Pfaff 8301 User manual

This instruction manual applies to machines
from serial number 2 777 829 and software
version 0398/003 onwards.
8301
INSTRUCTION MANUAL
296-12-18 995/002
Betriebsanleitung engl. 10.11

The reprinting, copying or translation of PFAFF Instruction Manuals, whether in whole or
in part, is only permitted with our previous authorization and with written reference to the
source.
PFAFF Industriesysteme
und Maschinen AG
Hans-Geiger-Str. 12 - IG Nord
D-67661 Kaiserslautern
The parts list for the machines can be downloaded free of
charge from the internet address
www.pfaff-industrial.com/pfaff/de/service/downloads.
As an alternative to the internet download the adjustment manual can also be
ordered in book form under part no.296-12-18 995.

Contents ..................................................................................Page
Contents
3
1Safety .................................................................................................................................... 5
1.01 Directives............................................................................................................................... 5
1.02 General notes on safety......................................................................................................... 5
1.03 Safety symbols ...................................................................................................................... 6
1.04 Important notes for the user.................................................................................................. 6
1.05 Operating and technical staff ................................................................................................. 7
1.05.01 Operating staff ....................................................................................................................... 7
1.05.02 Technical staff ........................................................................................................................ 7
1.06 Danger ................................................................................................................................... 8
2Proper use............................................................................................................................. 9
3Specifications ..................................................................................................................... 10
4Disposal of Machine ...........................................................................................................11
5Transportation, packing and storage ................................................................................ 12
5.01 Transportation to customer‘s premises ............................................................................... 12
5.02 Transportation inside the customer‘s premises................................................................... 12
5.03 Disposal of packing materials ..............................................................................................12
5.04 Storage ................................................................................................................................ 12
6Explanation of symbols..................................................................................................... 13
7Controls .............................................................................................................................. 14
7.01 Summary of control elements ............................................................................................. 14
7.02 Main switch ......................................................................................................................... 15
7.03 Pedal .................................................................................................................................... 15
7.04 Setting wheel for roller distance ..........................................................................................16
7.05 Setting wheel for roller pressure.......................................................................................... 16
7.06 Control panel........................................................................................................................ 17
7.06.01 Symbols on the display ........................................................................................................ 17
7.06.02 Function keys ....................................................................................................................... 18
8Installation and commissioning ....................................................................................... 19
8.01 Installation............................................................................................................................ 19
8.01 Adjusting the table-top height.............................................................................................. 19
8.02 Commissioning .................................................................................................................... 20
8.03 Switching the machine on/off ..............................................................................................20
9Preparation ......................................................................................................................... 21
9.01 Programme call-up and modification.................................................................................... 21
9.02 Setting roller distance and roller pressure ........................................................................... 21
9.03 Setting the differential transport .......................................................................................... 22
9.04 Additional transport rollers (optional) ................................................................................... 22
9.05 Inserting and removing the SD-memory card...................................................................... 23
10 Sealing ................................................................................................................................ 24
10.01 Sealing principle .................................................................................................................. 24
10.02 Error messages.................................................................................................................... 25

Contents
Contents ..................................................................................Page
4
11 Input .................................................................................................................................... 26
11.01 Access codes....................................................................................................................... 26
11.01.01 Inputting the access code.................................................................................................... 26
11.01.02 Modifying the access code.................................................................................................. 27
11.01.03 Assigning access rights ....................................................................................................... 27
11.02 Example of a parameter input.............................................................................................. 28
11.03 List of parameters................................................................................................................ 29
11.04 Error messages in the display..............................................................................................33
11.05 Programme Management.................................................................................................... 34
11.05.01 Calling up Programme Management ................................................................................... 34
11.05.02 Copying machine data to the SD card.................................................................................. 35
11.05.03 Copying data from the SD card to the machine memory .................................................... 36
11.05.04 Formatting the SD memory card ......................................................................................... 37
11.06 Internet update of the machine software ............................................................................ 38
11.06.01 Update with null modem cable............................................................................................38
11.06.02 Update with SD-card............................................................................................................ 39
12 Care and Maintenance....................................................................................................... 41
12.01 Maintenance intervals.......................................................................................................... 41
12.02 Cleaning the feed rollers ...................................................................................................... 41
12.03 Checking/adjusting the air pressure..................................................................................... 42
12.04 Cleaning the air filter of the air-filter/lubricator ..................................................................... 42
12.05 Exchanging the transport rollers .......................................................................................... 43
13 Connection diagram .......................................................................................................... 44
13.01 Pneumatics-switch diagram................................................................................................. 44
13.02 Circuit diagrams ................................................................................................................... 45

5
Safety
1 Safety
1.01 Directives
This machine is constructed in accordance with the European regulations indicated in the
conformity and manufacturer’s declarations.
In addition to this instruction manual, please also observe all generally accepted, statutory
and other legal requirements, including those of the user’s country, and the applicable
pollution control regulations! The valid regulations of the regional social insurance society for
occupational accidents or other supervisory authorities are to be strictly adhered to!
1.02 General notes on safety
●The machine may only be operated by adequately trained operators and only after these
have read the appropriate Instruction Manual!
●The danger and safety instructions attached to the machine must be followed!
●The machine may only be used for the purpose intended and may not be operated wit-
hout its safety devices. All relevant safety regulations must be adhered to.
●When changing the feed rollers or the hot air nozzle, when leaving the machine unatten-
ded or during maintenance work, the machine must be disconnected from the power
supply by pulling out the plug!
●The daily maintenance work may only be carried out by appropriately trained personnel!
●During repair and maintenance work on pneumatic devices the machine must be discon-
nected from the pneumatic supply system! The only exceptions permitted are during ad-
justment work and function tests 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!
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 operations!
●Only spare parts which have been approved by us are to be used for repairs! We draw
special attention to the fact that spare parts and accessories not supplied by us have not
been subjected to testing nor approval by us. Fitting and/or use of any such parts may
cause negative changes to the design characteristics of the machine. We shall not accept
any liability for damage caused by the use of non-original parts.

6
Safety
o
o
o
o
1.03 Safety symbols
Danger!
Special points to observe.
Danger of hands being crushed!
Danger of burns from hot surface!
Danger from electric voltage!
Caution
Do not operate without finger guard and safety
devices.
Turn off the main switch and let the machine cool
down before any setting up, maintenance or cleaning
work!
1.04 Important notes for the user
●This instruction manual belongs to the equipment of the machine and must be available
to the operating staff at all times.
●This instruction manual must be read before the machine is operated for the first time.
●Both operating and technical staff must be instructed on the safety devices of the machi-
ne and on safe working methods.
●It is the duty of the user to operate the machine in perfect running order only.
●The user must ensure that none of the safety devices are removed nor put out of wor-
king order.
●The user must ensure that only authorized persons operate and work on the machine.
●The user must make sure there is no high-frequency welding equipment being operated
in direct proximity to the machine that exceeds the EMC limit values according to
EN 60204-31 for the machine.
For further information please refer to your PFAFF agency.

7
Safety
1.05 Operating and technical staff
1.05.01 Operating staff
Operating staff are the persons responsible for setting up, operating and cleaning the machi-
ne and for removing any disturbances in the sewing area.
The operating staff is obliged to observe the following points, and must:
●always observe the notes on safety in this instruction manual!
●avoid using any working methods which adversely affect the safety of the machine!
●avoid wearing loose-fitting clothing or jewelry such as necklaces or rings!
●also ensure that only authorized persons are allowed near the danger area of the machine!
●immediately report to the user any changes to the machine that may affect its safety!
1.05.02 Technical staff
Technical staff are persons who have been trained in electrical engineering, electronics and
mechanical engineering. They are responsible for lubricating, servicing and repairing the ma-
chine.
The technical staff is obliged to observe the following points, and must:
●always observe the notes on safety in this instruction manual!
●switch off the on/off switch before carrying out any maintenance and repair work on the
machine!
●never work on parts or equipment still connected to the power supply! Exceptions to this
are only permissible according to regulations EN 50110.
●replace all safety covers after maintenance and repair work!

8
Safety
Do not operate the machine without finger guard 1!
Danger of crushing if the fingers are drawn in!
During operation do not place your hands in the area of feed roller 2 and
sonotrode 3! Danger of fingers being drawn in and crushed!
During operation do not touch sonotrode 3!
Danger of burns from the heat-generating surface!
Fig. 1 - 01
TE
P2 P3
P1
F1
P
P6
P4 P5
1
3
2
1.06 Danger
When the machine is in operation, a work area of 1 m must be kept free in
front of and behind the machine, so that access to the machine is possible at all
times without difficulty.

9
Proper use
2 Proper use
The PFAFF 8301 is an ultrasonic welding machine for the continuous welding of thin
thermoplastic materials, e.g. fleeces, felts, meshed or woven fabrics.
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!

Specifications
10
3 Specifications▲
Dimensions:
Width: ............................................................................................................ approx. 1200 mm
Depth: .............................................................................................................approx.. 800 mm
Height: ........................................................................................................... approx. 1310 mm
Passage width:................................................................................................. approx. 410 mm
Max. through-passage under transport rollers:.............................................................. 20 mm
Connectivity data
Operating voltage: ..................................................................230 V ± 10%, 50/60 Hz, 1-phase
Max. input power:......................................................................................................... 1000 VA
Mains protection:................................................................................................................16 A
Leakage current: .......................................................................................................... < 5 mA◆
Performance data:
Sealing pressure: .....................................................................................................100 - 500 N
Sealing power: ........................................................................................................max. 400 W
Sealing speed: .................................................................................................. 0,1 - 10 m/min*
Noise data
Emission sound level at the workplace:.............................................................LpA < 70 dB(A)■
(Noise measurement in acc. with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)
Net weight: ........................................................................................................approx. 120 kg
▲Subject to alterations
* Depending on transport roller diameter; stated max. value for 80 mm roller diameter
■K
pA = 2,5 dB
◆Due to the use of network filters there is a nominal leakage current of <5mA.

Disposal of Machine
11
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-
tions; 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!

Transportation, packing and storage
12
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
13
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
14
TE
P2 P3
P1
F1
P
P6
P4 P5
7 Controls
7.01 Summary of control elements
●Main switch 1, see Chapter 7.02
●Control panel 2, see Chapter 7.06
●Pedal 3, see Chapter 7.03
●Setting wheel 4for roller distance, see Chapter 7.04
●Setting wheel 5for roller pressure
●Upper transport roller 6
●Sonotrode 7
Fig. 7 - 01
1
3
4
6
7
2
5

Controls
15
Fig. 7 - 02
Fig. 7 - 03
7.03 Pedal
Foot switch functions
0= Rest position (welding stops)
+1= Transport roller is lowered to welding
position.
+2= Press and hold treadle:
Welding process begins and runs as
long as the treadle is pressed.
-1= Lift transport roller
7.02 Main switch
●The machine is switched on or off by
turning main switch 1.
Position "0": Machine is switched off
Position "I": Machine is switched on
About 30 seconds after the
machine is switched on,
the last basic menu called
up before the machine was
switched off will be displayed.
+1
0
-1
1
+2

Controls
16
TE
P2 P3
P1
F1
P
P6
P4 P5
7.04 Setting wheel for roller distance
●The distance between the upper
transport roller and the sonotrode is
adjusted by turning the setting wheel 1.
Sonotrode 2and transport
roller 3must never be in direct
contact!
Danger of machine damage!
Exempted are steel sonotrodes.
Fig. 7 - 04
P2 P3
P1
F1
P6
P4 P5
1
7.05 Setting wheel for roller pressure
●Roller pressure is adjusted by turning the
setting wheel 1.
●The roller pressure is shown on the scale
of the setting wheel.
●This roller pressure value can be input in
the display for each programme, but only
serves for memory purposes.
Fig. 7 - 05
1
32

Controls
17
P1 P2 P3 P4 P5 P6 F1 TE
P
7.06 Control panel
The control panel is used to display and access machine functions for set-up and welding, to
enter parameter values and to read error messages and service settings.
The control panel has the following control and display elements:
●The display screen 1consists of a two-line, alphanumerical LCD display with 16 symbols
per line and is used to show relevant information and selection parameters.
●The plus-minus keys 2are used to select or alter the functions and parameters shown on
the display.
●The function keys 3are used to switch the relevant function on or off. Activated functions
are shown in each case by an illuminated LED.
Fig. 7 - 05
1
3
2
7.06.01 Symbols on the display
In addition to texts and set values, the following symbols are shown on the display
Current program number
Maximum speed in current seam sector

Controls
18
7.06.02 Function keys
The function keys described in the following are used primarily for the
activation/ deactivation of machine functions. If the function is turned on,
the corresponding key LED lights up.
Where a value is to be set for the activated function, this can be done via
the +/- keys 2.
Pressing and holding the +/- keys will initially change the number value shown
above the key slowly. Holding the +/- key longer will speed up the speed at
which the number value changes.
The following description contains the relevant +/- keys as shown here.
Stop
The machine is stopped during the welding process.
Low/lift the transport roller
When activated, the transport rollers are lifted or lowered.
Programming keys
Programmes 1- 6are called up with these keys.
Alternatively, the programmes 0- 19 can be called up via the left +/- keys.
F1
Transport rollers are blocked (e.g. when replacing the transport rollers).
Scroll
Pressing and holding this key will scroll through the following sub-menus:
Amplitude, Speed, Welding Pressure (only advance registration function), Differential,
Parameters, SD Card.
TE
This key allows toggling between Production mode (LED off) and Input mode (LED on.
P
Here, a test programme can be created.
P6
P1 to
F1
TE
P

Installation and commissioning
19
8 Installation and commissioning
After the machine has been unpacked, check it for any damages caused during transportati-
on. If there are any damages, please notify the transport company and your
local PFAFF agency.
The machine must only be installed and commissioned by qualified personnel.
All relevant safety regulations must be strictly adhered to!
8.01 Installation
The site where the machine is installed must be provided with suitable connections for the
electric current, see Chapter 3 Specifi cations.
It must also be ensured that the standing surface of the machine site is fi rm and horizontal,
and that suffi cient lighting is provided.
8.01 Adjusting the table-top height
Fig. 8 - 01
●Slide the machine off the pallet.
●Loosen screw 1.
●Adjust the table tap to the required working height by increasing or reducing the height
of the stand and then level the table-top horizontally.
To avoid the stand tilting, adjust it evenly on both sides.
●To guarantee that the stand is standing securely, it must be positioned securely on the
ground with all four legs.
●The height can be adjusted with screw 2 ( nut 3).
1
2
1
3

Installation and commissioning
20
8.02 Commissioning
●Thoroughly clean machine as needed.
●Check the machine, particularly the electrical wiring, for any damage.
●Have skilled personnel check if the machine can be operated with the available mains
voltage.
Do not operate the machine if there is any discrepancy.
The machine may only be connected to an earthed socket!
●Connect the machine to the compressed air system. The manometer should display
a pressure of 6 bar. Set this value, if needed (see Section 12.03 "Checking the air
pressure of the maintenance unit").
8.03 Switching the machine on/off
●Turn the main switch in position "I" (see Section 7.02 "Main switch") to turn the machine
on.