Pfaff 8303-040 User manual

Instruction Manual
296-12-18 768/002
Betriebsanleitung engl. 10.03
8303- 040
- 041
- 042
This instruction manual applies to machines from the
following serial numbers onwards:
# 2628774

The reprinting, copying or translation of PFAFF instruction manuals, whether in whole or in
part, is only permitted with our previous consent and with written reference to the source.
PFAFF Industrie Maschinen AG
Postfach 3020
D-67653 Kaiserslautern
Königstr. 154
D-67655 Kaiserslautern
Redaktion / Illustration
HAAS-Publikationen GmbH
D-53840 Troisdorf

Contents
Contents ................................................................................. Chapter - Page
1Safety ........................................................................................................................... 1 - 1
1.01 Regulations ................................................................................................................... 1 - 1
1.02 General notes on safety ................................................................................................ 1 - 1
1.03 Safety symbols ............................................................................................................. 1 -2
1.04 Important points for the user ........................................................................................ 1 - 2
1.05 Operating and technical personnel................................................................................ 1 - 3
1.05.01 Operating personnel...................................................................................................... 1- 3
1.05.02 Technical personnel ...................................................................................................... 1- 3
1.06 Danger warning............................................................................................................. 1 -4
2Proper use.................................................................................................................... 2 -1
3Specifications .............................................................................................................. 3 - 1
4Disposal of the machine ............................................................................................. 4 - 1
5Transport, packing and storage ................................................................................. 5 - 1
5.01 Transport to the customer’s premises .......................................................................... 5 - 1
5.02 Transport within the customer’s premises.................................................................... 5 - 1
5.03 Disposal of packing ....................................................................................................... 5 - 1
5.04 Storage ......................................................................................................................... 5 - 1
6Explanation of the symbols ........................................................................................ 6 - 1
7Controls ....................................................................................................................... 7- 1
7.01 Summary of the controls............................................................................................... 7 - 1
7.02 Main switch ..................................................................................................................7- 2
7.03 Air shut-off valve ...........................................................................................................7- 2
7.04 Regulator for the sealing tape feed motion and sealing speed...................................... 7 - 3
7.05 Regulator for the hot air pressure and the feed roller pressure..................................... 7 - 3
7.06 Sealing tape feed key.................................................................................................... 7 - 4
7.07 Sealing temperature control panel ................................................................................ 7 - 4
7.08 Machine head keys and pedals ..................................................................................... 7 - 5
7.09 Potentiometer for the hot air nozzle swivel function ..................................................... 7 - 6
8Installation and commissioning ................................................................................. 8 - 1
8.01 Installation..................................................................................................................... 8 - 1
8.01.01 Adjusting the table height ............................................................................................. 8 - 1
8.01.02 Fitting the sealing tape reel holder ................................................................................ 8 - 2
8.01.03 Lampe anschließen ....................................................................................................... 8 -2
8.01.04 Connecting the pedals and the power supply ............................................................... 8 - 3
8.02 Commissioning ............................................................................................................. 8 - 4
8.03 Switching the machine on / off ..................................................................................... 8 - 5

Contents
Contents ................................................................................. Chapter - Page
9Setting up .................................................................................................................... 9 -1
9.01 Inserting the sealing tape.............................................................................................. 9 - 1
9.01.01 Adapting the sealing tape reel holder to the sealing tape reel ....................................... 9 - 1
9.01.02 Adjusting the sealing tape brake ................................................................................... 9 - 1
9.01.03 Inserting the sealing tape / adjusting the sealing tape width......................................... 9 - 2
9.02 Adjusting the penetration depth .................................................................................... 9 - 3
9.03 Adjusting the sealing tape feed stroke.......................................................................... 9 - 3
9.04 Adjusting the swivel function of the hot air nozzle ........................................................ 9 - 4
9.05 Adjusting the hot air pressure and the feed roller pressure........................................... 9 - 4
9.06 Adjusting the sealing temperature and the sealing speed............................................. 9 - 5
10 Heat sealing ............................................................................................................... 10 - 1
10.01 Heat-sealing principle .................................................................................................. 10 - 1
10.02 Carrying out a sealing operation .................................................................................. 10 - 2
10.03 Malfunctions ............................................................................................................... 10- 4
11 Care and maintenance .............................................................................................. 11 - 1
11.01 Clean hot-air nozzle ..................................................................................................... 11 - 1
11.03 Emptying the water container of the air filter / cleaning the filter............................... 11 - 2
11.02 Checking / adjusting the air pressure .......................................................................... 11 - 2
11.04 Lubricating the drive chains ........................................................................................ 11 - 3
12 Adjustment ................................................................................................................ 12 - 1
12.01 Notes on adjustment................................................................................................... 12 - 1
12.02 Tools, gauges and other accessories .......................................................................... 12 - 1
12.03 Height and lateral adjustment of the hot air nozzle ..................................................... 12 - 2
12.04 Clearance between the hot air nozzle and the feed rollers.......................................... 12 - 3
12.05 Setting the angle of the hot air nozzle ......................................................................... 12 - 4
12.06 End stop of the hot air nozzle swivel unit.................................................................... 12 - 5
12.07 Changing the heating cartridge ................................................................................... 12 - 6
12.08 Changing the temperature sensor............................................................................... 12 - 7
12.09 Tensioning the drive chains......................................................................................... 12 - 9
12.10 Tensioning the toothed belt ........................................................................................ 12 -10
12.11 Changing the feed rollers ............................................................................................ 12 -10
12.12 Tape cutting device ..................................................................................................... 12 -11
12.12.01 Knife............................................................................................................................ 12 -11
12.12.02 Air jet setting............................................................................................................... 12 -12
12.13 Checking the fuses ..................................................................................................... 12 -13
13 Circuit diagram ............................................................................................................ 13 - 1

1 - 1
Safety
1 Safety
1.01 Regulations
This machine was built in accordance with the European regulations listed 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 - including those of the country in which the machine will
be operated and all valid environmental-protection regulations. Regionally applicable
regulations of the social insurance society for occupational accidents or other supervisory
organisations 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 the
instruction manual has been completely read and understood !
●The danger and safety instructions on the machine itself are to be followed!
●The machine may only be used for the purpose for which it was intended and must not
be operated without its safety devices. Observe all relevant safety regulations!
●When replacing the feed rollers or the hot wedge, when leaving the workplace
unattended and during servicing or repairs, the machine must be switched off at the
mains switch and the plug pulled!
●Daily servicing work may be carried out only by appropriately trained personnel!
●Repairs and special maintenance work may be carried out only by technicians or persons
with appropriate training!
●Work on the electrical equipment may be carried out only by qualified electricians!
●Work is not permitted on live parts and equipment! Exceptions to this are contained 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
expressly point out that any replacement parts or accessories 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 shall not be
liable for any damage which may be caused by non-original parts.

1 - 2
Safety
1.03 Safety symbols
Danger!
Special points to observe.
Danger of hands being crushed!
Danger of burns from hot surface!
Danger from electric voltage!
Danger of injury for operating and specialist personnel!
1.04 Important points for the user
●This instruction manual is a component part of the machine and must be available to
operating personnel at all times.
The instruction manual must be read before commissioning the machine.
●The operating and technical personnel are to be instructed as to the machine’s safety
mechanisms and with regard to safe working methods.
●It is the duty of the owner to operate the machine only when it is in perfect running order.
●The owner is obliged to ensure that none of the safety mechanisms are removed from
the machine or deactivated.
●When processing PVC, PTFE and similar materials, the user must ensure that the
maximum permissible level of toxic fumes is not exceeded.
For further information please refer to the sales agency responsible.
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!
o
o
o
o

1 - 3
Safety
1.05 Operating and specialist personnel
1.05.01 Operating personnel
Operating personnel are persons responsible for the setting-up, operating and cleaning of the
machine as well as for dealing with faults arising in the sewing area.
The operating personnel is obliged to observe the following points and must:
●Always observe the Notes on Safety in the Instruction Manual!
●Never use any working methods which could impair safe work on the machine!
●Not wear loose-fitting clothing or jewellery such as chains or rings!
●Help to ensure that only authorised 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 safe use!
1.05.02 Specialist personnel
Specialist personnel are persons with special training in the fields of electrics,
electronics and mechanics. They are responsible for the lubrication, maintenance, repair and
adjustment 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 main switch before carrying out adjustments or repairs and ensure that it
cannot be switched on again unintentionally!
●Never work on parts or devices which are still connected to the power supply!
Exceptions are listed in the regulations EN 50110.
●Replace the protective covers after all repairs or maintenance work!

1 - 4
Safety
100-001
Fig. 1 - 01
Do not operate the machine without protective cover 1!
Danger of burns if hot air nozzle 2is touched when disengaged!
Do not place hands in the swivel range of hot air nozzle 2and swivel unit 3!
Danger of crushing during engaging and disengaging motions!
Do not place hands between adjustment wheel 4and protective cover 5!
Danger of crushing when the feed roller is raised!
1.06 Danger warning
100-059
4
5
1
3
2
4
5

2 - 1
Proper use
2 Proper use
The PFAFF 8303-040 is a hot-air sealing machine with front off-set post and 25 mm wide
feed rollers.
The PFAFF 8303-041 is a hot-air sealing machine with front off-set post and 28 mm wide
feed rollers.
The PFAFF 8303-042 is a hot-air sealing machine with rear off-set post and 25 mm wide
feed rollers.
The purpose of the machines is to heat-seal seams on waterproof and breathable membrane
sheeting of all types, using a heat-sealing tape.
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 inappropriate use of the machine!
Appropriate use of the machine presupposes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!

Specifications
3 - 1
3 Specifications ▲
Dimensions and weight:
Length:............................................................................................................ca. 1240 mm
Width: ...............................................................................................................ca. 600 mm
Height: ............................................................................................................ca. 1730 mm
Weight: ................................................................................................................. ca. 62 kg
Mains voltage set for: ...................................................... 230 V ± 10%, 50/60 Hz, 1 phase
Power consumption: ......................................................................................... ca. 3300 W
Heating capacity:..................................................................................................... 3000 W
Fuse protection: ............................................................................................. 2 x 16A, inert
Operating air pressure................................................................................................. 6 bar
Air consumption........................................................................................... 60 – 120 l/min.
Sealing temperature:....................................................20ºC to ca. 650ºC, infinitely variable
Sealing tape width:.......................................................................................... up to 26 mm
Sealing speed:................................................................................................1 – 10 m/min.
Noise data:
Noise emission level at workplace: .................................................................. < 70 dB(A)■
(Noise measurement in accordance with DIN 45 635-48)
▲ Subject to alteration
■ KpA = 2,5 dB

Disposal of the machine
4 - 1
4 Disposal of the machine
●The proper disposal of the machine is the responsibility of the customer.
●The materials used on the machine are steel, aluminium, brass and various plastics.
The electrical equipment consists of plastics and copper.
●The machine is to be disposed of in accordance with the locally valid environmental
protection regulations.
Special care is to be taken that parts soiled with lubricants are disposed of
separately in accordance with the locally valid environmental protection
regulations.

Transport, packing and storage
5 - 1
5 Transport, packing and storage
5.01 Transport to the customer’s premises
The machines are delivered completely packed.
5.02 Transport within the customer’s premises
The manufacturer bears no liability for transport within the customer’s premises.
5.03 Disposal of packing
The packing of this machine consists of paper, cardboard, fusible fabric and wood. Proper
disposal of the packing is the responsibility of the customer.
5.04 Storage
If not in use, the machine can be stored for up to six months as it is. During this time it
should be protected against dust and dampness.
If the machine is stored for longer periods, its parts, especially moving parts, must be
protected against corrosion, e.g. by a film of oil.

Explanation of the symbols
6 - 1
6 Explanation of the symbols
In this Instruction Manual, tasks to be carried out and important information are drawn to
your attention by symbols. The symbols have the following meanings:
Note, information
Cleaning, care
Lubrication
Servicing, repairing, adjustment, maintenance
(only to be carried out by specialist personnel)

Controls
7 - 1
100-060
7 Controls
7.01 Summary of the controls
Fig. 7 - 01
1Main switch, see Chapter 7.02
2Air cut-off valve, see Chapter 7.03
3Regulator for sealing tape feed motion, see Chapter 7.04
4Regulator for sealing speed, see Chapter 7.04
5Regulator for the hot air pressure, see Chapter 7.05
6Regulator for the feed roller pressure, see Chapter 7.05
7Sealing tape feed key, see Chapter 7.06
8Sealing temperature control panel, see Chapter 7.07
9Machine head keys, see Chapter 7.08
10 Pedals, see Chapter 7.08
11 Potentiometer for the hot air nozzle swivel function, see Chapter 7.09
10 2
8
9
1
4
5
6
11
3
7

Controls
7 - 2
2.0
0.5
1.0 1.5
2.5
00
1
234
5
6
50
60
40
30
20
10
0
100
50
60
40
30
20
10
0
100
7.02 Main switch
●The machine is switched on or off by
pressing main switch 1.
Position "0" : Machine is switched off
Position "1" : Machine is switched on
When switching the machine
on or off, please observe the
notes in Chapter 8.03
Switching the machine on
and off!
Fig. 7 - 02
7.03 Air shut-off valve
●By turning air shut-off valve 1, the
compressed air supply is shut off or
opened.
Before shutting off the air
supply, please observe the
notes in Chapter 8.03
Switching the machine on
and off !
Fig. 7 - 03
1
1

Controls
7 - 3
100
-
007
2.0
0.5
1.0 1.5
2.5
00
1
234
5
6
50
60
40
30
20
10
0
100
50
60
40
30
20
10
0
100
100
-
004
2.0
0.5
1.0 1.5
2.5
00
1
234
5
6
50
60
40
30
20
10
0
100
50
60
40
30
20
10
0
100
7.04 Regulator for the sealing tape feed motion and sealing speed
●The sealing tape feed motion is set
with regulator 1.
●The sealing speed is set with regulator 2.
Fig. 7 - 04
21
7.05 Regulator for the hot air pressure and the feed roller pressure
●The hot air pressure is set by pulling out
and turning regulator 1.
●The hot air pressure level can be read on
gauge 2.
●The feed roller pressure is set by pulling
out and turning regulator 3.
●The feed roller pressure level can be read
on gauge 4.
Fig. 7 - 05
1
23
4

Controls
7 - 4
100-055
100
-
008
2.0
0.5
1.0 1.5
2.5
00
1
234
5
6
50
60
40
30
20
10
0
100
50
60
40
30
20
10
0
100
7.07 Sealing temperature control panel
●By pressing key 1twice, the sealing
temperature can be reduced with key 2
or increased with key 3( the letters "SP"
appear in front of the temperature on the
display)
During adjustment the set
temperature is shown and
changed in display 4. After
adjustment the actual
temperature of the hot air
nozzle appears again on the
display automatically.
Fig. 7 - 07
123
4
7.06 Sealing tape feed key
●The sealing tape feed function (e.g.
for threading the sealing tape) is
switched on by pressing key 1.
To set off the function, the top
feed roller must be raised by
selecting the appropriate mode
or by using the pedal function,
see Chapter 7.08 Machine
head keys and pedals.
Fig. 7 - 06
1

Controls
7 - 5
100-005
7.08 Machine head keys and pedals
Fig. 7 - 08 Fig. 7 - 09
123
4
1
00-050
+1
+2
-1
+3
After the machine has been switched on, the top feed roller must be lowered
with the pedal setting "+1", before the functions of keys 1and 3can be
selected.
●By pressing key 1the "press" function is switched on or off. When the function is
switched on, diode 4flashes slowly. This function is used for the subsequent bonding of
the sealing seam without the application of a new sealing tape.
●If key 2is pressed a choice is made between the "feed roller raised" (diode 4is on) and
"feed roller lowered" (diode 4is off) modes.
●If key 3is pressed, the "feed roller in reverse" mode is switched on or off. If a fault
occurs, diode 4flashes quickly.
0
Summary of the pedal functions
Pedal Key 1on, (diode 4Key 2 on, Key 2 is off, Key 3 on,
setting flashes slowly) (diode 4is on) (diode 4is off) (diode 4is off)
"-1" Feed roller raised Feed roller raised Feed roller raised Feed rollers turn
in reverse
"0" Feed roller raised Feed roller raised Feed roller lowered -
or lowered
"+1" Feed roller lowered Feed roller lowered - -
"+2" Feed rollers start Sealing starts Sealing starts -
"+3" Engage heating Cut sealing tape Cut sealing tape -
nozzle

Controls
7 - 6
2.0
0.5
1.0 1.5
2.5
00
1
234
5
6
50
60
40
30
20
10
0
100
50
60
40
30
20
10
0
100
7.09 Potentiometer for the hot air nozzle swivel function
●Set the swivel function of the hot air
nozzle by turning screw 1.
Turn to the left
The hot air nozzle disengages
simultaneously with the selection of the
"cut sealing tape" function.
Turn to the right
The hot air nozzle does not disengage
until the pedal is released after the
sealing tape has been cut.
Centre position
By turning the key to the right or left, the
time delay between cutting the sealing
tape and disengaging the hot air nozzle
can be set.
Fig. 7 -10
1

Installation and commissioning
8 - 1
Fig. 8 - 01
21
1
8 Installation and commissioning
The machine must only be installed and commissioned by qualified personnel!
All relevant safety regulations must be observed!.
8.01 Installation
Suitable connections for power and compressed air, an even and firm floor surface and
sufficient lighting must be provided for at the installation site.
8.01.01 Adjusting the table height
●Loosen screws 1and 2and set the table at the required height.
●Tighten screws 1firmly.
●Set the pedals as required and tighten screws 2.