Pfaff Powerline 2545 User manual

This instruction manual applies to machines from the
following serial numbers onwards:
# 2 798 767
296-12-19 219/002
Betriebsanleitung engl. 09.12
INSTRUCTION MANUAL
2545
2546

This Instruction Manual is valid for all models and subclasses listed in the
chapter "Specifications".
The adjustment manual 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.296-12-19 220/002.
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

Index
Contents ..................................................................................Page
1Safety .................................................................................................................................... 5
1.01 Directives...............................................................................................................................5
1.02 General notes on safety......................................................................................................... 5
1.03 Safety symbols ...................................................................................................................... 6
1.04 Important points for the user................................................................................................. 6
1.05 Operating and specialist personnel........................................................................................ 7
1.05.01 Operating personnel .............................................................................................................. 7
1.05.02 Specialist personnel............................................................................................................... 7
1.06 Danger warnings.................................................................................................................... 8
2Proper use............................................................................................................................. 9
3Specifications ..................................................................................................................... 10
3.01 PFAFF 2545 / 2546 (BASIC, CLASSIC and PLUS) ............................................................... 10
3.02 Maximum speed ................................................................................................................. 11
3.03 Machine equipment and options ......................................................................................... 12
4Disposal of Machine .......................................................................................................... 13
5Transportation, packing and storage ................................................................................ 14
5.01 Transportation to customer‘s premises ............................................................................... 14
5.02 Transportation inside the customer‘s premises................................................................... 14
5.03 Disposal of packing materials ..............................................................................................14
5.04 Storage ................................................................................................................................ 14
6Explanation of symbols..................................................................................................... 15
7Controls .............................................................................................................................. 16
7.01 On/off switch ...................................................................................................................... 16
7.02 Sewing lamp switch (only on the PFAFF 2545 / 2546 CLASSIC and PLUS) ........................ 16
7.03 Pedal .................................................................................................................................... 17
7.04 Keyboard on machine head (only on the PFAFF 2545 / 2546 CLASSIC and PLUS) ............. 18
7.05 Knee switch (option) ............................................................................................................ 21
7.06 Knee lever (only on the PFAFF 2545 / 2546 BASIC)............................................................. 21
7.07 Lever for lifting the presser foot........................................................................................... 22
7.08 Adjusting the stitch length (on the PFAFF 2545 / 2546 BASIC and CLASSIC) ..................... 22
7.09 Adjusting the stitch length (on the PFAFF 2545 / 2546 PLUS)............................................. 23
7.10 Reverse feed lever ............................................................................................................... 23
7.11 Adjusting the top feed stroke (on the PFAFF 2545 / 2546 BASIC and CLASSIC)................. 24
7.12 Adjusting the top feed stroke (on the PFAFF 2545 / 2546 PLUS) ........................................ 24

Index
Contents ..................................................................................Page
7.13 Switchable needle thread tension (only on the PFAFF 2545 / 2546 BASIC ) ....................... 25
7.14 Bobbin thread monitor with remaining thread recognition by sensor (sub-class -926/06)
Bobbin thread control by reverse stitch counting (with P74 ED-L + PF 321) ....................... 25
7.15 Bobbin thread control by stitch-counting (with PicoDrive) ................................................... 26
7.16 Control panel........................................................................................................................ 26
8Preparation ........................................................................................................................ 27
8.01 Inserting the needle............................................................................................................. 27
8.02 Winding the bobbin thread, regulating the winder tension.................................................. 28
8.03 Bobbin-changing/threading, and regulating the bobbin thread tension................................ 29
8.04 Setting the bobbin thread control function by reverse stitch counting.....................................29
8.04 .01 Machines with P45 PD2-L and P74 ED-L..................................................................................29
8.04 .02 Machines with PF 321 ..............................................................................................................29
8.05 Setting the bobbin thread monitor with remaining thread recognition by sensor
(sub-class -926/06) ............................................................................................................... 30
8.05 .01 Machines with P74 ED-L ...................................................................................................... 30
8.05 .02 Machines with P74 ED-L ...........................................................................................................30
8.06 Threading needle thread and regulating its tension on the 2545 ............................................31
8.07 Threading needle thread and regulating its tension on the 2546 ............................................32
9Care and maintenance....................................................................................................... 33
9.01 Servicing and maintenance intervals ................................................................................... 33
9.02 Cleaning the machine .......................................................................................................... 33
9.03 Lubricating ........................................................................................................................... 34
9.04 Checking/regulating the air pressure ................................................................................... 35
9.05 Emptying/cleaning the water bowl of the air filter/regulator................................................ 35
10 Wearing parts ..................................................................................................................... 36

5
Safety
1 Safety
1.01 Directives
This machine is constructed in accordance with the European regulations contained 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 and all valid environmental protection regulations!
The regionally valid regulations of the social insurance society for occupational accidents or
other supervisory organizations 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 having
completely read and understood the Instruction Manual!
●All Notes on Safety and Instruction Manuals of the motor manufacturer are to be read be-
fore operating the machine!
●The danger and safety instructions on the machine itself are to be followed!
●This machine may only be used for the purpose for which it is intended and may not be
operated without its safety devices. All safety regulations relevant to its operation are to
be adhered to.
●When exchanging sewing tools (e.g. needle, roller presser, needle plate and bobbin),
when threading the machine, when leaving the machine unattended and during mainte-
nance work, the machine is to be separated from the power supply by switching off the
On/Off switch or by removing the plug from the mains!
●Everyday maintenance work is only to be 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!
The only 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 regulations!
●Only spare parts which have been approved by us are to be used for repairs! We express-
ly point out that any replacement parts or accessories which are 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 are not liable
for any damage which may be caused by non-original parts.

6
Safety
1.03 Safety symbols
Danger!
Points to be observed..
Danger of injury for operating and specialist personnel!
Caution
Do not operate without finger guard and safety devices.
Before threading, changing bobbin and needle, cleaning
etc. switch off main switch.
I
1.04 Important points for the user
●This Instruction Manual is an integral part of the machine and must be available to the
operating personnel at all times.
●The Instruction Manual must be read before operating the machine for the first time.
●The operating and specialist personnel is to be instructed as to the safety equipment of
the machine and regarding safe work methods.
●It is the duty of the user to only operate the machine in perfect running order.
●It is the obligation of the user to ensure that none of the safety mechanisms are removed
or deactivated.
●It is the obligation of the user to ensure that only authorized persons operate and work
on the machine.
Further information can be obtained from your PFAFF agent.

7
Safety
1.05 Operating and specialist personnel
1.05.01 Operating personnel
Operating personnel are persons responsible for the equipping, operating and cleaning of
the machine as well as for taking care of problems arising in the sewing area.
The operating personnel is required to observe the following points and must:
●always observe the Notes on Safety in the Instruction Manual!
●never use any working methods which could adversely affect the safety of the machine!
●not wear loose-fitting clothing or jewelery such as chains or rings!
●also ensure that only authorized 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 safety!
1.05.02 Specialist personnel
Specialist personnel are persons with a specialist education in the fields of electrics, electro-
nics and mechanics. They are responsible for the lubrication, maintenance, repair and adjust-
ment 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 On/Off switch before carrying out adjustments or repairs, and ensure that
it cannot be switched on again unintentionally!
●wait until the luminous diode on the control box is no longer blinking or on before begin-
ning adjustment or repair work.
●never work on parts which are still connected to the power supply! Exceptions are explai-
ned in the regulations EN 50110.
●replace the protective coverings and close the electrical control box afer all repairs or
maintenance work!

8
Safety
1.06 Danger warnings
A working area of 1mmust be kept free both in front of and behind the machi-
ne, so that easy access is possible at all times.
Never put your hands or fingers in the sewing area during sewing!
Danger of injury by the needle!
While setting or adjusting the machine do not leave any objects on the table nor
in the needle plate area! Objects may be trapped or flung out of the machine!
Do not run the machine without finger guard 1!
Danger of injury by up and down movement of needle!
Do not run the machine without take-up lever guard 2!
Danger of injury by moving take-up lever!
Do not run the machine without belt guards 3and 4!
Danger of injury by rotating v-belt!
Do not operate the machine without tilt lock 5!
Danger of crushing between sewing head and table!
Do not operate the machine without support 6! Danger due to top-heavy
sewing head! Machine can tip over backwards when tilted!
Fig. 1 - 01
2
1
3
4
5
6

9
Proper use
2 Proper use
The PFAFF 2545 BASIC, CLASSIC and PLUS are special high-speed, single needle lock-
stitch sewing machines with unison feed and a large, respectively extra large hook.
The PFAFF 2546 BASIC, CLASSIC and PLUS are special high-speed, two needle lockstitch
sewing machines with unison feed and a large, respectively extra large hook.
The machines are used for sewing lockstitch seams in the textile industry.
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!

10
Specifications
3 Specifications
3.01 PFAFF 2545 / 2546 (BASIC, CLASSIC and PLUS) ❋
Stitch type: .........................................................................................................301 (lockstitch)
Needle system: .............................................................................................................. 134-35
Version CN; CN9; CN12: ............................................. for processing medium-heavy materials
Version DN; DN12:.................................................................... for processing heavy materials
Needle size in 1/100 mm:
Version CN9: .............................................................................................................. 110 – 140
Version DN12: ........................................................................................................... 150 – 200
Max. stitch length:
Version CN; DN: ...............................................................................................................6 mm
Version CN9: ....................................................................................................................9 mm
Version CN12; DN12: .....................................................................................................12 mm
Max.thread size (synthetic):
Version CN.. : .................................................................................................................. 15/3▲
Version DN.. : .................................................................................................................... 8/3▲
Presser foot clearance: ..................................................................................................20 mm
Clearance width: ..........................................................................................................350 mm
Clearance height: .........................................................................................................120 mm
Bed plate dimensions: .......................................................................................640 x 200 mm
Noise data:
Noise emission level at workplace with a sewing speed of 2400 spm: ............ LpA < 80 dB(A)■
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO
Motor data: .................................................................... See instruction manual for the motor
Leakage current ........................................................................................................... < 5 mA◆
Air consumption per switch cycle: ...............................................................................0.146 NI
Net weight of sewing head: .................................................................................approx. 72 kg
Gross weight of sewing head : .............................................................................approx. 82 kg
❋Subject to alterations
◆Due to the use of network filters there is a nominal leakage current of < 5mA.
▲synthetic, or other sizes of comparable thread types
■K
pA = 2,5dB

11
Specifications
Top feed lift Stitch length range Max. speed / spm on version Cand with large hook Max. speed / spm on version Cand with extra-large hook Max. speed / spm on version Dand with large hook Max. speed / spm on version Dand with extra-large hook
1 - 2 mm up to 9 mm 3800◆3400◆3000◆2700◆
2,5 - 4 mm up to 9 mm 3200◆2800◆2800◆2700◆
4,5 - 5 mm up to 9 mm 2600◆2200◆2400◆2200◆
5,5 - 7 mm up to 9 mm 2000 1800 1800 1800
7,5 - 9 mm up to 9 mm 1800 1800 1600 1600
1 - 2 mm 9,5 - 12 mm 2200◆2200◆2200◆2200◆
2,5 - 4 mm 9,5 - 12 mm 2200◆2200◆2200◆2200◆
4,5 - 5 mm 9,5 - 12 mm 2200◆2200◆2200◆2200◆
5,5 - 7 mm 9,5 - 12 mm 2000 1800 2000 1800
7,5 - 9 mm 9,5 - 12 mm 1800 1800 1800 1800
3.02 Maximum speed
◆The max. speed on the PFAFF 2546 with needle gauge larger than 20 mm is 2000 spm.

12
Specifications
3.03 Machine equipment and options
PFAFF 2545 / 2546
BASIC CLASSIC PLUS
Vetical hook, large ●●●
Vetical hook, extra large ❍❍❍
Thread trimmer (-900/81), < 13 mm rest thread -●●
Thread trimmer (-900/82), < 5 mm rest thread -❍❍
Thread puller (-909/12), controlled -❍❍
Presser foot lift, manual via knee lever ●--
Presser foot lift (-910/04), electropneumatic -●●
Manual backtacking with mech. hand switch ●●●
Automatic backtacking (-911/35), electropneumatic -●●
1 preselectable stitch length ●● -
2 preselectable stitch lengths, can be switched alternately --
●
2 preselectable thread tensions, one can be switched on manually ●--
2 preselectable thread tensions, one can be switched on electropneu-
matically by hand switch -●●
1 presser foot stroke, manually adjustable, top feed stroke up to max. 9 mm ●● -
2 presser foot strokes, manually adjustable, preselectable quick stroke
adjustment with hand switch (electropneumatically controlled) --
●
Drop feed, adjustable ●●●
Oil level control through inspection glass ●●●
Oil level on display, with warning light on machine head -●●
Presser foot pressure, manually adjustable ●●●
Clutch motor ●--
DC-motor functionality PicoDrive P45 PD-L ❍--
DC-motor functionality P74 ED-L, PF 321 -●●
Control panel - PicoTop -●●
Remaining bobbin thread recognition function by stitch counting with
LED display -●●
Bobbin thread monitor with remaining thread recognition by sensor
(sub-class -926/06 --
❍
Integrated multiple switch on machine head + programmed multi switch -●●
Integrated LED sewing lamp on sewing head, dimmable ❍●●
Bobbin thread winding device ●●●
Attachment slider ●●●
Skip stitch detector SSD - ❍❍
Bobbin thread monitoring with thread detection - ❍❍
Safety coupling ●●●
●= standard, ❍= optional

13
Disposal of Machine
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
14
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
15
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)

16
Controls
7 Controls
7.01 On/off switch
Fig. 7 - 01a
2
Fig. 7 - 01
1
Machines with motor PF 321
●Operate main switch 2to switch the
machine on or off.
Machines with motor P45 PD2-L + P74 ED-L
●The power supply to the machine is swit-
ched on or off by turning switch 1.
7.02 Sewing lamp switch (only on the PFAFF 2545 / 2546 CLASSIC and PLUS)
●Switch the sewing lamp, which is inte-
grated in the machine head, on or off by
operating switch 1.
Fig. 7 - 01b
1

17
Controls
7.03 Pedal
●With the on/off switch on
0= Machine stop
+1= Sew
- 1= Raise presserfoot
- 2= Trim thread (on machines with
thread trimmer)
Fig. 7 - 03
0 +1
-1 -2

18
Controls
Fig. 7 - 04
7.04 Keyboard on machine head (only on the PFAFF 2545 / 2546 CLASSIC and PLUS)
2
1
3 4X5 6X7 8
B
A
●The machine has a keyboard with 8keys to activate different functions.
●In the keys 2– 7there are yellow LEDs. These shine when the respective function has
been allocated to key 1.
●Green LEDs are located above the keys 2- 7. These shine when the function has been
activated.
●Above key 1there are two symbol lamps.
Lamp Aindicates the status of the bobbin thread control.
Lamp Bshines when the minimum level of the oil supply has been reached.
●When the keys 1– 8are operated, the functions listed below are carried out.
Key 1: The functions of the keys 2- 7can be allocated to this key.
To program key 1, simultaneously press one of the keys 2- 7and key 1for approx.
3seconds.The function of the selected key is taken over and the yellow LED in this
key lights up
(For drive system P74 ED-L = standard)
For drive system PF 321, the value 94 is set under parameter 840 (= standard).
Key 2: Reverse sewing or intermediate backtacks during the seam.
(On drive system P74 ED-L under Parameter 634 other functions can be assigned to
this key: ON = Feed adjustment when machine has stopped and when machine is running
(standard)
OFF = Feed adjustment only when machine is running
For drive system PF 321, the value 16 is set under parameter 841 (= standard).
Xonly on the version PLUS

19
Controls
Key 3: Needle position change
This button can have the following functions assigned depending on the drive
system implemented and by way of changes to the parameter values:
P74 ED-L PF 321
Parameter Function Parameter Function
695 0 = Off
1 = needle raised without trimming
2 = needle position change (standard)
3 = single stitch
4 = single stitch in reverse
5 = moving forwards to needle
position step by step
6 = programmable tack on / off
842 0 = Function off
01 = Needle up without trimming
02 = Change needle position (standard)
03 = Single stitch
20 = Step-by-step approach to a
needle position forward
95 = Offset multi-backtack
96 = Backtack suppression (all autom.
backtack deactivated)
97 = Single stitch reverse
98 = Not used
Key 4: Calling up the pre-selected top feed lift.
(Diode on = high lift, diode off = low lift)..
This button can have the following functions assigned depending on the drive
system implemented and by way of changes to the parameter values:
P74 ED-L PF 321
Parameter Function Parameter Function
401 0 = Off
1 = when key pressed constant
second stroke (standard)
2 = second stroke only as long as key
pressed
If this key is operated, the second
voltage is switched on
This function can be switched off un-
der Parameter 764
843 0 = Off
01 = With button pressed constantly,
2nd lift (standard)
02 = 2nd lift only while button is
pressed
14 = Stroke adjustment (Flip Flop 1)
with speed limit N10
(Parameter 137 must be set to "On"
Key 5: Bartack suppression for one bartack.
This button can have the following functions assigned depending on the drive
system implemented and by way of changes to the parameter values:
P74 ED-L PF 321
Parameter Function Parameter Function
780 0 = Off
1 = tack inversion once (standard)
2 = tack suppression (all tacks
switched off)
3 = reverse move to needle position
step by step
4 = edge trimmer on / off
5 = programmable tack on / off
844 17 = Backtack inversion, single
(standard)
21 = Step-by-step approach to a
needle position reverse
95 = Offset multi-backtack
96 = Backtack suppression
(all autom. backtack deactivated)
97 = Single stitch reverse
98 = Not used

20
Controls
Key 6: Calling up the pre-set stitch length
Diode on = large stitch length, diode off = small stitch length.
This button can have the following functions assigned depending on the drive
system implemented and by way of changes to the parameter values:
P74 ED-L PF 321
Parameter Funktion Parameter Funktion
786 Function = Standard
This function can be switched off
under Parameter 786.
845 22 = Speed limitation n11 , Flip Flop 2
(Parameter 186 must be set to "On".
Key 7: If this key is operated, the second thread tension is switched on.
If this key is pressed for longer than about 2seconds, the machine moves to the
threading position - the needle is raised and the motor start inhibitor is activated
(sewing threads are not trimmed).
If the key is operated again, the motor start inhibitor is deactivated again
(For drive system P74 ED-L = standard)
For drive system PF 321, the value 93 is set under parameter 846 (= standard).
Key 8: EMERGENCY KEY
Needle is raised without trimming, the thread clamp is opened, the thread
tension is released, the presser foot raised and the motor start inhibitor activated.
Deactivation the motor safety lock
For drive system P74 ED-L - click the button 'Scroll'.
For drive system PF 321 - click the button 'E' (under parameter 847, the value 24 is
set = standard)
The method for setting parameters is described in the settings manual, and
may only be carried out by certified professionals!