Pfaff 3538-30/02 User manual

This instruction manual applies to machines
from the following serial numbers onwards: 2 804 345
and software version 0437/001.
3538
296-12-19 292/002
Instruction Manual engl. 10.15
INSTRUCTION MANUAL
-20/02
-30/02

This instruction manual applies to all models and subclasses listed in Chapter 3
Technical Data.
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
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 under order no. 296-12-19 293/002.

Table of Contents
Contents ..................................................................................................Page
1Safety .................................................................................................................................... 5
1.01 Directives............................................................................................................................... 5
1.02 General safety instructions .................................................................................................... 5
1.03 Safety symbols ...................................................................................................................... 6
1.04 Special points of attention for the owner-operator ................................................................ 6
1.05 Operating personnel and technical staff ................................................................................ 7
1.05.01 Operating personnel .............................................................................................................. 7
1.05.02 Technical staff........................................................................................................................ 7
1.06 Danger warnings.................................................................................................................... 8
2Proper Use............................................................................................................................ 9
3Technical Data................................................................................................................. 10
3.01 PFAFF 3538 ......................................................................................................................... 10
4Disposal of the Machine.................................................................................................... 11
5Transport, Packaging and Storage ................................................................................... 12
5.01 Transport to the customer’s premises ................................................................................ 12
5.02 Transport within the customer’s premises.......................................................................... 12
5.03 Disposal of the packaging materials .................................................................................... 12
5.04 Storage ................................................................................................................................ 12
6Work Symbols.................................................................................................................... 13
7Operating Controls ............................................................................................................14
7.01 Main switch ........................................................................................................................ 14
7.02 Light barrier.......................................................................................................................... 14
7.03 Stop button .......................................................................................................................... 15
7.04 Control panel........................................................................................................................ 16
7.04.01 Symbols on the display........................................................................................................ 17
7.04.02 Plus/minus keys................................................................................................................... 17
7.04.03 Function keys....................................................................................................................... 18
8Set-up and Initial Commissioning .................................................................................... 20
8.01 Set-up .................................................................................................................................. 20
8.01.01 Aligning the machine .......................................................................................................... 20
8.01.02 Mounting the reel stand ...................................................................................................... 21
8.02 Connecting the plug-in connections and ground cable ........................................................ 22
8.03 Initial start-up ....................................................................................................................... 23
8.04 Switching the machine on/off ............................................................................................. 23

Table of Contents
Contents ..................................................................................................Page
9Set-up.................................................................................................................................. 24
9.01 Inserting the needle............................................................................................................. 24
9.02 Threading the needle / adjusting the needle thread ............................................................ 25
10 Input .................................................................................................................................... 26
10.01 Sewing – automatic mode ................................................................................................... 27
10.02 Sewing – Unit with cutter and rack...................................................................................... 28
10.03 Input mode .......................................................................................................................... 29
10.04 Input mode .......................................................................................................................... 31
10.09 Parameter list....................................................................................................................... 32
10.10 Error messages.................................................................................................................... 36
11 Maintenance and Care....................................................................................................... 38
11.01 Maintenance intervals.......................................................................................................... 38
11.02 Cleaning the machine .......................................................................................................... 38
11.03 Checking / topping up the oil level of the oil tank for the front parts................................... 39
11.04 Checking / topping up the oil level of the gear mechanism................................................. 40
11.05 Checking / setting the air pressure ...................................................................................... 41
11.06 Emptying / cleaning the maintenance unit’s water tank...................................................... 41
12 Wearing Parts..................................................................................................................... 42

Safety
5
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, le-
gal and other regulations and legislation – also in the country of use – and the valid environ-
mental 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 manufactur-
er before starting up the machine!
Always follow the hazard and safety instructions attached to the machine!
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,
sewing foot, needle plate, feed dog etc.) and when threading, leaving the workstation, or
performing maintenance!
The daily maintenance work may only be carried out by suitably qualified personnel!
Repairs and special maintenance work may only be carried out by technical staff or peo-
ple with appropriate training!
Unless otherwise stated, the machine must be isolated from the power supply and pneu-
matic supplies before any servicing work or repairs are performed! The only permitted
exceptions are for adjustment work and functional tests by appropriately trained techni-
cal staff!
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 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
6
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.
Danger of hands being crushed!
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
This instruction manual is a part of the machine and must be made available to the oper-
ating personnel at all times. The instruction manual must have been read before the ini-
tial start-up.
The operating personnel and technical staff must be instructed about the machine’s safe-
ty 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.
I

Safety
7
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:
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 before starting any adjustment or repair work and secure it
against reactivation!
Working on live parts and equipment is prohibited!
Exceptions are regulated by the EN 50110 standards.
Unless otherwise stated, the machine must be isolated from the power supply and pneu-
matic supplies before any servicing work or repairs are performed!
Exceptions are permitted solely for function tests.
Reattach the safety covers following repair and maintenance work!

Safety
8
Fig. 1 - 01
1.06 Danger warnings
A work area of 1mmust be kept around the machine during operation 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!
Danger of hands being crushed!
Do not operate the machine without the protective cover 1!
Risk of injury from the feed band!
Do not operate the machine without the take-up lever guard 2!
Risk of injury due to movement of the take-up lever!
Do not operate the machine without the belt guard 3!
Risk of injury due to the rotating driving belt!
2
3
1

Proper Use
9
2 Proper Use
The PFAFF 3538 is a sewing machine for efficiently hemming pocket openings.
Any usage not approved by the manufacturer is deemed misuse! The manufac-
turer 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
10
3 Technical Data
3.01 PFAFF 3538
Stitch type:.......................................................................................................401 (chainstitch)
Design B: ......................................................... for the machining of medium-weight materials
Design C: ...........................................................for the machining of medium-heavy materials
Needle thickness: ........................................................................................................ 80 – 140
Needle system:................................................................................................................ 62x57
Thread thickness max......................................................................................................... 11/3
Speed max.:................................................................................................. 4000 stitches/min.
Stitch length max:..........................................................................................................4.5 mm
Noise data:
Noise emission level at workplace with a sewing speed of n = 2400 min-1: ...... LpA = 75 dB(A)
(Noise measurement in accordance with DIN 45 635-48-A-1,ISO 11204, ISO 3744,
ISO 4871)
Motor data: ................................................................................. see motor instruction manual
Air consumption per switching cycle:...........................................................................0.146 Nl
Net weight of sewing head with stand:............................................................. approx. 308 kg
Gross weight of sewing head with stand: ......................................................... approx. 521 kg
Subject to alterations
KpA = 2.5dB

11
Disposal of the Machine
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 pro-
tection regulations, with a specialised company being contracted if necessary.
Please ensure that parts coated with lubricants are disposed of separately in ac-
cordance with the locally valid environmental protection regulations!

Transport, Packaging and Storage
12
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
13
6 Work Symbols
Activities to be performed or important information in this instruction manual are empha-
sised 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
14
7.02 Light barrier
The LED in the light barrier indicates the
following status:
– LED lights up green = Reception indica-
tor (If there is no sewing material below
it).
– LED flashes green or yellow = Setting
aid/soiling indicator.
– LED lights up yellow = Output indicator
(if there is no sewing material below it).
7 Operating Controls
7.01 Main switch
Fig. 7 - 01
1
Turning the main switch 1switches the
machine on and off.
Fig. 7 - 02

Operating Controls
15
7.03 Stop button
Press the stop button:
Machine and feed band stop.
Release the stop button:
Press the F4key on the control panel to
start the machine or insert new pocket
blanks.
Fig. 7 - 03
1

Operating Controls
16
7.04 Control panel
The control panel is used to display and access machine functions for set-up and sewing, to
enter parameter values and to read error messages and service settings.
Fig. 7 - 04
F1 F2 F3
F4
00
000
0
3500 1 3,5 2000
The control panel has the following operating and display controls:
The display 1comprises a two-line alphanumeric LCD display with 16 characters per line
and is used to display the corresponding information and selection parameters.
The plus/minus keys 2are used for selecting or altering the functions and parameters
shown on the display.
The function keys 3are used for turning the corresponding function on and off.
Switched-on functions are each indicated by the lit LED.
1
3
2

Operating Controls
17
7.04.01 Symbols on the display
In addition to clear texts and set values, the following symbols appear on the display.
Symbol Function
Current program number
Piece counter
Speed
Stitch length
SD memory card
Machine memory
Enter
7.04.02 Plus/minus keys
The corresponding set values are selected and altered using the appropriate plus-minus
keys. At the same time the set value shown above is changed slowly at first by pressing
and holding the corresponding plus or minus key. If the key is held pressed for longer, the
set value changes more quickly.
Fig. 7 - 05
F1 F2 F3
F4
00
000
0
3500 1 3,5 2000
Plus/minus keys
The displayed values can be increased or decreased using the respective key on the display
+
–

Operating Controls
18
7.04.03 Function keys
If a function is on, this is always indicated by the correspondingly lit LED. Detailed explana-
tion of functions:
Thread machine
The sewing head is moved back so that the machine can be threaded.
The thread tension is opened when threading.
This key corresponds to number 1when entering the code number.
Chain cutter on/off (with subclasses 2and 3).
The chain is separated at the start and end of the pocket during the sewing operation.
This key corresponds to number 2when entering the code number.
Stacker on/off (with subclass 3)
The sewn pockets are automatically stacked during the sewing operation if the cover of
the stacker is closed.
This key corresponds to number 3when entering the code number.
Label feeder on/off (with subclass 4).
This key corresponds to number 4when entering the code number.
Fill the unit
The unit is filled after pressing the key. FILL 3538 appears on the display.
Now pocket blanks must be fed in until the unit is completely filled. The unit is filled
when the length entered in parameter 503 is reached. If the unit is filled, it automatically
switched to the sewing operation.
This key corresponds to number 5when entering the code number.
Sew until the unit is empty (with subclasses 2and 3)
The unit sews until all pocket blanks are sewn after pressing the key.
EMPTY 3538 appears on the display. The unit automatically switches to ready for sewing
when the unit sews until it is empty.
This key corresponds to number 6when entering the code number.
F1key
This key is reserved for special functions.
This key corresponds to number 7when entering the code number.
F2key
This key is reserved for special functions.
This key corresponds to number 8when entering the code number.
F3key
This key is reserved for special functions.
This key corresponds to number 9when entering the code number.
F1
F2
F3

Operating Controls
19
F4key
The unit continues to sew after the "Remove fabric" message although there is still mate-
rial under the initial light barrier.
Scroll
If this key is pressed, the input menus on the display are scrolled through.
TE key
The machine changes from sewing mode to stitch input mode if this key is pressed.
Piece counter / counter
These keys can be used to switch between the piece counter and the counter. If the re-
spective function is switched on, a menu appears to set the counter to a preset, variable
value when pressing the key.
Coded via parameters 811 and 812.
The piece counter key corresponds to number 0when entering the code number.
Separate chain (with subclasses 2and 3)
The chain cutter is activated once after pressing the key.
Raise/lower band feed
This is raised if the band feed is lowered and lowered if the band feed is raised. Coded
via parameter 813.
Raise/lower presser foot
This is raised if the presser foot is lowered and lowered if the presser foot is raised. Cod-
ed via parameter 813.
Band feed forwards
The band feed moves forward while the key is pressed.
Coded via parameter 813.
Band feed backwards
If the band feed is raised, the band feed moves backwards while the key is pressed.
Coded via parameter 813.
F4
00
0
00
0

Set-up and Initial Commissioning
20
8.01.01 Aligning the machine
Loosen the adjustable feet 1.
Align the machine horizontally by turning the levelling feet.
All four levelling feet must sit firmly on the ground.
Tighten the lock nuts on the levelling feet 1.
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!
Adequate stability of the stand must be guaranteed, even during the sewing
operations.
8.01 Set-up
Suitable electrical and pneumatic supply connections must be provided at the erection site,
see Chapter 3 Technical Data.
The erection site must 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.
Fig. 8 - 01
1
1
1