A9500 User and Maintenance Manual ENG_120710009

Air Jet weaving machine

Cod. 120710009 02-2012

USE AND MAINTENANCE MANUAL MANUAL Translation of the original instructions

Manufacturer's address: ITEMA S.p.A. Via Cav. Gianni Radici, 4 24020 COLZATE COLZATE (BG) Italia

Administrative and Legal Office

Via Cav. Gianni Radici, 4 - 24020 COLZA COLZATE TE (BG) Italia Sales office

Via Cav. Gianni Radici, 4 - 24020 COLZA COLZATE TE (BG) Italia Tel. (+39) 035 7282111 Fax (+39) 035 740505 E-mail: info@itemagroup [email protected] .com Customer Service

Via Cav. Gianni Radici, 4 - 24020 COLZA COLZATE TE (BG) Italia Tel. (+39) (+39) 035 7285111 Fax (+39) 035 725288 E-mail: [email protected] E-mail: [email protected]

All rights to graphics and text in this manual are owned by by ITEMA S.p.A. No part may be reproduced repro duced or transmitted, even partially, to a third party without per mission of ITEMA S.p.A. ITEMA S.p.A. reserves the right to modify this manual without notice.

Index

USER AND MAINTENANCE MANUAL

TABLE OF CONTENTS GENERAL INFORMATION 1

SYMBOLS

2

WARNINGS

3

GENERAL RULES

4

TECHNICAL ASSISTANCE

5

BASIC INFORMATION

5.1 5.2 5.3 5.4 5.5

REFERENCES OPERATOR’S POSITION MANUFACTURER'S NAME PLATE ELECTRICAL DATA PLATE DISCLAIMER

4.1

REQUEST FOR ASSISTANCE

SAFETY AND ACCIDENT PREVENTION RULES 1

DECLARATION OF CONFORMITY AND EC MARKING

2

GENERAL SAFETY RULES

3

SAFETY USE FOR INSTALLATION

4

SAFETY RULES FOR USE

5

SAFETY RULES FOR OPERATOR HEALTH

6

FIRE RISK

7

SAFETY RULES FOR MAINTENANCE

7.1 7.2 7.3

CLEANING OPERATIONS SERVICING THE ELECTRIC SYSTEM EXTERNAL POWER SOCKET (available on request)

8

SAFETY DEVICES

8.1 8.2

INTANGIBLE SAFETY BARRIER (machines with CE markings) INTANGIBLE SINGLE-RAY SAFETY BARRIER (PHOTOELECTRIC CELL DEVICE) (optional) (machines without CE markings) SAFETY TUBE FOR TAKE-UP ROLLER CONTROL BOX SAFETY DEVICE MAIN SWITCH EMERGENCY STOP PUSHBUTTONS PUSHBUTTON PANEL CONTROLS

8.3 8.4 8.5 8.6 8.7 1

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Index


8.7.1 SIDE PUSHBUTTON PANEL 8.7.2 CENTRAL PUSHBUTTON PANEL (only for machine width 2800 – 3600) 8.8 HOW THE MACHINE WORKS 8.8.1 FAST SPEED 8.8.2 SLOW MOTION (jogging) 8.8.3 MANUAL FORWARD/BACKWARD PICK-FINDING 8.8.4 LIGHT SIGNAL OF STARTING MOVEMENT 8.8.5 FUNCTIONS BUTTONS (F1 - F2) 8.8.6 AUTOMATIC BACKWARD REPOSITIONING AND PICK-FINDING 8.9 TYPES OF MACHINES STOP 8.9.1 NORMAL STOP 8.9.2 EMERGENCY STOP 8.10 WARNING LIGHTS 8.10.1 MAIN LAMP 8.10.2 SIDE LAMPS 9

SAFETY CHECKS

10

NOISE EXPOSURE RULES

10.1 INFORMATION ON THE EFFECTS OF LOUD NOISE ON THE HEARING 10.1.1 EFFECTS ON THE HEARING 10.2 NOISE EMISSIONS OF THE MACHINE 10.2.1 EXPLANATION OF THE MEASUREMENTS GIVEN 10.2.2 ACOUSTIC MEASUREMENT 11

HOW TO REDUCE VIBRATIONS

11.1 SHOCK ABSORBERS 11.2 FLOATING FLOORS 12

DECOMMISIONING AND SCRAPPING

13

FACSIMILE of the CE Conformity Declaration

2

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Index


SECTION 1 GENERAL LAYOUT AND TECHNCIAL CHARACTERISTICS

1

1.1

GENERAL LAYOUT LIST OF MACHINE’S MAIN COMPONENTS

2

MACHINE TECNICHAL CHARACTERISTICS

2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2

MACHINE TYPE MACHINE VERSIONS NOMINAL WIDTHS MOTORIZATION SHEDDING MACHINES COLOR SELECTION BEAM TYPE OVERALL DIMENSIONS ELECTRICAL CONNECTION POSITION EXAMPLE OF INSTALLATION LAYOUT

3

ELECTRICAL CHARACTERISTICS

3.1 3.2 3.3 3.4 3.4.1 3.5

INSTALLED POWER ABSORBED POWER POWER FACTOR SURGE CURRENT PROTECTION DEVICES AUXILIARY SOCKETS

4

PNEUMATIC FEATURES

4.1 4.2 4.3 4.4 4.5 4.5.1 4.5.2 4.5.3 4.5.4

AIR MEASUREMENT UNIT AIR FEATURES AIR CONSUMPTION MACHINE AIR SYSTEM APPORXIMATE LAYOUT OF AN AIR SYSTEM INTAKE FILTER SYSTEM COMPRESSOR DRYER AIR TANK

5

ADVICE FOR INSTALLING CONDITIONING SYSTEMS

5.1

OPTMIAL HUMIDITY TEMPERATURE CONDITIONS

3

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Index


SECTION 2 TRANSPORT AND INSTALLATION

1

PRELIMINARY OPERATION BEFORE STARTING UP

1.1

SEQUENCE OF OPERATIONS TO START UP

2

FLOORING PREPARATION

2.1 2.2

FLOOR PAVING SLAB FLOORING

3

HOISTING AND TRANSPORT

3.1 3.2 3.3 3.4

MACHINE UNLOADING FROM ITS CONTAINER HOISTING FROM ABOVE HOISTING AND TRANSPORT USING TROLLEYS TRANSPORT WITH TROLLEYS

4

UNLOADING THE SWITCHBOARD

4.1

UNLOADING THE SWITCHBOARDS BY MEANS OF HOISTING TOOLS

5

REMOVAL OF THE ANTI-RUST PROTECTION

6

LEVELLING

6.1

LOOMS WITH BEAMS FITTED WITH 1000 OR 1100 DIAMETER FLANGES

7

ELECTRICAL CONNECTION

8

MANUAL MOVEMENT OF THE MACHINE

9

PNEUMATIC CONNECTION

10

ENCODER AND GRADAUATED DISK

4

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Index


SECTION 3 PREPARATION FOR START UP

1.1

SIMPLE BEAMS

1.1.1 DIAGRAM FOR MOUNTING SIMPLE BEAMS CONFORMING TO ISO-DIN REGULA TIONS 1.2 POSITIONING OF THE FLANGES 1.2.1 REDUCTION FROM THE RIGHT-HAND SIDE 1.2.2 SYMMETRICAL REDUCTION FROM BOTH SIDES 1.3 THE CLOTH ROLLER BEAMS 1.4 SAFETY REGULATIONS FOR TRANSPORTING, LOADING AND UNLOADING BE AMS 1.5 SIMPLE BEAM ASSEMBLY 1.5.1 SBM BEAM VERSION 1.5.2 STANDARD BEAM VERSION 1.6 MOUNTING THE BEAMS ON THE WARPING MACHINES 2

HEALD FRAMES AND HEALDS

2.1

2.3

DIMENSIONS OF HEALD FRAMES FOR MACHINES WITH WIDTH FROM 1900 TO 2600 DIMENSIONS OF HEALD FRAMES FOR MACHINES WITH WIDTH FROM 2800 TO 3600 HEALDS

3

REED

3.1 3.2 3.3

FEATURES CALCULATING THE TOTAL REED WIDTH AND THREADING UP REED CLEANING

4

SELVEDGES AND WASTE SELVEDGES

4.1 4.1.1 4.1.2 4.2 4.2.1

SELVEDGES LENO DEVICE SELVEDGES TUCKED-IN SELVEDGES WASTE SELVEDGES WASTE SELVEDGES FEED

2.2

5

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Index


SECTION 4 MECHANICAL AND TEXTILE ADJUSTMENTS

1 1.1 1.2 1.3

FABRIC SUPPORT STANDARD SUPPLY SUPPLY OF CUT FABRIC SUPPORT (LIP IN THE REED) SUPPLY OF TELESCOPIC FABRIC SUPPORT (LIP IN THE REED)

2

FASTENING THE REED

3

MOUNTING AND POSITIONING THE AUXILIARY NOZZLES

4

TEMPLES

4.1 4.2

POSITIONING ADJUSTMENT

5

LATERAL SCISSORS

5.1 5.2 5.3

BLADE PRELOADING ADJUSTMENT ADJUSTMENT OF BLADE OPENING LENGTHWISE ADJUSTMENT AND ADJUSTMENT IN DEPTH

6

MAIN NOZZLE AND TANDEM NOZZLE GROUP

6.1 6.2 6.3

NOZZLES TANDEM NOZZLES USE OF NOZZLES AND TANDEM NOZZLES

7

PHOTOCELLS AND STRETCHING NOZZLE GROUP

7.1 7.2

PHOTOCELLS STRETCHING NOZZLE GROUP

8

WORKING WITH FULL WIDTH REED

8.1 8.2 8.3 8.4

WEFT STRETCHING NOZZLE POSITIONING THE BENDING BEAM PHOTOCELLS ITN STRETCHING NOZZLE (option) (patent) FASTENING THE PHOTOCELL CABLES

9

AIR INLET (for cut reed execution)

10

F.A.R. DEVICE - on request

10.1 F.A.R. DEVICE FOR FULL REED WIDTH - on request

11

WEAVING WITH WASTE SELVEDGE 6

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Index


11.1 SELVEDGE CONVEYOR 12

SELVEDGES

12.1 SELVEDGE BINDING 12.2 LENO DEVICE "ELD SPLITZ" 13

BACK ROLLER

13.1 13.2 13.3 13.4 13.5 13.6

ADJUSTING THE BACK ROLLER INCLINATION HORIZONTAL ADJUSTMENT VERTICAL ADJUSTMENT (figure 2) SPRING POSITION ADJUSTING THE SPRINGS TIMING OF THE DRIVEN BACK ROLLER

14

SHED SIZE

14.1 ADJUSTING THE LEVERS FOR STAUBLI CAM MOTIONS 14.2 ADJUSTING THE LEVERS FOR STAUBLI DOBBIES 15

ADJUSTING THE HEALD FRAME TIE-RODS

15.1 DEAFULT SETTING FOR DOBBY 15.2 MACHINES WITH TAPPET MOTION WITH LEVELLING 15.3 MACHINES WITH TAPPET MOTION WITHOUT LEVELLING 16

SHED CLOSING ADJUSTMENT

17

CALIBRATING THE MAIN NOZZLES AND TANDEM NOZZLES

17.1 CALIBRATING THE INSTRUMENT WITH A PRESSURE GAUGE 17.1.1 CLEANING 17.1.2 CALIBRATING 17.2 NOZZLES 17.3 TANDEM NOZZLES 18

PNEUMATIC ADJUSTMENTS

18.1 CALIBRATING THE PRESSURES 18.1.1 CONTINUOUS BLOW 18.1.2 WEFT THREADING UP BLOW 18.1.3 AUXILIARY NOZZLE PRESSURE 18.1.4 STRETCHING NOZZLE ADJUSTMENT PRESSURE 18.1.5 NOZZLE BLOW PRESSURE OF PNEUMATIC TUCKERS 18.1.6 ADJUSTING THE F.A.R. FLOW RATE 19

WEFT DENSITY

19.1 CALCULATING THE FABRIC SPEED 20

PRODUCTION SPEED 7

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Index 21

USER AND MAINTENANCE MANUAL WINDING OF THE FABRIC

21.1 STRETCHING BAR 21.2 UPPER FABRIC PRESSING CYLINDER 21.3 FABRIC ROLL CYLINDER 22

WARP STOP MOTION

22.1 WARP STOP MOTION WITH DROP WIRES 22.2 HEIGHT OF THE OVAL BARS OF THE WARP STOP MOTION 22.2.1 HEIGHT OF THE WARP STOP MOTION ROWS

SECTION 5 LUBRICATION 1

GENERAL

1.1

SUPPLY CONDITIONS

2

OIL LUBRICATIONS SYSTEMS

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.8.1 2.9 2.9.1 2.9.2

LUBRICATION SYSTEM AND CONTROL DEVICE MINIMUM PRESSURE SWITCH MAXIMUM PRESSURE SWITCH PUMP MOTOR REPLACING THE FILTERS CHECKING THE LUBRICANT LEVEL REPLACING THE LUBRICANT (DRAINING AND FILLING) TYPES OF LUBRICANT SYMBOLS USED UNITS TO BE FILLED WITH LUBRICATING OIL PRESSURE LUBRICATION CIRCUIT TANK FABRIC REGULATOR AND LET-OFF UNITS

3

GREASE LUBRICATION

4

TIE-RODS LUBRICATION

8

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Index


SECTION 6 MAINTENANCE 1

REGULAR CHECKS (PREVENTIVE MAINTENANCE)

1.1 1.2 1.3 1.4 1.5

DAILY CHECKS (D) WEEKLY CHECKS (W) MONTHLY CHECKS (M) SIX-MONTHLY CHECKS (S) YEARLY CHECKS (Y)

SECTION 7 APPENDIX 1

USING THE FLOWMETER

1.1 1.2

CONNECTION READING THE FLOWMETER

2

SHARPENER FOR WEFT CUT BLADES (on request)

3

ADJUSTMENT SHEET

4

SCREW TIGHTENING TORQUES

9

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Index

10


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General information


GENERAL INFORMATION

11

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General information

12


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General information


1. SYMBOLS If there is a possible danger, the following symbols are used to draw the user ’s attention to the safety instructions in this manual:

Warning symbol: hazardous points (risk of injury or death).

Warning symbol: live parts (risk of injury or death).

Warning symbol:

ATTENTION

to avoid material damages.

Compulsory warning symbol: all work must be carried out with the loom stopped, power switched off and padlock in place.

Important instructions mentioned in the text of the manual are indicated by the use of the following symbol:



Important information:



The distances indicated in all figures and tables are expres-

13

pay special attention to these instructions.

sed in millimeters (mm).

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General information 2


CAUTIONS

The machine must be used only for the work and type of products for which it was designed and built.

ATTENTION DANGER: If toxic textile materials are used, all necessary and further safety precautions must be taken. When weaving certain types of yarn, the machine may produce dust. In this case, a suitable dust exhaust system needs to be fitted to guarantee the safety of the workplace in compliance with local hygiene regulations.



In addition to the standards listed below, the person in charge of the machine must observe the current health and safety at work regulations.

Before using the machine, the people in charge (head and operators) must be familiar with the contents of the chapter on “M ACHINE SAFETY”. The instructions for use and maintenance contained in this manual, together with the manuals regarding the ELECTRONICS, WIRING DIAGRAMS, SPARE PARTS and SHEDDING MACHINE, are an integral part of the ocumentation required by the users of this machine and must be read carefully by these so that they may use the machine in the correct manner. These documents must be kept for future consultation. Always comply with safety regulations and instructions given in this manual. The loom has to be started up by the manufacturer ’s technicians only when the machine and its accessories have been installed correctly. The user is therefore requested to carry out all the operations described in the present manual with necessary care. ITEMA declines any responsibility for faults, breakdowns, accidents, etc. due to lack of knowledge of the prescriptions contained in this manual or, in any case, lacks in applying them. The same goes for any modifications, variations and/or the installation of accessories which have not received prior approval. In particular, ITEMA declines any responsibility for damage arising from: natural disasters; misuse; lack of maintenance;

• • •

•

unauthorized repairs and tampering; dust and fluff inside the control box; dust and fluff on the motor ventilation fan;

•

damage to the electronics due to condensate or contact with external conductive elements.

• •

ATTENTION DANGER: Do not allow unauthorized people to approach the machine. Only qualified operators may use, service and repair the machine. Said operators must be physically and mentally suitable to carry out such work and not under the influence of alcohol or drugs.

14

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RULES

All machine personnel must be fully trained. They must be familiar with the manual and, where possible, have attended a special training course at the manufacturer ’s factory. We also recommend ensuring that the above personnel pay close attention to the manufacturer ’s technicians during the first start-up of the machine. Maintenance requires a few simple operations that can be carried out by the operator in charge of the machine. The rules contained in this manual should be closely followed to ensure the best duration of the machine and the lowest running costs. Do not wait for the various components to become worn. Timely replacement of components means better machine efficiency and, at the same time, savings in time and money as greater damage to the machine is avoided.

 4

When changing spare-parts, always and exclusively use “ITEMA or iginal” spare parts. The use of non original spare parts renders the warranty null and void.

TECHNICAL ASSISTANCE

The ITEMA Customer Ser vice is at the Customers’ disposal to solve any problems regarding the use and maintenance of the machines.

4.1

REQUEST FOR ASSISTANCE

Before requesting assistance, a careful analysis of the pro blems and their causes ought to be carried out. The message has to include the following information: - the details of the defects, referring to the loom type and the corresponding adjustment and spare parts manuals; - the checks carried out; - the adjustments made and their effects; - the serial number of the machine(s) concerned; - any other useful information. Requests should be addressed to:

ITEMA S.p.A. CUSTOMER SERVICE Via Cav. Gianni Radici 4 24020 COLZATE (BG) Italy Tel. (+39) 035 7285111 Fax (+39) 035 7285400 E-mail [email protected] Web http://www.itemagroup.com

15

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GENERAL

5.1

REFERENCES

USER AND MAINTENANCE MANUAL M ANUAL

The terms listed below are used in this manual to describe descr ibe the positions with reference to the machine: m achine: Weaver ’s side Beam side Left (LH) Right (RH)

= the front of the machine = the back of the machine. = the side of the creel and the shedding machine. = the opposite side.

Narrow looms = looms with nominal width equal to or under 2300 mm. Wide looms = looms with nominal width equal to or over 2600 mm.

16

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General information


The following terms are used in this manual to indicate the different types of supply for certain accessories: Accessory = material or equipment supplied on request (on payment). Standard supply = material or equipment supplied with each machine (free). “One-off ” supply

5.2

= material or equipment that can be purchased separately; at least one supply is required.

OPERATOR’S POSITION

The machine normally operates automatically and does not require the presence of the operator. With the machine in automatic mode, the operator can control the machine from the control panel on the Console. It is not possible to establish a fixed position, as the adjustm ents, start-up operations, slow motion movements and thread repairs can be carried out in different areas of the machine.

5.3

MANUFACTURER’S NAME PL A ATE TE

The name plate is located on the main frame (right-hand side) and shows the machine identification details.

17

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General information


5.4

ELECTRI ELEC TRICAL CAL DA DAT TA PLA PLATE TE

5.5

DISCLAIMER

The Manufacturer reserves the right to modify the machine to meet any manufacturing or commercial requirements, without the obligation to update the instruction instr uction manuals and the spare par ts catalogue immediately. immediately.

18

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Machine safety


SAFETY AND ACCIDENT PREVENTION RULES

19

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Machine safety

20


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Machine safety


If there is a possible danger, the symbol is used to draw the user ’s attention to the safety instructions in this manual: In addition to the standards listed below, the person in charge of the machine must observe the current health and safety at work regulations. Always comply with safety regulations and instructions given in this manual. ITEMA declines any responsibility arising from misuse of the machine. Maintenance, repairs, etc. must be carried out by SKILLED PERSONNEL. Otherwise apply to the “ITEMA After -Sales Ser vice”. RESERVATIONS: “ITEMA” does not guarantee repairs and declines any responsibility for consequent damage if the repairs have not been carried out by its own personnel

1.

DECLARATION OF CONFORMITY AND CE MARKING

Only A9500 machines that bear the marking on their identification plates fully comply with the general safety requirements provided for by DIRECTIVE 2006/42/EC. The statement of conformity to this Directive is included in the CD supplied along with the machine. Since the competent authorities may ask to see this document and since the manufacturer cannot issue new original copies, we recommend that this is kept in a safe place. Please note that if the machine should be resold at a later date, the “Statement of Confor mity” must also be provided with the machine.

2.

GENERAL SAFETY RULES

The machine is equipped with the requisite safety devices in conformity with industrial safety legislation for textile equipment. The person in charge of the machine must be familiar with the safety devices installed and their correct use. The person in charge of the machine appoints the operators authorized to handle it and defines and limits the scope of their tasks. Only these operators may handle the machine. In addition, the person in charge of the machine must instruct the operators on the following:

•

general safety and accident prevention rules; specific rules applicable to weaving machines; location of the controls on the machine and their action/effect; location of the “EMERGENCY STOP PUSHBUTTONS” on the machine for prompt action;

•

meaning of the visual warning signals.

• • •

21

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Machine safety


Safety covers or protective devices must be in place, correctly fastened and in perfect working condition during all operations belonging to regular machine performance. If the safety covers are damaged, or are removed for any reason and the protective devices are disconnected or shorted, they must be reset before starting the machine up again.

Visitors must abstain from any contact with the machines and from actuating the controls; their access to the factory premises shall be allowed only if escorted by duly qualified company staff.

3.

SAFETY RULES FOR INSTALLATION

TRANSPORT, UNLOADING AND ASSEMBLY OF THE MACHINE may only be carried out by skilled authorized

personnel. THE SUPPLY VOLTAGE must be in accordance with the machine ratings on the control box. Pay attention to not

reverse the phases. THE ELECTRICAL SUPPLY CONNECTIONS must be made in conformity with prevailing standards.

that all power supply cables are in a good state of repair. The machine must be protected against sudden and accidental movement during setting up and testing. Whenever the machine is to remain idle for extended periods, switch it off and pr ess the emergency stop pushbutton.

4.

SAFETY RULES FOR USE

The operator must carry out only those tasks entrusted to him by his superior and proceed according to the rules described below. ATTENTION DANGER: Never start the machine up if it has been stopped for special operations (adjustments, maintenance, lubrication, etc.).

Before starting work, CHECK for any visible faults on the safety devices, and make sure that the emergency stop pushbuttons work properly. Never start the machine up if any instruments, lights, etc. on the control panel are found to be faulty. MAKE SURE THAT: •

•

•

•

no unauthorised persons are close to the machine; no objects (tools, rags, etc.) are lying on the machine; all doors and safety covers are closed; after starting the machine up, no strange noises are heard; otherwise, stop the machine at once and investigate the reasons.

NEVER WEAR: •

clothes that may catch in moving parts (scarves, headscarves, rings, bracelets, wrist watches, etc.).

22

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Machine safety


DO WEAR:

•

clothes with pockets that fasten down in which to carry the tools; closed shoes with non-slip soles;

•

a cap to cover long hair.

•

ATTENTION DANGER:

Do not disconnect protection and safety devices while the machine is in operation. Keep hands away from moving parts when starting the loom up. Do not carry out any work on the machine while in operation. Keep at a safe distance from any moving parts.

When the machine is working, avoid: touching moving parts; opening or removing safety covers or protective devices; •

•

•

removing excess yarns or fibres; touching the fabric near to the reed, the temples, the weft cutter and the take-up roller;

•

handling and laying tools, objects, detergents or other items on the machine.

•

The machine must be attended by an operator while it is running. At the end of his shift, the operator must inform his successor and his superior of any malfunctions and/or dangerous faults, even if they have not involved stopping the machine.

ATTENTION DANGER: RESIDUAL RISKS. For reasons of technology, some moving parts are not protected. This is particularly so in the case of the reed and the heald frames. We therefore recommend that all operators take special care that they do not come into contact with these parts, even accidentally. Stop the machine before carrying out any work on these parts. ATTENTION DANGER: RESIDUAL RISKS. The machine moves in slow motion after weaving stops and automatic pickfinding cycles: do not approach the moving parts and do not carry out any work on the machine while the lights in the warning strip are flashing (paragraph 7.12).

23

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Machine safety 5.


SAFETY RULES FOR OPERA OPERATOR TOR HEAL HEALTH TH

During normal operation of the machine, some yarns produce dust or microfibres that could pose a threat for the operator ’s health, especially if these yarns have been chemically treated. The user is responsible for assessing the level of harm in order to take the necessary necessar y measures to protect his workers’ health. Generally speaking, the law demands that there be a suitable dust-extraction system to guarantee the safety of the workplace. If this is not by itself enough, individual protection equipm ent should be used (masks, (mask s, gloves, gloves, goggles).

6.

FIRE RISK The weaving room must be designed to allow for the installation of manual fire extinguishers or fixed automatic fire-fighting systems. Make sure that the compressed air supply cut-off valve is in an easily accessible position.

During weaving, most yarns generate flammable dust. B

Various factors determine the t he actual fire risk, including the buildup of dust, excessive excessiv e temperatures, non-conforming electrical or electronic equipment, short-circuits and flammable volatile substances.

A

Proper machine maintenance and cleaning and the presence of an adequate dust-extraction system help minimize the risk of fire. The use of the thermal cutter system (paragraph 22.4, section 3) is only permitted with yarns that are non flammable at the cutting temperature. If case of fire, adopt all a ll means of fire-fighting; in particular, par ticular, IMMEDIATEL IMMEDIATELY: Y: 1.

cut the power supply by flipping the main switch (A) on the control box

2.

to O (figure 1). quickly put out the fire, using the fire-extinguishers available and, at the same time, call other people to come and help.

3.

cut the power supply on the main line by flipping switch (B) upstream

4.

the machine (figure 1). close the compressed air cut-out valve (if present).

Fig. 1

24

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Machine safety 7.


SAFETY RULES FOR MAINTENANCE

All maintenance, repair, lubrication and cleaning operations of the machine must be carried out with the MACHINE AT A STANDSTILL, POWER CUT OFF and PADLOCK ON. Each member of maintenance staff should therefore have his/her own padlock with which lock the main switch.

All repairs shall be carried out by skilled staff headed by the PERSON IN CHARGE, who will hand them the key to the control box and have it returned at the end of the job.

Some checks and adjust ments require that th at the M ACHINE BE MOVED MANUALL MANUALLY Y (follow the instructions given at chapter 9, section 2).

ATTENTIO TTENTION N DANGER: Do not allow unauthorized people to approach the machine.

During repairs, the safety devices must be disconnected only by SKILLED PERSO NNEL who will take all the necessary precautions to avoid personal injury or damage to the machine itself.

7.1

CLEANING OPERA OPERATIONS TIONS

ATTENTION

When cleaning and washing, take care in using aggressive detergents, acids, lyes, etc. Follow the detergent manufacturer s instructions. ’

Use protective clothing (overalls, gloves, goggles, etc.). During cleaning operations, a certain amount of dust will be lifted: use the appropriate individual protection eq uipment. Take special care in the presence of m icro-fibres or yarns that have had harmful chemical treatment.

25

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Machine safety


ATTENTION DANGER: The cooling fan A under the main motor cover B continues turning for as long as the machine is powered up. Cut the electricity supply before removing the main left-hand safety cover.

A

B

Fig. 2 RESIDUAL RISK: If the safety cover needs to be removed during maintenance with the machine still powered up, avoid coming into contact with the cooling fan A.

26

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Machine safety

7.2


SERVICING SERV ICING THE ELECTRIC SYSTEM Servicing of the electric system may only be carried out by SKILLED ELECTRICIANS who are familiar with the electrical characteristics of the machine and with prevailing safety regulations.

In particular: make sure that the main switch A is turned off and then pull out the blocking tab; then lock with a padlock B (figure 1); •

•

•

•

•

make sure that there are no live parts by using a voltmeter; before mounting any equipment, connect it to the yellow-green earth cable. When disassembling, this cable must be the last to be removed; re moved; do not clean the electric components with water or other fluids. ATTENTION DANGER: The power supply cable coming from the main line and the terminals L1, L2 and L3 on the main switch (plus the terminals PE and N - if fitted) are always live (figure 2). The area containing the main switch can only be accessed by removing the panel secured with screws.

A

PE

N

L1 L2 L3

B Fig. 1

Fig. 2

ATTENTION DANGER: If more than one person is involved in servicing, all must be warned before starting up the machine again.

27

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Machine safety

7.3


EXTERNAL POWER SOCKET (available on request) (see fig. 1)

Machines with 380, 400 and 415 V rating supplied by a line with a neutral wire can be fitted on request with a singlephase 220 V socket (A, Figure 1), to be used exclusively for service tools. The max capacity of this socket is 16 A.

ATTENTION DANGER: This socket is fed from above the main switch on the machine, i.e. the external socket is permanently live, regardless of whether or not the machine is powered up. A differential magnetothermal switch (2, Figure 4) next to the machine s main switch protects and ’

cuts the external socket circuit. The nominal capacity of this device is 16A; the differential rating is 30 mA (class A).

B

A

Fig. 1

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Machine safety 8


SAFETY DEVICES

The figures below show where the main safety, control and warning devices are fitted on the machine.

1.1 INTANGIBLE SAFETY BARRIER 1.2 SAFETY TUBE FOR TAKE-UP ROLLER 1.3 WARNING LIGHTS 1.4 PUSHBUTTON PANEL CONTROLS 1.5 MAIN SWITCH 1.6 CONTROL BOX SAFETY DEVICE

1.3

1.7 EMERGENCY STOP PUSHBUTTONS

1.1 1.1

1.3 1.3

1.7

1.4 1.2 1.7 1.4

1.7 Loom H. 2800 - 3600 1.6

1.5

1.4

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Machine safety

8.1


INTANGIBLE SAFETY BARRIER (machines with CE markings) (see figures 1 - 1a - 1b)

This system of protection consists of: - a transmitter A and a receiver B at either side of the machine; - a control device inside the control box This safety device is placed to cover the entire length of the shed. This protection prevents any machine movement when there is an object in the danger zone, as foreseen under current European law.

The machine acts as follows: Every time the machine starts a new cycle, the entire safety system is checked to ensure that it works proper ly. If there are any malfunctions, the machine cannot be star ted up. If the light beam is interrupted at the moment that any movement is requested (fast start, pick- finding or slow motion), this is not possible and a warning message appears on the display while the white emergency light comes on. If the light beam is interru pted during any automatic movement and fast spe ed, the signal is ignored and there is no stop.

ATTENTION

RESIDUAL RISK Any automatic movements in the process of being made are not interrupted. Depending on the machine setup, fast speed startup may be preceded by automatic movements in slow motion (the warning lights flash). If the barrier is interrupted, the command is ignored, but any automatic movements already underway are not stopped.

B

A

Fig. 1

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Machine safety


ATTENTION DANGER: The intangible barrier does not provide any protection during machine operation and automatic movements: comply with the safety regulations (see chapter 4 of this section) and pay attention to the visual warning signals (C). C

Fig. 1a INTANGIBLE SAFETY BARRIER POSITION: Before starting the machine, you need to position the barrier according to fig. 1b.

Fig. 1b ATTENTION DANGER: The position of the photoelectric cells must never be modified, for whatever reason, to avoid affecting the correct operation of the safety device.

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Machine safety


8.2 INTANGIBLE SINGLE-RAY SAFETY BARRIER (PHOTOELECTRIC CELL DEVICE) (optional) (machines without CE markings) (see fig. 1c) The intangible single-ray safety barrier A of the protection photocell in versions without CE markings is optional; it works exactly like the intangible protection barr ier. This safety device is found near the beat-up area and covers the entire length of the shed, especially at thos e points where crushing may occur between the temples and the reed.

A Fig. 1c

8.3

SAFETY TUBE FOR TAKE-UP ROLLER

(see fig. 2) The machine is fitted with a safety tube B that blocks the passage between the fabric pressing roller C and the fabric deviator. This tube turns freely and must be positioned as shown in the figure. ATTENTION DANGER: It is compulsory to work with the safety tube correctly installed.

B C

Fig. 2

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Machine safety

8.4


CONTROL BOX SAFETY DEVICE (see fig. 3 - 4)

The doors used to access the inside of the control box have been fitted with special locks with a key (A) to prevent these from being accidentally opened or opened by unauthorised personnel. CAUTION: When the door is open, the control box is still powered up and so always switch off the power supply at the mains before opening this door.

The control box key must only ever be handed to authorised personnel.

A

A B

Fig. 3

8.5

Fig. 4

MAIN SWITCH (see fig. 4)

The main switch (B), on the side of the control box, is a safety switch that can be moved to one of the following positions: I

-Power switched on: the machine can be started up.

0

-Power switched off: the machine cannot be started up -Power switched off: padlocking position in the OFF position and with the locking tang extracted.

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Machine safety

8.6


EMERGENCY STOP PUSHBUTTONS

(see fig. 5 e 6 ) The emergency stop pushbuttons A are red non-return pushbuttons with a yellow base. When pressed, the machine stops immediately and no further movement is possible. Accertarsi, prima di rimettere in funzione la macchina, di avere risolto il pericolo che si è presentato e per il quale è stato procurato l'arresto della macchina.

Each machine has three emergency stop push buttons, two at the front and one on the main electrical box.

A A

Fig. 5

34

Fig. 6

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Machine safety

8.7


PUSHBUTTON PANEL CONTROLS

8.7.1 SIDE PUSHBUTTON PANEL (see fig. 7)

STOP (black) EMERGENCY (red)

START (green)

FORWARD PICK-

BACKWARD PICK-

FINDING (white)

FINDING (white)

FORWARD SLOW

BACKWARD SLOW

MOTION (grey)

MOTION (grey)

FUNCTION BUTTONS

SELECTOR (white) FORWARD OR BACKWARD

35

Fig. 7

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Machine safety


8.7.2 CENTRAL PUSH BUTTONS (only for machine 2800-3600) (see fig. 8)

Fig. 8

SLOW MOTION

START

(grey)

(green) STOP (black)

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Machine safety

8.8


HOW THE MACHINE WORKS

8.8.1 FAST SPEED

The normal machine mode, during which the weaving takes place, is called FAST SPEED. The startup request is given by pressing the two START buttons at the same time The warning lights flash briefly to indicate that the machine is about to start up (paragraph 8.9). The command is aborted if the photoelectric cell safety barrier is interrupted (paragraph 8.1, 8.2) during the startup request. Depending on the set program, the machine can carry out a few automatic slow motion cycles before starting the machine up in fast speed.

8.8.2 SLOW MOTION (JOGGING) BACKWARD

FORWARD

SLOW

SLOW

MOTION

MOTION

The machine can be moved at a slower speed, in the presence of the operator, in order to make the machine adjustments and positioning. Press the relevant SLOW MOTION button (grey) to start forward movement (paragraph 7.9) and both the two SLOW MOTION buttons at the same time for reverse movement. Movement stops as soon as you release the button(s).

8.8.3 MANUAL FORWARD/BACKWARD PICK-FINDING FORWARD

BACKWARD

PICK -

PICK -

FINDING

FINDING

The shedding machine makes a complete turn in slow motion and the loom stops when you press the FORWARD PICK-FINDING button or the BACKWARD PICK-FINDING button.

8.8.4 LIGHT SIGNAL OF STARTING MOVEMENT

The red lamp flashes concurrently with the side lamps ( Parag. 8.10.2)

8.8.5 FUNCTIONS BUTTONS (F1 - F2)

Please refer to the Console Manual for the supplementary functions F1 and F2.

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Machine safety


8.8.6 AUTOMATIC BACKWARD REPOSITIONING AND PICK-FINDING Depending on the set program, the machine can carry out a few automatic slow positioning and pick-finding cycles of the shedding machine, both after giving the command for a normal stop and before starting the machine up in fast speed. ATTENTION DANGER: Once the automatic movements have started, the photoelectric cell safety barrier is disabled and movement is no longer interrupted by this barrier. During the operating modes indicated in paragraphs 8.8.1, 8.8.2 e 8.8.3, the warning lights flash to indicate that the machine is moving (paragraph 7.12.). Only when the warning lights stop flashing has the machine finished all automatic movements and returned to a safe condition.

Never approach the moving parts and especially do no t attempt to repair warp t hreads or recover weft threads until the lights stop flashing. Observe the appropriate safety rules.

8.9

TYPES OF MACHINE STOP

8.9.1 NORMAL STOP A normal stop consists of the procedure that stops the machine when running at fast speed and restores the conditions for the next start-up. A normal stop is provoked by using the black STOP button (paragraph 7.9), as well as other causes such as weaving problems and the set program. When the machine receives a request for a normal stop, it completes the current cycle in fast speed and can, depending on how it has been programmed, follow with one or more automatic repositioning and pick-finding cycles (paragraph 7.10.4). The STOP button does not stop automatic movements ATTENTION DANGER: If the warning lights flash (paragraph 7.12), it means that the machine is carrying out an automatic cycle. Never approach the moving parts and especially do not attempt to repair warp threads or recover weft threads until the lights stop flashing. Observe the appropriate safety rules.

8.9.2 EMERGENCY STOP When you press one of the red emergency stop pushbuttons (paragraph 7.8), you provoke an emergency stop causing the machine to stop as soon as possible thanks to the main brake. At the same time, all the motors are cut to prevent any further movement. The emergency stop pushbuttons must be released and the start-up procedure followed in order to star t the machine up again. An emergency stop can also be commanded automatically by the onboard control system if there is a malfunction that may compromise the safety of the operator or the machine. Always check for error messages and only start the machine up again once you have removed the cause.

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Machine safety


8.10 WARNING LIGHTS The purpose of the warning lights is the remote signalling of a machine status which requires action or attention.

8.10.1 MAIN LAMP (see fig. 9) The main lamp, mounted on the control box, has the following multicolored divisions for warning functions: (15) BLU

15

(16) ORANGE

A+B+C+D (ALL LAMPS) 16 17

(17) WHITE (18) GREEN

18

FLASHING call technical service

Fig. 9

B (ORANGE)

A (BLU)

Broken weft stop

A+C (BLU - WHITE)

Display message

A B C D

A B C D

A B C

A Broken warp stop

B C D

C (WHITE)

A B Loom stop:set production reached C

D

D

B+C (WHITE +ORANGE)

A+B+D (BLU - ORANGE - WHITE)

A Set production reached without any B C loom stop D

stop alarm or loom not powered up

39

A B C D

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Machine safety


A+B (BLU - ORANGE)

D (GREEN)

A stops due to end spool

B C D

on during device testing

A B C D

You can invert the colours at will by dismantling the lamp and changing the position of the colours. You cannot, however, change the associated positions for the warnings. Example: The weft stop is always rappresented by the lamp A, indipendently from the choosen colour.

8.10. 2

SIDE LAMPS (see fig. 10)

The ORANGE lamps A are placed on the either end of the upper cross bar. These flash both when the loom starts up in fast speed and when movements are made in slow motion. The flashing lamps warn that the machine is starting up, that the machine is currently carrying out a pick-finding cycle, other automatic movements or running in slow motion (paragraphs 7.10). As the lamps form part of the safety system and so are checked before each loom start-up: the machine will not start if there is a problem with the lamps ATTENTION DANGER: Never approach any moving parts until the warning lights stop flashing and observe all appropriate safety rules.

A

Fig. 10

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Machine safety 9


SAFETY CHECKS

AFTER ANY MAINTENANCE AND REPAIR WORK

Before returning the machine to operation, the plant manager must check that all repairs have been completed, that all safety devices are working properly and that all personnel not directly involved in running the machine are nowhere near the machine. MONTHLY INSPECTION

Make sure that the electrical connection sheaths show no signs of damage. SIX-MONTHLY INSPECTION

Inspect all the safety devices. YEARLY INSPECTION

The machine must be subjected to yearly inspection by SKILLED PERSONNEL to make sure that all safety devices are running smoothly and that the different parts of the machine are in a good state of repair. We recommend recording these annual checks, also in the light of any local laws concerning the employer ’s obligations in terms of health and safety at work (workplace and plant).

10

NOISE EXPOSURE RULES

This weaving machine produces more than 85 dB(A) acoustic pressure in the area where the operator works. For this reason, the department head must ensure that all legal requirements are met and especially: For this reason, the department head must ensure that all legal requirements are met and especially: - supply staff with the required protective gear; - inform staff on the safety regulations and on the risks which arise if all necessary precautions are not followed; - carry out regular checks on the hearing of his personnel and check for side-effects caused by excessive noise levels (many countries have obligatory hearing tests at set intervals); - place suitable signs in the workplace reminding the operators of the need to wear personal safety devices in the weaving rooms.

Some thought should also be given to the possibility of m oving away from the noisiest areas any operators who might as well carry out their work in a soundproof environment and those whose health proves to have been impaired after medical tests.

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Machine safety


10.1 INFORMATION ON THE EFFECTS OF LOUD NOISE ON THE HEARING Exposure to noise may cause: - inconvenience (if temporary) or damage (if permanent) to hearing; - physiological damage or inconvenience (to the blood circulation, respiratory, digestive or nervous systems); - psychological damage or upset (difficult to evaluate, in so far as linked to the subject ’s personal experience); - lack of attention and dedication to the job, difficulty in perceiving sound communication.

10.1.1 EFFECTS ON HEARING The effects on hearing are the best known and most commonly happen in the workplace. Damage from noise pollution has its own peculiar features: - it increases with the time of exposure, but not proportionally; - it affects subjects with low resistance, children and the elder ly to the greatest extent, but neither constantly nor according to a given ratio; - it is most disturbing if it interferes with a person ’s sleep and rest. Note that extended exposure to noise does not lead to the body becoming accustomed to this input, unlike other forms of sensorial stimulation. Recovery generally takes longer than the period of exposure to the noise. It should be stressed that, even if a person does not complain of any disturbance or feels only slightly affected by noise pollution, this does not mean that his body has become accustomed or im mune to this.

In order to assess the amount of damage to hearing, the total amount of energy absorbed by the individual within a unit of time needs to be established, expressed in terms of “continuous equivalent noise level”. Account must also be taken of such factors as impulsiveness, tone and so on. In brief, the main factors that cause damage to hearing are: - the level of sound pressure; - the time of exposure; - the spectral composition of the noise.

42

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Machine safety


10.2 NOISE EMISSIONS OF THE MACHINE 10.2.1 EXPLANATION OF THE MEASUREMENTS GIVEN Equivalent sound pressure level (LAeq)

This is the index of the sound perceived by the human ear. It depends on the distance from the detection source to the sound source. Sound power level (LWA)

This is a given characteristic of the machine in certain operating conditions, and the basis on which the sound intensity level on the environment where the machine is installed can be calculated (of particular sound characteristics). Decibels (A) (dB (A))

The decibel scale is a measurement scale that is normally used to indicate noise levels and is non-dimensional. The human ear is sensitive in different ways to the various frequencies. The weighting curves (A,B,C), with which different weights are attributed to the levels of noise corresponding to different frequencies, have been standardized. The DIRECTIVE 2006/42/EC requires the weighting curve A, and the values are shown in dB (A). Peak sound pressure level (LPC)

This is the maximum instantaneous level of sound pressure. Regulations of the DIRECTIVE 2006/42/EC require that this value is given according to scale C only if it is greater than 135 dB. The peak sound pressure level (LPC) are less than 135 dB.

10.2.2 ACOUSTIC MEASUREMENT Noise level measurements have been carried out on several machines with different technical characteristics and while weaving different styles. Two significant findings are set out below, with a graph from which the mean sound pressure level referred to machines with different characteristics can be quickly extrapolated. The charts are only indicative, in so far as sound pressure levels are affected by a number of different factors, such as: the construction characteristics of the weaving room, the floor p lan of the machines, etc.

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Machine safety


Please consult ITEMA for special requirements. Model .......................................... A9500 Width .......................................... 1900 Shedding machine .................... STÄUBLI DOBBY Type ............................................ cloth (graph A) No. of frames ............................. 10 Warp ........................................... Micrell Dtex Polyester 83 - 41.8 threads/cm Weft ............................................ Micrell Dtex Texturized Polyester 83 - 41.8 threads/cm Weave ......................................... Figured Speed ......................................... 725 picks/min Sound pressure level ==> LAeq = 94.1 dB(A) Sound intensity levels ==> LWA = 112.8 dB(A) Uncertainty of the measurement Uncertainty of the measurement

==> ± 4 dB(A) ==> ± 4 dB(A)

Model ............................................ A9500 Width ............................................ 1900 Shedding machine ...................... tappet motion Type .............................................. down-proof (graph B) No. of frames ............................... 4 Warp .............................................Worsted cotton Ne 40/1 - 48 threads/cm Weft ..............................................Worsted cotton Ne 40/1 - 43.3 wefts/cm Weave ........................................... Plain Speed ........................................... 920 picks/min Sound pressure level : ==> LAeq = 93.1 dB(A) Sound intensity levels : ==> LWA = 108.8 dB(A)

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Machine safety 11


HOW TO REDUCE VIBRATIONS

The alternating movement typical of the machines produces a spectrum of vibrations that is transmitted by the feet to the structure. This spectrum depends on various factors (speed, weave, style, etc.).

11.1 SHOCK ABSORBERS One way to reduce the number of vibrations transmitted is to place shock absorbers between the floor and the machine. Contact ITEMA directly or the local dealer for further details.

11.2

FLOATING FLOORS

If the loom is to be installed in a new building or one that has undergone substantial renovation, we recommend using “floating” floors, i.e. floors that do not come into direct contact with the other building structures (foundations or walls) but rest on an insulating material (figure 1). The total surface of the floor can be subdivided into smaller sections to reduce vibrations further. Contact ITEMA directly or the local dealer for further details.

Shock absorbing material Reinforced concrete floor 0 0 4

0 5 5

0 2 1

Reinforced concrete basin

Fig. 1

12

DECOMMISSIONING AND SCRAPPING

During maintenance the replaced parts must be disposed of in accordance with current laws. This is especially true of lubricants, plastics and electrical and electronic components. Always comply with the safety rules when scrapping these parts. Components must be disposed of in accordance with current laws. This is especially true of lubricants, plastics and electrical and electronic components. 45

29 - 02 - 2012

Machine safety 13


Facsimile of the CE conformità declaration.

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SECTION 1 GENERAL LAYOUT AND TECHNICAL CHARACTERISTICS

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48

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General layout and technical characteristics USER AND MAINTENANCE MANUAL 1

GENERAL LAYOUT

The machine’s main components are listed and illustrated below. The terms used to identify the different components should be used for all written and verbal communications. These terms have been used throughout the MANUAL for an easier understanding of the matters dealt with (in particular when requesting service). We would therefore invite operators to learn and use these ter ms correctly.

1.1

LIST OF THE MACHINE’S MAIN COMPONENTS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Upper cross bar Breast Motor Main Control box Intangible safety barrier Microprocessor display keyboard Spool creel Cloth roller Heald frames False selvedge and waste collection bin Regolatore di densità di trama Reed Warning lamps Pushbutton panel Take-up roller

4

13

7

1

9

12

15

13

5

14

11 2

14 3

49

6

8

29 - 02 - 2012

10

General layout and technical characteristics USER AND MAINTENANCE MANUAL 16 17 18 19 20

Lateral heald guide Warp beam Central heald guide Warp let-off Main switch

16

19

50

18

20

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TECHNICAL FEATURES

2.1

MACHINE TYPE

Air-jet weaving machine to produce a wide range of fabrics made from natural, synthetic or artificial fibres.

2.2

MACHINE VERSIONS

The machine is produced in different versions depending on the nominal width, the shedding machine type and the beam type. All machines are equipped with electronic take-up roller and warp let-off controlled by a microprocessor (for further information, refer to the “console user manual”). The weft density for the standard versions is 10 to 150 picks/cm.

2.2.1 NOMINAL WIDTHS The nominal widths being produced are (in mm): 1900 - 2100 - 2300 - 2600 – 2800 - 3400 - 3600

The maximum reed width is the same as the machine's nominal width. The reed width reduction is 800 mm and is only executed on the right-hand side, with the exception of machines with twin beams and Jacquard machines where the reduction of the fabric is 400 mm per part.

2.2.2 MOTOR DRIVES high torque brushless motor with electronic converter.

2.2.3 SHEDDING MACHINES The shedding machine is manufactured in the following versions: 1) tappet motion, to control up to 11 frames, with or without the device for levelling the frames at loom stop; 2) dobby to control up to 16 frames; All shedding machines are equipped with automatic pick finding, synchronized with all mechanisms and programmable via the console microprocessor. When the machine stops due to warp or weft breakage, it is automatically brought to the most appropriate position (programmable on the console) to allow the weaver to operate. Afterwards the weaver has only to give the restart command. For looms equipped with dobby or tappet motion, after a warp or weft stop, the automatic heald levelling function on the console can be programmed in order to prevent damaging stretching of the war p threads while the machine is at a standstill, waiting for servicing by the operator.

2.2.4 COLOUR SELECTION The machine may be equipped with weft launch devices (nozzles) to weave with two or four colours.

2.2.5 TYPE OF WARP BEAM The machine is manufactured with different types of warp beam with the flange diameter from 500 to 1100 mm: 1) simple beam; 2) bilateral twin beam for machines with nominal width from 2600 mm to 3600 mm.

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General layout and technical characteristics USER AND MAINTENANCE MANUAL

2.3

OVERALL DIMENSIONS

Points for positioning machines with beam diameter 800; 1000; 1100. All measurements in the following figures are given in millimeters. For the position of the electrical connections, see paragraph 1.3.1.

MACHINES WITH BEAM DIAMETER 800

C B A

LOOM WIDHT

A

B

C

1900

4560

2220

-

2100

4760

2420

-

2200

4860

2520

-

2300

4960

2620

-

2600

5260

2920

1055

2800

5460

3120

1155

3400

6060

3720

1455

3600

6260

3920

1555

52

29 - 02 - 2012

General layout and technical characteristics USER AND MAINTENANCE MANUAL MACHINES WITH BEAM DIAMETER 1000

C B A

LOOM WIDHT

A

B

C

1900

4560

2220

-

2100

4760

2420

-

2200

4860

2520

-

2300

4960

2620

-

2600

5260

2920

1055

2800

5460

3120

1155

3400

6060

3720

1455

3600

6260

3920

1555

53

29 - 02 - 2012

General layout and technical characteristics USER AND MAINTENANCE MANUAL MACHINES WITH BEAM DIAMETER 1100

C B A

LOOM WIDHT

A

B

C

1900

4560

2220

-

2100

4760

2420

-

2200

4860

2520

-

2300

4960

2620

-

2600

5260

2920

1055

2800

5460

3120

1155

3400

6060

3720

1455

3600

6260

3920

1555

54

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2.3.1 POSITION OF ELECTRICAL CONNECTIONS For the electric power feeding is possible to choose one the two points indicated in the image below to insert the cables in the electrical cabinet.

2.3.2 EXAMPLE OF AN INSTALLATION PLAN

A = 2000 mm for machines having a width up to 2300 mm; A = 4000 mm for machines having a width up to 3600 mm.

These dimensions enable the passage of simple beams. When using trolleys for beam transport, the dimensions of the trolleys must also be taken into account. B = 1200 mm for beams with flanges Ø 800 mm;

1400 mm for beams with flanges Ø 1100 mm

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ELECTRICAL FEATURES

The machines are available with many voltages and for networks with frequencies of 50 or 60 Hz, given on the metal plate attached to the electric switchboard.

3.1

INSTALLED ELECTRICAL POWER

The machines are available with HI DRIVE brushless motor. The following apparent power data (KVA) are given for electrical sizing of the machine power supply. Main motor: HI DRIVE motor 9.5 KVA;

•

•

Auxiliary DC supplies (including ETD and EWC1) 2.8KVA

•

External equipment 1.2 KVA.

The installed electrical power of the basic machine is 13.5 KVA for machine with dobby, equipped with HI DRIVE motor. The options available result in an increase in power of the basic machine: •

second let-off (EWC) with standard motor 0.3 KVA;

•

standard aspirator 0.87 KVA;

•

high-powered aspirator 1.35 KVA;

•

thermal cutter 0.2 KVA.

The machine can be directly connected to the mains with the nominal voltages: 380/400/415/440 V (-15%,+10%) 50/60 Hz. For other voltage values, an adaptor autotransformer should be placed between the mains and the machine, which will bring the power voltage of the machine to 400 V (the machine will have a rating of 400 V).

3.2

POWER INPUT

The power input - and therefore the machine ’s power consumption during operation - depends on the following parameters: machine speed; lubrication system oil temperature; weaving width; shedding machine; style type. In general you can consider values from 2.5 to 5.5 KW .

3.3

POWER FACTOR

The power factor is variable according to the load and speed of the machine. We recommend to use a power factor of 0.67 as a reference for machines equipped with HI-DRIVE, due to the high harmonic content of the current absorbed by the converter. The total harmonic distorsion THD of the absorbed current of the HI DRIVE machine is in the order of 70-75%.

3.4

INRUSH CURRENT

When the machine is started in continuous speed, the current absorption is in the order of 180 A. The duration of this peak depends on the running speed of the machine. Generally, the peak lasts approximately 130 mS with a machine speed of 900 picks/min. During start-up, the power voltage of the machine must not go below a certain limit (-15% of the nominal voltage). The power supply line must therefore be sized taking into account, not only the current carrying capacity, but also the maximum drop in voltage allowed (in turn, dependent on the loadless mains voltage), with a current of 180 A. Purely as an indication, the following table shows the maximum length of power supply cable in relation to the crosssection and the loadless mains voltage

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Sect. [mm2] \ mains V [V]

380

400

415

440

6

39

43

47

51

10

65

71

78

84

16

102

111

121

131

25

153

168

183

198

35

208

228

248

269

50

282

309

337

364

70

371

408

444

480

95

469

515

561

607

Maximum length of copper conductors [m] The table has been determined supposing that: • the power factor of the load is 0.65; • the impedence of the mains and substation t ransformer = 0.13 Ohm; • copper conductors; • three-pole cable.

3.4.1 PROTECTIONS Take the following points into consideration when sizing the main protections. When the machine is started from "cold", the absorbed current is considerably higher than the nominal "hot" absorbed current, and decreases until the nominal value is reached in about 2-3 hours. For example, a machine with width 1900, started from "cold", at 900 picks a minute, absorbs approximately 23-25 A (indicative value that depends on the style, on the shedding machine, etc.). In this case, a thermal magnetic circuit breaker must be installed with a nominal ther mal current of 32 A (if necessar y, adjusted to a lower value, for example 27 A). Due to the differential absorption of the current caused by the anti-noise filters of the main drive or inverter, the differential protection must be delayed with sensitivity greater of equal to 500. The differential protections must be class "B" (in accordance with standard EN50178). If not, the residual current circuit breaker could trip unnecessarily when the machine is started up or running.

3.5

AUXILIARY SOCKETS

On the switchboard there is the socket P1 to be used only for connecting the weft prewinder. The voltage at socket P1 is the same as the line supply.

P3

Socket P2 is to be used for connecting the signals of the prewinders. Socket P3 is fitted only when the machine is equipped on request

P2

P4

with a “KNOT FEELING DEVICE” function.Socket P4, monophase at 220 V is available only on request. Socket P5 to be used only for connecting the multifunction device (stroboscope).

57

P1 P5

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PNEUMATIC FEATURES

4.1

AIR MEASUREMENT UNIT

Pressure

The most common measurement unit is the bar (kg/cm2 is rarer). The British system uses psi (pounds/square inch).

searched in

n i n e v i g

bar Kg/cm2 psi

bar

Kg/cm2

psi

1

1,02

14,5

0,98

1

14,2

0,069

0,07

1

Air flow

The measurement unit normally used is m3/h (cubic metres per hour) or l/s (litres per second). The prefix N (Normal) is often used in front of the measurement unit (e.g. Nm3/h). It indicates that the data refers to the environment pressure.

The British system uses cfm (cubic feet per minutes).

searched in m3 /h n i n e v i g

4.2

m3 /h l/s cfm

l/s

cfm

1

0,277

1,698

3,6

1

2,118

0,589

0,472

1

AIR FEATURES

- Air pressure at system entrance recommended: 7 bar. - Air dew point at 7 bar : 2°C. - Dew point at atmospheric pressure: -25°C. - Maximum oil content in air : 1 mg/m3. - Maximum particle size and concentration: 5 mg/m3.

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4.3

AIR CONSUMPTION

The compressed air requirement depends on a number of factors: - insertion speed (loom speed [rpm] x weaving width [m]); - loom speed; - yarn count; - yarn type; - yarn quality.

The formula to calculate (approximately) the compressed air requirement is: Ac = (speed) x (reed w.) x (K) in which factor K is given by the table:

Yarn

Count

K

O.E. cotton

Ne 5 - Ne 10

0,053 - 0,043

O.E. cotton.

Ne 10 - Ne 30

0,043 - 0,035

carded cotton

Ne 12 - Ne 30

0,040 - 0,032

worsted cotton

Ne 30 - Ne 100

0,036 - 0,025

synthetic filament fibres

Den 20 - Den 100

0,050 - 0,040


Den 100 - Den 500

0,040 - 0,050


Den 500 - Den 1000

0,050 - 0,060

artificial fibres

Den 30 - Den 400

0,032 - 0,040

highly twisted yarns

Den 70 - Den 300

0,050 - 0,053

wool

Nm 60 - Nm 30

0,032 - 0,038

EXAMPLES: Fabric

Weft

Reed width

Speed

Air consumption

m

Rpm

Nm3 /h

Denim

O.E. Cotton Ne 6

1,70

950

83

House textile

O.E. Cotton Ne 30

3,15

700

90

Shirts

O.E. Cotton Ne 40

1,65

850

40

Shirts

O.E. Cotton Ne 50

1,70

900

53

Clothing

O.E. Cotton Ne 95

1,70

950

55

Clothing

Carded cotton Ne 24

1,60

950

54

Clothing

Dtex 84 Viscose

1,62

950

59

PES 1000 Den

1,70

700

76

PES 167/36

1,70

1000

67

Nm 48/1 wool

1,70

700

40

NOTE for a correct understanding

The higher values refer to higher speeds and/or higher yarn counts. Generally, fluffier yarns require less air (the air “holds on” better to the weft). 10 Nm3/hour means 1 kW of installed compressor.

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4.4

MACHINE AIR SYSTEM

15 13 12 14 11

8

7

16 10

17

9 5 4 6 19

3

2

18 Fig. 1

1

Loom air system legend (figure 1) 1 Air inlet 2 Filter 3 Main air adjustment and distribution unit 4 First chamber fitted in the loom cross-member to feed auxiliary nozzles 5 Second chamber fitted in the loom cross-member to feed auxiliary nozzles 6 Unit of four auxiliary nozzles with solenoid valve 7 Chamber to feed pre-nozzle and nozzle unit 8 Air adjustment and distribution unit for nozzles 9 Air adjustment and distribution unit for pre-nozzles 10 Pre-nozzles 11 Nozzles 12 Chamber for straightener nozzle 13 Straightener nozzle 14 Straightener nozzle solenoid valve 15 Right-hand FAR 16 Right-hand FAR solenoid valve 17 Left-hand FAR 18 Left-hand FAR solenoid valve 19 Prewinders

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A9500 User and Maintenance Manual ENG_120710009

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