................................................................. 69
13.05.01 Adjustment aid..................................................................................................................... 69
13.05.02 Machine drive home position .............................................................................................. 70
13.05.03 Needle in needle hole centre............................................................................................... 71
13.05.05 Hook lubrication ................................................................................................................... 73
13.05.06 Needle bar rise, hook-to-needle clearance, needle height and bobbin case position finger 74
13.05.07 Thread check spring and slack thread regulator .................................................................. 75
13.05.08 Bobbin winder...................................................................................................................... 76
13.06 Adjusting the thread trimmer............................................................................................... 77
13.06.01 Pre-adjusting the control cam .............................................................................................. 77
13.06.02 Roller lever setting............................................................................................................... 78
13.06.03 Aligning the thread trimmer laterally.................................................................................... 79
13.06.04 Knife position ....................................................................................................................... 80
13.06.05 Front turning point of the thread catcher............................................................................. 81
13.06.06 Manual cutting control ......................................................................................................... 82
13.08.07 Control cam (recalibrating) ................................................................................................... 83
13.07 Adjusting the loading plate .................................................................................................. 84
13.07.01 Basic setting of the loading plate height.............................................................................. 84
13.07.02 Loading plate position.......................................................................................................... 85
13.07.03 Insertion depth of the loading plate ..................................................................................... 86
13.08 Aligning the sewing head .................................................................................................... 87
13.08.01 Sewing head height ............................................................................................................. 87
13.08.02 Aligning the sewing head laterally ....................................................................................... 88
13.09 Aligning the surface plate .................................................................................................... 89
13.10 Adjusting the positioning tube ............................................................................................. 90
13.10.01 Presetting the positioning tube............................................................................................ 90
13.10.02 Front final position of the positioning tube .......................................................................... 91
13.10.03 Height and alignment of the positioning tube...................................................................... 92
13.11 Height of the needles .......................................................................................................... 93
13.12 Adjusting the spreader......................................................................................................... 94
13.13 Adjusting the table extension .............................................................................................. 95
13.14 Adjusting the loading clamp................................................................................................. 96
13.14.01 Loading clamp height........................................................................................................... 96
13.14.02 Position of the loading clamp............................................................................................... 97
13.15 Adjusting the brushes.......................................................................................................... 98
13.15.01 Adjusting the long brushes .................................................................................................. 98
13.15.02 Adjusting the short brushes................................................................................................. 99
13.16 Adjusting the knife unit...................................................................................................... 100
13.16.01 Presetting the knife unit .................................................................................................... 100
13.16.02 Knife unit height................................................................................................................. 101
13.16.03 Changing the knife............................................................................................................. 102
13.17 Aligning the workholder bar............................................................................................... 103

Table of Contents
Contents ..................................................................................Page
13.17.01 Zero point of the workholder bar ....................................................................................... 103
13.17.02 Workholder bar stop .......................................................................................................... 104
13.18 Setting the pneumatic table pressure................................................................................ 105
13.19 Adjusting the pressure controller....................................................................................... 106
13.20 Adjusting the stacker ......................................................................................................... 107
13.21 Adjusting the small parts stacker....................................................................................... 108
13.22 Boot key............................................................................................................................. 109
13.23 Service menu..................................................................................................................... 110
13.23.01 Cold start ........................................................................................................................... 112
13.23.02 Machine configuration ....................................................................................................... 113
13.23.03 Loading / updating the operating program......................................................................... 114
13.24 Sewing motor menu .......................................................................................................... 115
13.25 Parameter settings ............................................................................................................ 116
13.25.01 Selecting and changing parameters................................................................................... 116
13.25.02 List of parameters.............................................................................................................. 117
14 Control .............................................................................................................................. 119
14.01 Home position / diagnostics / pin assignment ................................................................... 119
14.01.01 Power supply A30.............................................................................................................. 119
14.01.02 Basic control unit A20........................................................................................................ 121
14.01.03 Sewing drive A22............................................................................................................... 123
14.01.04 Stepping motor drive ......................................................................................................... 124
14.01.05 CAN nodes A10, A11, A12 ................................................................................................ 125
14.02 Explanation of error messages .......................................................................................... 127
14.02.01 General errors .................................................................................................................... 127
14.02.02 CAN errors ......................................................................................................................... 129
14.02.03 Stitch generation................................................................................................................ 129
14.02.04 Sewing motor errors.......................................................................................................... 130
14.02.05 Stepping motor drive errors............................................................................................... 131
14.03 List of inputs and outputs .................................................................................................. 132
14.03.01 CAN node 1 ....................................................................................................................... 132
14.03.02 CAN node 2 ....................................................................................................................... 133
14.03.03 CAN node 3 ....................................................................................................................... 134
14.03.04 Special outputs .................................................................................................................. 135
15 Pneumatic Circuit Diagram ............................................................................................. 136
16 Circuit Diagrams ........................................................................................................... 143
Reference list for the circuit diagrams................................................................... 143

Safety
7
1 Safety
1.01 Directives
The machine was built in compliance with the regulations specified in the EC declaration 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
The 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!
Always read the safety instructions and the instruction manual of the motor manufacturer
before starting up the machine!
Always follow the hazard and safety instructions attached to the machine that must not
be removed!
The machine may only be operated for its intended purpose and only with the associated
safety covers, while adhering to all the relevant safety requirements.
The 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, presser foot, needle plate etc.) when leaving the workstation and performing
maintenance!
The daily maintenance work may only be carried out by suitably qualified personnel!
The machine must be isolated from the power supply and pneumatic supplies before
any maintenance work and repairs are performed! The only permitted exceptions are for
adjustment work and functional tests by appropriately trained technical staff!
Repairs and special maintenance work may only be carried out by technical staff or
people with appropriate training!
Work on electrical equipment may only be carried out by qualified technical staff!
Work on parts and equipment under voltage is not permitted!
Exceptions are regulated by the EN 50110 standards.
Modifications and changes to the machine may only be made in compliance with all of
the relevant safety requirements!
Only the 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 and/or using these products may therefore have neg-
ative 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
8
1.03 Safety symbols
Hazard point!
Special points of attention
Risk of injury to operating personnel and technical staff!
Danger area due to laser beam!
Attention!
Do not operate without the finger guard and safety cov-
ers!
Turn off the main switch before set-up, maintenance
and cleaning work!
Only one person in the work area!
Only one person may be in the work area of the machine during operation!
Do not lean on!
The feed mechanism can be damaged if you lean on the infeed table!
1.04 Special points of attention for the owner-operator
This 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.
The operating personnel and technical staff must be instructed about the machine's
safety covers and about safe working methods.
The owner-operator may only operate the machine in a flawless condition.
The owner-operator must ensure that no safety covers are removed or disabled.
The owner-operator must ensure that only authorised persons work on the machine.
Additional information can be requested from the responsible sales centre.

Safety
9
1.05 Operating personnel and technical staff
1.05.01 Operating personnel
Operating personnel are persons responsible for setting up, operating and cleaning the
machine, and for error clearance in the work area.
The operating personnel are obligated to comply with the following points:
The safety instructions provided in the instruction manual must be followed for all work!
Any work method jeopardising machine safety must be refrained from!
Tight-fitting clothing must be worn. The wearing of jewellery such as chains and rings is
prohibited!
Care must be taken to ensure that no unauthorised persons are located in the machine's
hazard zone!
Any 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:
The safety instructions provided in the instruction manual must be followed for all work!
Turn off the main switch and secure it against reactivation before starting any adjustment
and repair work!
Never work on live parts and equipment! Exceptions are regulated by the EN 50110
standards.
Reattach the safety covers following repair and maintenance work!

Safety
10
1.06 Danger warnings
A work area of 1 m must be kept free in front of and behind the machine to
ensure unobstructed access at all times.
Do not reach into the work area of the machine during the sewing operation!
Risk of injury from the needles in the sewing head and feed unit!
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 look at the laser beam with or without optical aids!
Risk of retinal injuries to the eye from the concentrated light!
Only operate the machine with the closed covers 1 and 2!
Risk of injury from moving machine parts!
The emergency stop push-button 3 is used to stop the machine immediately in
emergency situations.
Fig. 1 - 01
1
23
5
4

Proper Use
11
2 Proper Use
The PFAFF 3519-5/01 is an automatic sewing machine and is used for sewing single and
double-point breast darts on jackets.
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
12
3 Technical Data
Stitch type:.........................................................................................................301 (lockstitch)
Needle system:.................................................................................................................... 134
Needle size in 1/100 mm: ............................................................................................. 80 - 100
Stitch length:..........................................................................................................0.5 - 3.0 mm
Max. stitch count: ......................................................................................... 4300 stitches/min
Start backtack stitch length: ................ Standard stitch length of half of standard stitch length
Start backtack stitch count: ................................................................................................ 1 - 9
Starting / end stitch condensation stitch length: .........................................................1 - 3 mm
Starting / end stitch condensation stitch count: .................................................................. 1- 9
Size of sewing area
Dart depth:.................................................................................................................5 - 12 mm
Dart length: ............................................................................................................80 - 395 mm
Max. sewable material thickness: ....................................................................................4 mm
Machine dimensions
Length:..........................................................................................................approx. 2,800 mm
Width: ............................................................................................................1,200 - 1,800 mm
Height: ...........................................................................................................approx. 1400 mm
Weight
Net weight ......................................................................................................... approx. 628 kg
Gross weight ..................................................................................................... approx. 796 kg
Connection data
Operating voltage: ............................................................................... 230 V ± 10 %, 50/60 Hz
Max. input power:.............................................................................................................3 kVA
Fuse protection:...................................................................................................1 x 16 A, inert
Leakage current: .......................................................................................................... < 5 mA
Working air pressure.......................................................................................................... 6 bar
Air consumption:...............................................................................approx. 25 l/working cycle
Ambient temperature
85% rel. humidity (condensation not permitted) ......................................................... 5 - 40 °C
Noise data
Noise emission level at workplace with a sewing speed of 4300 min-1:........LpA < 81.9 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204,
ISO 3744, ISO 4871)
Subject to alterations
Due to the use of network filters there is a nominal leakage current of < 5 mA.
KpA = 2.5 dB

Disposal of the Machine
13
4 Disposal of the Machine
It is up to the customer to dispose of the machine properly.
The materials used for the machine include steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
The machine must be disposed of in accordance with the locally valid environmental
protection 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!

Transportation, Packaging and Storage
14
5 Transportation, 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 consist 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 6 months 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
15
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
16
7 Operating Controls
7.01 Main switch
Turning the main switch 1 switches the
power supply on or off.
Fig. 7 - 01
1
7.02 Push-buttons on the machine control unit
Pressing the push-button 1 after
switching on the power supply via the
main switch, see chapter 7.01 Main
switch, switches the machine control
unit on and the machine is ready for
operation.
The push-button 1 lights up
when the machine is ready for
operation.
Fig. 7 - 02
1

Operating Controls
17
7.03 Switch for the suction air blower (option)
The suction blower integrated
into the machine is only
required if there is no vacuum
network at the erection site.
Pressing the push-button 1 switches the
suction air blower on.
Pressing the push-button 2 switched the
suction air blower off.
Fig. 7 - 03
1
2
7.04 Emergency stop push-button
Pressing the emergency stop push-
button 1 stops the machine immediately
in emergency situations.
The emergency stop push-
button 1 must only be pressed
in emergency situations!
After releasing the depressed
EMERGENCY STOP push-
button 1, the machine can be
switched on again via the push-
button on the machine control
unit, see chapter 7.02 Push-
buttons on the machine
control unit.
Fig. 7 - 04
1

Operating Controls
18
Fig. 7 - 05
7.05 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
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. Pictograms or texts
without a border are only used for display purposes and cannot be called up by pressing
them.
The SD card 2 in the control panel can be used to import seam programs and operating
software.
Fig. 7 - 06
1
7.06 Pedal
Pressing the pedal 1 switches the
suction air for the infeed table and the
positioning tube on or off.
1
2 GB
max.
2

Operating Controls
19
7.07 Start keys
The sewing cycle is started by pressing the two start keys 1 at the same time.
After processing the sewing cycle, the lit start keys 1 show that the next
sewing cycle can be started.
When the threading aid function is active, the infeed table is moved forward and the
hook area of the sewing head becomes accessible after pressing both of the start keys 1
at the same time.
Fig. 7 - 07
1
1
7.08 Key for small parts stacker
Pressing the key 1 switches the small
parts stacker on or off.
Fig. 7 - 08
1

Set-up and Initial Start-up
20
8 Set-up and Initial Start-up
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!
8.01 Set-up
Suitable electrical and compressed air 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.
8.01.01 Aligning the machine
Loosen the nuts 1 and turn the feet 2 so that the machine is horizontal.
Tighten the nuts 1.
The alignment on the lower frame tubes can be checked with a spirit level.
Fig. 8 - 01
1
2