Pfaff 8390 User manual

296-12-19 126/002
Betriebsanleitung engl. 05.12
This instruction manual applies to machines
from software version 0376/008 and serial
number 2769 247 onwards
INSTRUCTION MANUAL
8390

This Instruction Manual is valid for all models and subclasses listed in the
chapter "Specifications".
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.296-12-19 126.
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

Contents ..................................................................................Page
Contents
1Safety .................................................................................................................................... 6
1.01 Directives ............................................................................................................................... 6
1.02 General notes on safety......................................................................................................... 6
1.03 Safety symbols ...................................................................................................................... 7
1.04 Important notes for the user.................................................................................................. 7
1.05 Operating and technical staff ................................................................................................. 8
1.05.01 Operating staff ....................................................................................................................... 8
1.05.02 Technical staff ........................................................................................................................ 8
1.06 Danger ................................................................................................................................... 9
2Proper use........................................................................................................................... 10
3Specifications .....................................................................................................................11
4Disposal of Machine .......................................................................................................... 12
5Transportation, packing and storage................................................................................ 13
5.01 Transportation to customer‘s premises ............................................................................... 13
5.02 Transportation inside the customer‘s premises................................................................... 13
5.03 Disposal of packing materials ..............................................................................................13
5.04 Storage ................................................................................................................................ 13
6Explanation of symbols..................................................................................................... 14
7Controls .............................................................................................................................. 15
7.01 Summary of controls ........................................................................................................... 15
7.02 Main switch ......................................................................................................................... 16
7.03 Foot switch (optional)........................................................................................................... 16
7.04 Pedal .................................................................................................................................... 17
7.05 Double foot switch (optional) ............................................................................................... 18
7.06 Adjustment wheel for the roller clearance........................................................................... 19
7.07 Joystick ................................................................................................................................ 19
7.08 Control panel........................................................................................................................ 20
8Installation and commissioning ....................................................................................... 21
8.01 Installation............................................................................................................................ 21
8.02 Commissioning .................................................................................................................... 22
8.03 Switching the machine on/off .............................................................................................. 23
8.04 Selecting the language and units......................................................................................... 24
8.05 Carrying out a reference run ................................................................................................ 25
9Preparation ......................................................................................................................... 28
9.01 Adjusting the feed roller clearance ...................................................................................... 28
9.02 Selecting the production type:.............................................................................................29
9.03 Entering the sealing parameters (Manual Heat Sealing)...................................................... 31
9.03.01 Entering the sealing temperature ........................................................................................33
9.03.02 Entering the sealing speed .................................................................................................. 34
9.03.03 Stipulating the hot wedge type (only on the PFAFF 8390-010) ............................................ 35
9.03.04 Adjusting the contact pressure of the hot wedge (only on the PFAFF 8390-010)................ 36
9.03.05 Stipulating the nozzle type and hot air volume (only on the PFAFF 8390-020) .................... 36

Contents
Contents ..................................................................................Page
9.03.06 Entering the roller pressure ................................................................................................. 38
9.04 Adjusting the control panel .................................................................................................. 39
10 Heat sealing........................................................................................................................ 40
10.01 Heat sealing principle........................................................................................................... 40
10.02 Manual heat sealing............................................................................................................. 41
10.03 Creating/editing a heat sealing program .............................................................................. 43
10.03.01 Notepad ............................................................................................................................... 44
10.03.02 Basic functions for the program input.................................................................................. 45
10.03.03 Sealing parameters .............................................................................................................. 46
10.03.04 Functions for switching to other zones ................................................................................ 47
10.03.05 Entering further sealing parameters .................................................................................... 49
10.03.06 Concluding programming..................................................................................................... 51
10.03.07 Example of how to enter a sealing program........................................................................ 52
10.04 Programmed heat sealing with individual programs............................................................ 57
10.05 Creating/processing sequences........................................................................................... 58
10.06 Programmed heat sealing with sequences.......................................................................... 59
10.07 Error messages.................................................................................................................... 61
10.08 Carriage menu ..................................................................................................................... 62
11 Input .................................................................................................................................... 63
11.01 Summary of the functions in the input mode...................................................................... 63
11.02 Program management .........................................................................................................65
11.03 Further settings.................................................................................................................... 67
11.03.01 Feed roller parameters......................................................................................................... 69
11.03.02 Rights of access .................................................................................................................. 70
11.04 Installation and commissioning ....................................................................................... 72
11.04.01 8390-010 (Hot wedge sealing machine) ............................................................................... 72
11.04.02 8390-020 (Hot air sealing machine).......................................................................................74
11.05 Advanced programming....................................................................................................... 76
11.05.01 Manual datasets (recipes).................................................................................................... 76
11.05.02 Function "POS1 speed" ........................................................................................................ 79
11.05.02 Function "HEATOUTDELAY" .................................................................................................80
12 Care and Maintenance....................................................................................................... 82
12.01 Servicing and maintenance intervals ................................................................................... 82
12.02 Cleaning ............................................................................................................................... 82
12.03 Checking/adjusting the air pressure..................................................................................... 83
12.04 Cleaning the air filter of the air-filter/lubricator ..................................................................... 83
12.05 Grinding the hot wedge (only on the PFAFF 8390-010)........................................................ 84
13 Adjustment ......................................................................................................................... 85
13.01 Notes on adjustment ........................................................................................................... 85
13.02 Tools, gauges and other accessories ................................................................................... 85
13.03 Changing the feed rollers..................................................................................................... 86
13.04 Adjusting the feed rollers..................................................................................................... 87
13.05 Changing the hot wedge (only on the PFAFF 8390-010)) ..................................................... 88

Contents ..................................................................................Page
Contents
13.06 Adjusting the hot wedge on the PFAFF 8390-010................................................................ 89
13.06.01 Positioning the hot wedge crosswise to the feed direction................................................. 89
13.06.02 Adjusting the height and counter-balancing the weight of the hot wedge .......................... 90
13.06.03 Hot wedge to feed roller clearance and contact pressure ................................................... 91
13.07 Adjusting the hot air nozzle on the PFAFF 8390-020 ........................................................... 92
13.07.01 Lateral adjustment and setting the angle of the hot air nozzle ............................................ 92
13.07.02 Adjusting the height and feed roller clearance of the hot air nozzle ................................... 93
13.08 Changing the heating cartridge (only on the PFAFF 8390-020)............................................ 94
13.09 Changing the temperature sensor (only on the PFAFF 8390-020)) ...................................... 95
13.10 Protective switch and boot key............................................................................................ 96
13.11 Service menu....................................................................................................................... 97
13.11.01 Machine configuration ......................................................................................................... 98
13.11.02 Loading/updating the operating program with SD-Card .................................................... 100
13.12 Description of the error numbers....................................................................................... 102
13.12.01 General errors .................................................................................................................... 102
13.12.02 Temperature control error .................................................................................................. 103
13.12.03 DC-motors error (Feed rollers) ........................................................................................... 104
13.12.04 Error with carriage.............................................................................................................. 104
13.13 List of outputs and inputs .................................................................................................. 105
13.13.01 Digital Outputs................................................................................................................... 105
13.13.02 Digital Inputs...................................................................................................................... 105
13.13.03 Analog Outputs.................................................................................................................. 106
13.13.04 Analog Inputs..................................................................................................................... 106
13.14 Parameter settings............................................................................................................. 107
13.14.01 Selection and changing parameters................................................................................... 107
13.14.02 List of parameters.............................................................................................................. 108
14 Circuit diagrams .............................................................................................................. 109
15 Pneumatic-circuit diagrams .............................................................................................115

6
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 pollu-
tion control regulations! The valid regulations of the regional social insurance society for oc-
cupational 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 wi-
thout 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 operating the main switch or 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.

7
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!
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 boundaries of the track system are electronically stored in the machine.
For this reason, the machine must not be moved when switched off!
If the machine is moved when switched off, the stored values are no longer correct.
●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.
o
o
o
o

8
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!

9
Safety
1.06 Danger
When the machine is in operation, a work area of 1m must be kept free in
front of and behind the machine, so that access to the machine is possible at all
times without difficulty.
If toxic vapours occur during processing, use extractor!
Danger to health if the toxic vapours are inhaled!
Do not operate the machine without protective cover 1and only operate the ma-
chine with protective cover folded down. Danger of crushing when the heating
element 3is engaged and disengaged, as well as a danger of burns if touched!
During operation do not place hands near the feed rollers 4!
Danger of crushing if the fingers are drawn between the rollers!
Do not operate the machine without protective cover 5! Danger of crushing
when operating the machine through the belt drive and chain-gear drive!
For the operation of the safety edge, attach fixtures 6at both track ends!
Overrunning the track ends can cause damage to the machine!
Fig. 1 - 01
1
2
3
4
5
41
2
3
135-021
6

10
Proper use
2 Proper use
The PFAFF 8390-010 is a mobile, hot wedge sealing machine mounted on a track system.
The PFAFF 8390-020 is a mobile, hot air sealing machine mounted on a track system.
The machines are used for sealing heavy, large and flexible thermoplastic materials, for ex-
ample, tarpaulins, covers, and tents.
Any and all uses of this machine which have not been approved of by the
manufacturer are considered to be inappropriate! The manufacturer cannot be
held liable for any damage caused by the inappropriate use of the machine!
The appropriate use of the machine includes the observance of all operational,
adjustment, maintenance and repair measures required by the manufacturer!

11
Specifications
3 Specifications ▲
Dimensions and weight:
Length: .......................................................................................................... approx. 1840 mm
Width: ............................................................................................................ approx. 1200 mm
Height: (without tape holder): ....................................................................... approx. 1400 mm
Clearance width: .............................................................................................approx. 480 mm
Clearance between rollers: ...............................................................................approx. 20 mm
Net weight: ........................................................................................................approx. 305 kg
Mains voltage (set for): ...........................................................230 V ± 10%, 50/60 Hz, 1 phase
Power input
8390-010 (hot-wedge version):.............................................................................max. 1 500 W
8390-020 (hot-air version): ...................................................................................max. 3 500 W
Heating capacity
8390-010 (hot-wedge version):........................................................................ approx. 1 000 W
8390-020 (hot-air version): ...............................................................................approx. 3 300 W
Fuse: .................................................................................................................................. 16 A
Working air pressure:............................................................................................ 6 bar + 10 %
Air consumption
8390-010 (hot-wedge version):...................................................................................... 30 l/min
8390-020 (hot-air version): ................................................................................... 30 - 150 l/min
Sealing speed: ................................................................................................. max. 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)
Ambient temperature
85% rel. humidity (condensation not permitted): ...................................................... 5 – 40° C
Sealing temperature
8390-010 (hot-wedge version):............................................................................... max. 500 °C
8390-020 (hot-air version): ..................................................................................... max. 650 °C
▲Subject to alterations
◆Depending on the equipment, up to 20 m/min
■K
pA = 2,5 dB

Disposal of Machine
12
4 Disposal of Machine
●Proper disposal of the machine is the responsibility of the customer.
●The materials used for the machine are steel, aluminium, brass and various plastic
materials. The electrical equipment comprises plastic materials and copper.
●The machine is to be disposed of according to the locally valid pollution control regula-ti-
ons; if necessary, a specialist ist to be commissioned.
Care must be taken that parts soiled with lubricants are disposed of separately
according to the locally valid pollution control regulations!

Transportation, packing and storage
13
5 Transportation, packing and storage
5.01 Transportation to customer‘s premises
The machines are delivered completely packed.
5.02 Transportation inside the customer‘s premises
The manufacturer cannot be made liable for transportation inside the customer‘s premises
nor to other operating locations. It must be ensured that the machines are only transported
in an upright position.
5.03 Disposal of packing materials
The packing materials of this machine comprise paper, cardboard and VCE fibre. Proper dis-
posal of the packing material is the responsibility of the customer.
5.04 Storage
If the machine is not in use, it can be stored as it is for a period of up to six months, but It
should be protected against dust and moisture.
If the machine is stored for longer periods, the individual parts, especially the surfaces of
moving parts, must be protected against corrosion, e.g. by a film of oil.

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

15
Controls
Fig. 7 - 01
7 Controls
7.01 Summary of controls
1Main switch, see Chapter 7.02
2Pedal, see Chapter 7.04
3 Foot switch (available as an option), see Chapter 7.03
4 Double foot switch (available as an option), see Chapter 7.05
5 Adjustment wheel for roller clearance, see Chapter 7.06
6Control panel, see Chapter 7.08
7Top feed roller
8Bottom feed roller
9Key-switch, see Chapter 11 .03.02 Rights of access
10 Joystick, see Chapter 7.07
2
1
5
6
7
8
9
3
10
4
2

16
Controls
7.02 Main switch
●The machine is switched on or off by
turning main switch 1.
Position "0" : Machine is switched off
Position "1" : Machine is switched on
When switching the
machine on or off, please ob-
serve the notes in Chapter 8.04
Switching the machine on and
off!
Fig. 7 - 02
1
7.03 Foot switch (optional)
●Move to the next sealing section in the
programmed sealing operation by pres-
sing foot switch 1.
Alternatively, a knee switch can
be ordered for this function.
Fig. 7 - 03
1

17
Controls
Fig. 7 - 04
7.04 Pedal
The function method of the
pedal depends on the select-
ed pedal mode (level or flip-flop
mode), see Chapter 11.03
Further settings
-1
+2
+1
0
Sealing / level mode
0= Rest position / Stop sealing process
+1= Lower top feed roller or welding speed setting in acc.
w. parameter "POS1speed" (see chapter 11 .05.02).
+2= Engage heating element and Sealing start
-1= Interrupt sealing process and Raise top feed roller
Sealing / flip-flop mode
0= Rest position
+1= Lower top feed roller
+2= Start / Stop sealing
-1= Interrupt sealing process and Raise top feed roller
Reference run (carriage menu)
0= Rest position / Stop
+1= Move at low speed
+2= Move at high speed
-1= Change direction

18
Controls
7.05 Double foot switch (optional)
Fig. 7 - 05
1
2
During the sealing process
●By pressing the foot switch 1 or 2 , the adjustable speed difference from carriage speed
to roller speed is switched. The value of the speed difference can be set under parameter
Gswred (see Chapter 13.14.02).
1= Decrease carriage speed over the roller speed (reduction of material build-up)
2= Increase carriage speed over the roller speed
After a sealing stop (switch / correct the carriage position to the sealing material)
●By pressing the foot switch 1 or 2 the carriage is moved.
1= move the carriage slowly against the sealing direction
2= move the carriage slowly in the sealing direction
In the carriage menu
●By pressing the foot switch 1 or 2 the carriage is moved.
1= Move the carriage slowly against the sealing direction (after 3seconds with the foot
switch pressed, change-over to high speed)
2= Move the carriage slowly in the sealing direction (after 3seconds with the foot switch
pressed, change-over to high speed)
During the sealing process with parameter "Diffmode = 1"
●By pressing the foot switch 1 or 2 , the value for the differential correction (speed differ-
ence from top to bottom feed roller) is gradually altered.
1= Gradually decrease speed of the top feed roller
2= Gradually increase speed of the top feed roller
The differential correction is displayed in % on the control panel.

19
Controls
7.06 Adjustment wheel for the roller clearance
●After loosening clamp screw 1, the
clearance between the top and bottom
feed rollers is changed by turning adjust-
ment wheel 2.
The clearance can be read on the scale.
7.07 Joystick
●The machine can move along the track
bed using joystick 1, so long as the rel-
evant mode on the control panel is set,
see Chapter 10.08 Carriage menu.
Fig. 7 - 06
2
1
Fig. 7 - 07
1

20
Controls
2 GB
max.
7.08 Control panel
The current operating conditions are displayed on control panel 1. Operation takes place in a
constant dialogue between the control unit and the operator. For this purpose, depending on
the operating condition of the machine, different symbols and/or texts are displayed. If the
symbols or texts are framed, these show functions which can be selected by pressing the
appropriate position on the monitor. By pressing the corresponding function this is carried
out or switched on or off immediately, or a further menu appears, e.g. for entering a value.
Activated functions are shown with inverted symbols. Unframed symbols or texts are only
used for display purposes and cannot be selected by pressing.
To read welding programs or install machine software, use the sd-card 2in the control
panel.
Description of the functions
Normal symbol = function switched off (inactive)
Inverted symbol = function switched on (active)
Fig. 7 - 07
12