Pfaff POWERLINE 3741 User manual

296-12-19 008/002
Betriebsanleitung engl. 06.12
DOKU-SEAM-SYSTEM
3741
3745

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
Register 01.................................................................................................5
1Safety .................................................................................................................................... 7
1.01 Directives...............................................................................................................................7
1.02 General notes on safety......................................................................................................... 7
1.03 Safety symbols ...................................................................................................................... 8
1.04 Important points for the user................................................................................................. 8
1.05 Operating and specialist personnel........................................................................................ 9
1.05.01 Operating personnel .............................................................................................................. 9
1.05.02 Specialist personnel............................................................................................................... 9
1.06 Danger warnings.................................................................................................................. 10
Register 02............................................................................................... 11
2Input .................................................................................................................................... 14
2.01 General information ............................................................................................................. 14
2.02 Overview of the functions ................................................................................................... 15
2.03 Description of the functions ................................................................................................ 16
2.03.01 Overlapping functions .......................................................................................................... 16
2.03.02 Operating modes ................................................................................................................. 17
2.03.03 Tools..................................................................................................................................... 17
2.04 Creating seam programs .....................................................................................................18
2.04.01 Sewing parameter input....................................................................................................... 22
2.04.02 Input of action at beginning of seam sector ........................................................................ 23
2.04.03 Input of end of seam sector ............................................................................................... 24
2.04.04 Input of action at end of seam sector ................................................................................. 25
2.04.05 Thread force......................................................................................................................... 27
2.05 Service................................................................................................................................. 29
2.06 Cold start ............................................................................................................................. 30
2.07 Users – rights....................................................................................................................... 31
2.08 Backup – restore .................................................................................................................. 33
2.09 Label-editor .......................................................................................................................... 35
2.10 Defining options and interfaces ........................................................................................... 37
Register 03...............................................................................................37
3Betriebsanleitung............................................................................................................... 39
3.01 Proper use............................................................................................................................ 40
3.02 Specifications....................................................................................................................... 41
3.03 Disposal of Machine ............................................................................................................ 42
3.04 Transportation, packing and storage .................................................................................... 43
3.04.01 Transportation to customer‘s premises ............................................................................... 43

Index
Contents ................................................................................ Page
3.04.02 Transportation inside the customer‘s premises................................................................... 43
3.04.03 Disposal of packing materials .............................................................................................. 43
3.04.04 Storage ................................................................................................................................ 43
3.05 Explanation of symbols........................................................................................................ 44
3.06 Controls ...............................................................................................................................45
3.06.01 On/off switch / Sewing lamp switch .................................................................................... 45
3.06.02 Power bar ............................................................................................................................ 45
3.06.03 Keyboard on machine head..................................................................................................46
3.06.04 Pedal .................................................................................................................................... 48
3.06.05 Lever for lifting the presser foot........................................................................................... 48
3.06.06 Knee switch (optional).......................................................................................................... 49
3.06.07 Bobbin thread supply monitor ............................................................................................. 49
3.06.08 Adjustment of the stand height (optional) ........................................................................... 50
3.06.09 Touch-screen monitor .......................................................................................................... 50
3.06.10 Label-printer......................................................................................................................... 51
3.06.11 Hand-held scanner ............................................................................................................... 51
3.06.12 PC ........................................................................................................................................ 51
3.07 Setting up............................................................................................................................. 52
3.07.01 Log-in ................................................................................................................................... 52
3.07.02 Language selection.............................................................................................................. 52
3.07.03 Inserting the needle ............................................................................................................ 53
3.07.04 Winding the bobbin thread, regulating the winder tension (PFAFF 3741+ 3745 PLUS) ....... 54
3.07.05 Winding the bobbin thread, regulating the winder tension (PFAFF 3745 PREMIUM).......... 55
3.07.06 Bobbin-changing/threading, and regulating the bobbin thread tension................................ 56
3.07.07 Threading the needle thread (PFAFF 3741 PLUS + 3745 PLUS) ............................................57
3.07.08 Threading the needle thread (PFAFF 3745 PREMIUM) ..........................................................58
3.08 Sewing................................................................................................................................. 59
3.08.01 Calling up / carry out the sewing operation (without camera for bobbin thread monitor)....59
3.08.02 Calling up / carry out the sewing operation (with camera for bobbin thread monitor)......... 60
3.08.03 Regulating the needle thread tension (PFAFF 3741 + 3745 PLUS)........................................ 62
3.08.04 Regulating the needle thread tension (PFAFF 3745 PREMIUM) ........................................... 64
3.08.05 Description of the functions ................................................................................................ 66
3.08.06 Concluding the sewing operation ........................................................................................ 68
3.09 Care and maintenance ......................................................................................................... 69
3.09.01 Servicing and maintenance intervals ................................................................................... 69
3.09.02 Cleaning the machine .......................................................................................................... 69
3.09.03 Lubricating ........................................................................................................................... 70
3.09.04 Checking/regulating the air pressure ................................................................................... 71
3.09.05 Emptying/cleaning the water bowl of the air filter/regulator................................................ 71
3.10 Wearing parts....................................................................................................................... 72

Index
Contents ................................................................................ Page
Register 04...............................................................................................73
4Adjustment ......................................................................................................................... 76
4.01 Notes on adjustment ........................................................................................................... 76
4.02 Tools, gauges and other accessories for adjusting ............................................................. 76
4.03 Abbreviations ....................................................................................................................... 76
4.04 Explanation of the symbols.................................................................................................. 76
4.05 Adjusting the basic machine ................................................................................................77
4.05.01 Basic position of the balance wheel (adjustment aid).......................................................... 77
4.05.02 Zero position of the bottom and needle feed ...................................................................... 78
4.05.03 Feed dog motion of bottom feed dog and needle feed .......................................................79
4.05.04 Feeding motion of the bottom feed dog .............................................................................. 80
4.05.05 Height of the bottom feed dog ............................................................................................ 81
4.05.06 Feeding stroke difference .................................................................................................... 82
4.05.07 Preliminary adjustment of the needle height....................................................................... 83
4.05.08 Needle rise, hook clearance, needle height and bobbin case position finger ...................... 84
4.05.09 Bobbin case opener ............................................................................................................. 85
4.05.10 Bobbin winder...................................................................................................................... 86
4.05.11 Thread check spring and thread regulator............................................................................ 87
4.05.12 Sewing foot pressure........................................................................................................... 88
4.05.13 Lubrication ........................................................................................................................... 89
4.05.14 Reengaging the slip clutch................................................................................................... 90
4.06 Adjusting the thread trimmer -900/81.................................................................................. 91
4.06.01 Resting position of the roller lever / radial position of the control cam................................ 91
4.06.02 Position and height of the thread catcher ............................................................................ 92
4.06.03 Knife pressure...................................................................................................................... 93
4.06.04 Bobbin thread clamp spring ................................................................................................. 94
4.06.05 Manual cutting test .............................................................................................................. 95
4.07 Setup.................................................................................................................................... 96
4.07.01 Set reference position.......................................................................................................... 96
4.07.02 Stitch length adjustment...................................................................................................... 97
4.07.03 Commissioning the scanner ................................................................................................ 98
4.07.04 Commissioning the camera ................................................................................................. 99
4.07.05 Adjustment of edge guide photocell................................................................................. 102
4.08 Parameter settings............................................................................................................. 103
4.08.01 Selecting and altering the parameters ............................................................................... 103
4.08.02 Parameter list..................................................................................................................... 104
4.09 Description of the error messages .....................................................................................112
4.10 Inputs / Outputs..................................................................................................................113
4.11 Pin assignment ...................................................................................................................114
4.12 Importend Sevice-information............................................................................................117

Index
Contents ................................................................................ Page
Register 05............................................................................................. 117
5Calibration ........................................................................................................................ 120
5.01 General information ........................................................................................................... 120
5.01.01 Calibration .......................................................................................................................... 120
5.01.02 Traceability ......................................................................................................................... 120
5.01.03 Standards........................................................................................................................... 120
5.01.04 Gauging office, German Calibration Office DKD................................................................ 121
5.02 Calibration procedure......................................................................................................... 121
5.02.01 Check / adjust the needle reference position..................................................................... 121
5.02.02 Check / adjust the trigger signals....................................................................................... 122
5.02.03 Check the zero position of the monitor power signal ........................................................ 123
5.02.04 Checking the setting of the sewing head........................................................................... 124
5.02.05 Recording the characteristic thread strength curve ........................................................... 124
5.03 Checking the calibration (calibration result)........................................................................ 127
Register 06.............................................................................................127
6Circuit diagrams............................................................................................................... 129
6.01 Pneumatics-switch diagram PFAFF 3741 + 3745 .............................................................. 129
6.02 Block diagram PFAFF 3741 + 3745 (with control unit P374 ED) ......................................... 130
6.03 Circuit diagrams ................................................................................................................. 132

Register 01

7
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.

8
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.

9
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!

10
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
6
5

PFAFF Industriesysteme und Maschinen AG, 67661 Kaiserslautern
Declaration of acknowledgement
of the documentation for the PFAFF-DOKU-SEAM-SYSTEM
Customer:................................................................................................................................................
Address:...................................................................................................................................................
Machine: PFAFF 3741 ................................... Serial-Nr.: ................................................................
Machine: PFAFF 3745 ................................... Serial-Nr.: ................................................................
PC-software: ................................................. Control software:.....................................................
Each person working on the PFAFF-DOKU-SEAM-SYSTEM must be familiar with and understand the
contents of these technical documents. The operating and qualified personnel must be appropriately
authorised to handle the machine, i.e. qualified and instructed. The operator promises to train his
personnel accordingly. Furthermore the user have to take care, to calibrate the machine, when the
control-box or the thread-force-sensor was changed.
We hereby confirm that we have read and understood the documentation for the PFAFF-DOKU-SEAM-
SYSTEM, and that in addition to the advice in the documentation, we will also follow the local safety and
accident prevention regulations.
Place:...................................................................................... Date:................................................
Operator:...................................................................................................................................................

Register 02

This instruction manual applies to
machines from software version 1.8
and serial number 2 763 625 onwards
Kurzanleitung zur Eingabe engl. 06.12
SHORT INSTRUCTIONS
FORTHE INPUT
3741
3745

Input
14
2 Input
2.01 General information
The effective pull of the needle thread (needle thread tension) is determined during sewing
for each stitch by means of a sensor installed in the needle thread path of the sewing ma-
chine.
In the process, through a special measuring principle, measuring errors, caused for example
by fluctuating temperatures, can be ruled out.
The signals are evaluated on the PC and displayed on the touch-screen monitor on a user in-
terface for Windows ® XP. The analysis of these signals gives information about the machine
setting and the quality of each individual stitch sewn.
The seam sector for which the system is to be activated (docu-seam sector) is determined
either by a sensor, by knee switch, with a pre-selected seam length or by stitch counting.
The docu-seam system compares the established thread pull with the previously entered
limit values and issues an evaluation of the seam on the touch-screen monitor. If the seam
is a good seam, an appropriate signal is given to the PC interface and a label can be printed,
which can then be attached to indicate the appropriate quality of the seam. The label can be
designed individually with an editor.
The docu-seam system also activates a missed stitch recognition function and, depending
on how it is set, reacts to following types of error:
- missed stitch,
- needle thread breakage, end of needle thread
- bobbin thread breakage, end of bobbin thread
- broken needle
- deviations from edge guide
The use of specified materials can be ensured and documented through the prompt to enter
appropriate codes (e.g. scanning of barcodes for thread spindle, material, bobbin).
All inputs, for separate user groups, can be carried out directly over the user interface of the
touch screen monitor. Several languages are available for the user interface. All data entered
and established can be processed on standard databases and spreadsheets.

Input
15
2.02 Overview of the functions
Pop-ups: - Instruction box - Error - Warning - Keyboard - Language selection - Help mode
- Log-in
- Selection of oper-
ating mode
- Tools - Change of
user
- Switch off
switch to desktop / computer
- Seam program selection +
configuration
- Production
Pop-ups: - Error - Warning
Info display
Switch to:
- Manual interruption - Manual sewing - Test seam - Work instructions - Winding
Popups: - Settings
- Seam program
creation
Work instructions
- Label- editor
- Users and rights - Equipment + interfaces - Backup and restore - Evaluation and printing
- Parameterization - Service - Calibration - Cold start
Inputs/outputs
Feed
regulator
configuration
Thread
force
Drives Sensors Version
Scanner
commissioning
Camera
commissioning

Input
16
2.03 Description of the functions
Each function is selected by tapping the appropriate symbols on the touch-
screen monitor.
2.03.01 Overlapping functions
Mode selection
The menu for selecting the operating mode is called up, see Chapter 2.03.02 Operating
modes.
Choice of language
A menu for selecting the language setting is opened, see Chapter 8 Setting up in the In-
struction Manual.
Help mode
After calling up the help mode, the next function selected is described.
Online help
After activation of the help module, the online help can be called up, including language and
document selection.
Confirm
The selection is confirmed, entered or altered values are saved.
Stop
The selection process is cancelled, entered or altered values are not saved.
Back
The superordinate level is selected.
Drag and Drop
With this function it is possible to move the window to any position.
Work order
With this function, a previously created work order can be displayed.