A9500 User and Maintenance Manual ENG_120710009

Air Jet weaving machine

Cod. 120710009 02-2012 USE AND MAINTENANCE MANUAL Translation of the srcinal instructions

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

Administrative and Legal Office

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

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

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

All rights to graphics and text in this manual are owned by ITEMA S.p.A. No part may be reproduced 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

4.1

REQUEST FOR 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

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

GENERAL LAYOUT

1.1

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

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

4.5.3 DRYER 4.5.4 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 1.2.2 1.3 1.4

REDUCTION FROM THE RIGHT-HAND SIDE SYMMETRICAL REDUCTION FROM BOTH SIDES THE CLOTH ROLLER BEAMS 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

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

2.2 2.3 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

SELVEDGES LENO DEVICE SELVEDGES TUCKED-IN SELVEDGES WASTE SELVEDGES

4.2.1 WASTE SELVEDGES FEED

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

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

8.4

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

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

1.5

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 original” spare parts. The use of non srcinal 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 problems 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


The terms listed below are used in this manual to describe the positions with reference to the machine: 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 adjustments, start-up operations, slow motion movements and thread repairs can be carried out in different areas of the machine.

5.3

MANUFACTURER’S NAME PLATE

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

ELECTRICAL DATA PLATE

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 manuals and the spare par ts catalogue 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 srcinal 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 Conformity” 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 MACHINEmay only be carried out by skilled authorized

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

reverse the phases. THE ELECTRICAL S UPPLY 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 press 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 OPERATOR HEALTH

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 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 equipment should be used (masks, 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 actual fire risk, including the buildup of dust, excessive 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 means of fire-fighting; in particular, IMMEDIATELY: 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.

4.

cut the power supply on the main line by flipping switch (B) upstream 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 th at the M ACHINE BE MOVED MANUALLY (follow the instructions given at chapter 9, section 2).

ATTENTION DANGER: Do not allow unauthorized people to approach the machine.

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

7.1

CLEANING OPERATIONS

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 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 isturned off and then pull out the blocking tab; then lockwith 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; 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 16 A; the differential rating is 30 mA (class A).

B

A

Fig. 1

28

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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 1.3

1.6 CONTROL BOX SAFETY DEVICE 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 properly. If there are any malfunctions, the machine cannot be started 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 barrier. This safety device is found near the beat-up area and covers the entire length of the shed, especially at those 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 (grey)

START STOP (black)

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(green)

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 start 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

B+C (W HITE +ORANGE)

A Set production reached without any B C loom stop D

39

D

A+B+D (BLU - OR ANGE - WHITE)

stop alarm or loom not powered up

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 headmust ensure that all legal requirementsare 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 moving 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 elderly 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.

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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 p ower 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 plan 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

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Machine safety 13


Facsimile of the CE conformità declaration.

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SECTION 1 GENERAL LAYOUT AND TECHNICAL CHARACTERISTICS

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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 terms 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

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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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General layout and technical characteristics


2

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 warp 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 2100

4560 4760

2220 2420

-

2200

4860

2520

-

2300

4960

2620

-

2600

5260

2920

1055

2800

5460

3120

1155

3400

6060

3720

1455

3600

6260

3920

1555

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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 2800

5260 5460

2920 3120

1055 1155

3400

6060

3720

1455

3600

6260

3920

1555

53

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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

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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 Maximum length of copper conductors [m]

561

607

The table has been determined supposing that: • the power factor of the load is 0.65; • the impedence of the mains and substation transformer = 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 thermal 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.

P4 Socket P3 is fitted only when the machine is equipped on request with a “KNOT FEELING DEVICE” function.Socket P4, monophase

P2

at 220 V is available only on request. Socket P5 to be used only for connecting the multifunction device (stroboscope).

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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 Kg/cm

psi

1

1,02

14,5

0,98

1

14,2

0,069

0,07

1

bar in n e iv g

bar 2

Kg/cm psi

2

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 3

in n e v i g

m /h l/s cfm

4.2

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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29 - 02 - 2012


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 PES 167/36

1,70 1,70

700 1000

76 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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4.5


APPROXIMATE LAY-OUT OF AN AIR SYSTEM (figure 2)

r e y r D

r o s s e r p m o C

r e y r D

r o s s e r p m o C

Compressor room

Weaving room

Legend

Fig. 2

( 1 ) compressor ( 2 ) dryer ( 3 ) intake air filter ( 4 ) tank ( 5 ) distribution piping

Please note that it is very important that the system must be installed outside the weaving room for the following reasons: - effect on the factory air conditioning system; - fast clogging of the filters because of the fluff and filaments in the air of the weaving room; - problems arising from the vaporized oil from artificial yarns.

4.5.1 INTAKE AIR FILTER An air filter for stopping dust and particles from 1 to 5 μm is sufficient to guarantee good air quality and should be put as close to the compressor as possible.

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29 - 02 - 2012


4.5.2 COMPRESSOR When choosing the compressor type, a suitable safety margin is necessary to absorb the style and speed variables. The consumption rate of any auxiliary services also needs to be taken into account. In the case of small installations where lubricated compressors have to be used, a series of filters must be fitted in cascade to ensure that the air quality conforms with the values indicated.

4.5.3 DRYER This is for removing any humidity from the air. A well-designed system should not have pressure losses of more than 0.140 bar between the intake and the outlet.

4.5.4 AIR TANK This acts as a pressure accumulator providing the system with air when required, and indicates the air pressure during checks.

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General layout and technical characteristics 5


ADVICE FOR INSTALLING AN AIR CONDITIONING SYSTEM

Many factors influence the capacity to obtain the best results in quality and production of weaving machines; one of the most important of these factors is the condition of the area where the machine is working, whether het thermohygrometric conditions or the amount of dust present. It is therefore extremely important to be able to control and modify the temperature, humidity and dust levels in the weaving room. Modern air conditioning systems are designed to control all of these three parameters and, in particular, the nonoversaturated types give the best results. The arrangement of the ducts and the air outflow and delivery openings is fundamental. This is because if these are arranged carefully, the environmental conditions will be perfectly uniform and air currents can be generated across the machine, taking away heat, bringing humidity and removing any dust that collects. It is not possible to say how many air changes are necessary, as this number results from calculations obtained according to the local conditions of the air before and after it is introduced into the room. It is however important to remember that, particularly when weaving cotton, the number of changes may be conditioned more by the need to remove dust than by the thermohygrometric conditions required. In the following diagram the suggested positioning of the air inlets of the return air that is sent to the plant from the room, is shown. The inlets must be positioned under the loom, but not under the tie-rods of the shedding machine, to allow a good "draught" and an efficient dust rem oval from the loom. The preferred shape is circular because it gives the best ratio between perimeter and surface area, increasing the efficiency of the suction. It is not recommended placing the return openings in corridors. The delivery openings, however, must be distributed with the greatest uniformity. Finally, we would like to suggest that the working of the air conditioning system should be checked regularly, and particularly the condition of the filters, which if blocked can considerably increase the amount of dust in the room.

Recommended position for the air inlets for looms of W. 1900 ÷ 2600

BEAM SIDE 260

C

C

0 5 2

0 0 7

0 0 3

B 400

B

A

A WEAVER SIDE

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NOMINAL WIDTH

A

B

C

1900

1235

500

650

2100

1335

550

700

2300

1435

600

750


5.1

OPTIMAL HUMIDITY AND TEMPERATURE CONDITIONS If the following conditions and values are not adhered to, a loss in performance could result.

64

Fibres

Relative air humidity

Temperature

Cotton

da 75% a 80%

da 22°C a 24°C

Silk

da 65% a 70%

da 22°C a 24°C

Wool

da 60% a 70%

da 22°C a 24°C

Artificial

da 60% a 70%

da 22°C a 24°C

Synthetic

da 60% a 70%

da 22°C a 24°C

Pol./Cotton

da 60% a 70%

da 22°C a 24°C

Pol./Wool

da 60% a 70%

da 22°C a 24°C

Linen

da 80% a 85%

da 22°C a 24°C

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SECTION 2 TRANSPORT AND INSTALLATION

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Trasport and installation 1


PRELIMINARY OPERATIONS BEFORE STARTING UP

The following operations are to be carried out by the customer’s personnel before the arrival of the ITEMA technician. A) Checking the flooring (chapter 2, section 2). B) Transport and positioning of the machine in the weaving room. These operations should be carried out respecting the instructions given in chapter 2 (section 2). C) Installing and levelling (chapter 4) the machine. D) Checking the lubricant levels and topping up the oil for the tappet motion (consult the specific manual). E) Electrical connection to the main power line (chapter 6). F) Pneumatic connection (chapter 9). G) Loadless starting up of the machine. H) Preparation of the style to be produced: - preparation of the beam with warp; - drawing-in of the warp in the healds; - reed threading; - fitting of the warp stop motion detectors. I) Preparation of the large spools with the yarn for the waste selvedge (if the machine is equipped with the special device). L) Preparation of the spools for the leno device. M) Fitting of the creel and of the prewinder supports according to the instructions supplied with the equipment. N) Fitting of the warp beam with the heald frames, starting from the second machine being started up. For the first machine, during the starting stage, this operation is carried out by a ITEMA technician. O) Preparation of the electronic dobby programmes - preparation of the cam pack for weaves for machines with tappet motion. The presence of the following personnel is requested on arrival of the ITEMA technician and they should follow the start up of the loom until completion of the job: 1 weaving assistant, who will always be with the ITEMA technician, to learn all the necessary information. 1 person to handle heavy duties. 1 weaver to mend warp breakages and for waste selvedge threading. It is necessary to make sure that ambient temperature and humidity in the weaving room meet the processing requirements. If these preliminary operations have not been carried out, ITEMA S.p.A. reserves the right to decide, based on the conditions found, whether or not its technician should proceed with the start-up of the machine. If the procedure is postpo ned, any travelling expenses will be charged to the customer.

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Trasport and installation 1.1


SEQUENCE OF OPERATIONS TO START UP

The tables below show the sequence of operations to be carried out to start up. We recommend that the operator photocopies the following tables before start up and uses them as a guide, checking off the operations already carried out. TRANSPORT AND INSTALLATION SEQUENCE

68

OPERATIONS

1°

Carry the machine into the weaving room.

2°

Position the machine in the provided area.

3°

Unpack the machine and take off, if present, the wooden slides for container transport.

4°

Separate the accessories to be mounted on the machine from the spare ones.

5°

Remove any protecting oil from the machine.

6°

Top up oil for shedding machine / check the points to be greased.

7°

Remove the cloth roller from the machine.

8°

Remove the beam cylinder from the machine.

9°

Remove the right-hand leno device (splitz).

10°

Remove the warp stop motion rows from the machine.

11°

Remove the bar for passages of the excess threads from the machine.

12°

Unload the switchboard and take off its supports.

13°

Level the machine.

14°

Carry out the electrical connection.

15°

Carry out the pneumatic connection.

16°

Switch the motor on (check the rotation direction).

17°

Check all the levels of the devices working in oil bath.

18°

Move the machine by hand to check that all the devices move freely.

29°

Check the machine synchronism (encoder).

20°

arry out loadless start up, if necessary.

29 - 02 - 2012

Trasport and installation

USER AND MAINTENANCE MANUAL MECHANICAL ADJUSTMENT FOR START UP

SEQUENCE

69

OPERATIONS

1°

Simulation of the reed width.

2°

Position the cloth support plate.

3°

Position the auxiliary nozzles.

4°

Position the temple support.

5°

Position the left-hand lateral scissors.

6°

Position the launch nozzles and pre-nozzles.

7°

Calibrate the launch nozzles and pre-nozzles.

8°

Adjust the back roller position.

9°

Check the back roller adjustment at + 0 (zero).

10°

Check the lever scale of the shedding machine.

11°

Adjust the height of frame tie-rods (from the 2nd loom).

12°

Remove the central heald guides.

13°

Place the cloth for thread knotting between fabric pressing and winding cylinders.

14°

Load the heald frames and the beam.

15°

Hook the frame connections to the shed movement tie rods.

16°

Position and fasten the threaded reed.

17°

Position the right-hand lateral scissors.

18°

Position the photocell unit (if provided).

19°

Position the straightener nozzle (if provided).

20°

Fasten the photocell cables.

21°

Position the F.A.R. device (if provided).

22°

Position the collection inlet.

23°

Position and time the RIGHT-HAND leno device.

24°

Time the LEFT-HAND leno device.

29 - 02 - 2012


USER AND MAINTENANCE MANUAL LOOM START UP (PNEUMATIC and TEXTILE adjustments)

SEQUENCE

OPERATIONS

1°

Knot the thread bunches to the cloth.

2°

Thread up the leno device binding threads.

3°

Position and fit the temples.

4°

Assemble the creels with their prewinders.

5°

Consult the Prewinder manual.

6°

Set the data for the prewinders from the console.

7°

Adjust the prewinders.

8°

Load the creel with the weft cones.

9°

Program the WEFT TRANSPORT.

10°

Program EWC - ETD.

11°

Program the colour pattern in the console.

12°

Program the weave in the console.

13°

Check the pressure of the threading up and cut blow - check the press. and rate of nozzle and prenoz. continuous blow .

70

14°

Check the pressure of the lateral tuck-in devices.

15°

Check the pressure of the nozzles of the auxiliary nozzles.

16°

Weave approx. 3-4 cm of fabric at slow speed.

17°

Set in order the broken and excess threads.

18°

Position the drop wires if necessary.

19°

Insert the warp stop motion rows in the drop wires.

20°

Adjust the warp stop motion.

29 - 02 - 2012


USER AND MAINTENANCE MANUAL FINAL ADJUSTMENTS AND CHECKS

SEQUENCE

71

OPERATIONS

1°

Final start up of the machine with the style at minimum speed.

2°

Program the weft density in the console (Console manual).

3°

Input the exact picks/cm required in the console.

4°

Adjust the shed closing.

5°

Adjust the weft braking (Prewinder manual).

6°

Increase to production speed.

7°

Check the pressure of the nozzles of the auxiliary nozzles.

8°

Check the pressure of the straightener nozzle.

9°

Check weft start and arrival times in the console.

10°

Adjust the weft stretching gripper.

11°

Adjust the lateral tuck-in devices.

12°

Adjust the F.A.R. device (if provided).

13°

Check the fabric quality.

14°

Carry out the final operation check of the machine.

15°

Check that all bolts and screws are correctly tightened.

16°

Check that all parts are correctly greased and lubricated.

17°

Fill in the adjustment sheet (see the last pages of this manual).

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PREPARATION OF THE FLOORING

Owing to the alternating movements of large masses in quick motion, weaving machines cause the transmission to the floor, through their bearing surfaces, of considerable dynamic forces, in addition to the static forces due to the dead weight of the machine and of the fabric and warp beams. The tables below list the indicative maximum static and dynamic loads. The total load for the purpose of structural calculations must therefore take into account, on each single machine, the static load due to the weight of the machine “P”, the vertical dynamic loads “F” acting on each bearing foot, the total horizontal dynamic load “FC” in the direction of the movement of the sley, the vertical dynamic load generated by the movement of the heald frames “FL” and the not negligible weight of the warp be am and of the fabric .

F

P4

F1L FC F

P3 Fig. 1

F P2 Check the plate on the loom to F

FC

know the static load.

P1

The load due to the weight of the beam and of the fabric is calculated on the basis of the type of yarn, of the diameter of the beam, of the fabric and of the diameter of the cloth roller. The total static load due to the machine weight P (measured in Newton) corresponds to the value given on the machine plate (see. Sec.2 par.3.2) times 9.81. The portion of total static laod for each foot can be calculated according to the following table. Static load for each foot (N)

72

P1

P2

P3

P4

P total

0.36 x P

0.24 x P

0.24 x P

0.16 x P

Machine mass (kg) x 9.81

29 - 02 - 2012



The strength of dynamic forces depends on the machine nominal width and on its working speed and can be determined on the basis of the following tables: Max dynamic laod (N) Total horizontal

Vertical dynamic load for

Dynamic load for

dynamic load

each foot

one heald frame

FC

F

F1L

1900

1.9 x V2 / 1000

2.3 x V2 / 1000

1500

2100

3.0 x V2 / 1000

2.8 x V2 / 1000

1500

2300 2600

4.0 x V2 / 1000 7.2 x V2 / 1000

3.3 x V2 / 1000 5.2 x V2 / 1000

1500 1500

2800

8.5 x V2 / 1000

5.8 x V2 / 1000

1500

Nominal width

2

3400

12.5 x V / 1000

7.7 x V2 / 1000

1500

3600

13.9 x V2 / 1000

8.4 x V2 / 1000

1500

V = machine speed in RPM With regard to these tables, the following remarks should be considered: - force values are given in Newtons (N); (1 N = 0.1 kg. approx.); - maximum load of each foot on the floor is obtained by adding the relevant dynamic load and static load, i.e. P1 + F, P2 + F, P3 + F, P4 + F;

- the values are approximate since they can vary according to the shedding machine and machine preparation; - the weight of the yarn and that of the beam are not taken into account. Therefore they must be added and considered as a uniform weight on the back feet; - the heald frame’s dynamic loads (F1L) do not depend on the warp yarn. The force generated by a heald frame being raised is balanced by that of a heald frame being lowered. Their composition therefore depends on the type of weave. Example Machine with nominal width 1900 mm, with dobby operating at a speed of 900 picks per min. FC

= 1.9 x 9002/1000 = 1540 N

F

= 2.3 x 9002/1000 = 1860 N

P total = 9.81 x 3500 kg

= 34335 N (3500 kg = value on the machine plate)

The maximum load on foot 1 is therefore: P1 = 0.36 x 34335 = 12360 N The maximum load on foot 1 is therefore: P max = P1 + F = 12360 + 1860 = 14220 N

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With regard to the characteristics of the floor on which the machines are installed, follow the indication in the paragraph 2.1 and 2.2.

2.1

FLOOR PAVING

Place a layer of about 40 cm of dry compressed coarse aggregate and a 20 cm thick layer of concrete class 250 supplied (lower and upper sides) with two electrically welded nets or similar connections.

When building a new facility or carrying out restructuring work, it is advisable to lay “floating” floors, built in such a way that the floor is not directly in touch with the other elements of the building (see paragraph 9.2, Safety and Accident Prevention Regulations Section).

2.2

SLAB FLOOR

The slab must be able to withstand min.10000 N/m2. Resonance may occur and must be taken into consideration along with the vibrations which are always present. Consequently, after establishing the position of the machines, an inspection should be carried out with a survey by authorized technicians.

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HOISTING AND TRANSPORT

ATTENTION:DANGER! THE DESCRIBED PROCEDURE MUST BE FOLLOWED CAREFULLY. Non-observance of these instructions may cause the machine to tilt. Transport and hoisting of the machine should be carried out only by means of the auxiliary equipment indicated. Reference should be made to the machine ’s total weight shown in the previous tables.

ATTENTION

3.1

In order to prevent the dangerous formation of condensate, before its installation in the weaving room, the machine must be acclimatized by leaving it in an adjacent room, which reduces the temperature and the humidity variations.

UNLOADING THE MACHINE FROM ITS CONTAINER (figure 1 - 2 - 3 - 4)

1) Attach the metal cable C, that has an ultimate tensile strength of 6.000 Kg. and a max. hanging load of 2.000 Kg., to hook A found on the iron plate connecting the wooden side members D. 2) Attach the cable C to fork lifttruck E, that has a minimum carrying load of 7.000 Kg. and a minimum lifting fork length of 1.700 mm. 3) Pull the machine with the fork lifttruck E until a maximum of a 1/4 of its total length is sticking out (figure 1).

A G C D

E

H

Fig.1

B

D

E

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29 - 02 - 2012

F

Fig. 2



4) Shorten the metal cable C and position the forks of forklift truck E under the side members D (figure 2). 5) Reverse slowly with forklift truck E until the reference marks B on the side members are visible (figure 3). 6) Using a second forklift truck, with the same characteristics as the first, position the forks in correspondence to the reference marks B on the side members D and place the two wooden beams G (size 500x75x75 supplied in each container), onto the forks of fork lifttruck F, so that they are positioned between, but not touching, the two side members D (figure 3). 7) Lift the forks of forklift truck F until the machine has been raised a few centimetres. 8) Unhook the metal cable C and reverse the first forklift truck E. 9) Move truck H forward until the machine has been completely removed from the container (figure 4). 10) Lower the forks of forklift truck F until the machine is about 10 centimetres from the ground. 11) If the path is clear, move the machine into the acclimatization room. 12) If the path is obstructed or uneven, position the machine on the ground and transport it with the appropriately sized trolley.

D F

B A G Fig. 3

H F E

Fig. 4

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HOISTING FROM ABOVE (bridge crane, crane, etc.) CAUTION: the machine must be hoisted by means of a crane.This operation must be carried out carefully, following the instructions given below and with suitable hoisting equipment taking into account the table of static loads (masses).

The weight of the machine is indicated on the tare plate on the right-hand frame at the back (figure 5) Hoisting is done using chains or cables of the appropriate strength and length, using the four L eyebolts supplied, ensuring that they are fixed in the correct position. Unsure the screws V have been fastened with a torque of 250 Nm. Length of chains or cables must be adjusted in order their slope is more than 40°. After positioning the machine, the eyebolts must be removed and stored for future use. Lift the machine carefully by a few centimetres making sure that all the chains or cables are taut and that the machine does not tilt to one side.

L

V

Fig. 5

ATTENTION DANGER: the machine is heavier on the motor side, so the length of the hoisting chains or cables must be set in such a way that the hoisting hook is perpendicular to the centre of gravity. If the machine starts to tip when being lifted, bring it back down immediately and then adjust the length of the chains or cables properly.

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HOISTING AND TRANSPORT USING TROLLEYS

The machine may be hoisted on a jack and transported on trolleys only on flat surfaces. Do not use lift trucks.

The following equipment is necessary to hoist and transport the machine in the weaving room: - hydraulic jack M with a minimum load capacity of 5000 kg (see figure 6); - four transport trolleys N (figure 8) with a minimum load capacity of 2000 kg each. In this position, the jack lifts both machine feet (front and rear).

M Fig. 6 The figure shows the positioning of the jack that, at each side (left or right), lifts simultaneously the front and rear feet of the machine. WARNING: Do not lift the machine by placing the jack in a different position.

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TRANSPORT WITH TROLLEYS

Place the jack as described at paragraph 3.3. Lift the machine enough to place the trolleys under the feet of the frames, as shown in figure 8, and then lay down the machine on the trolleys. After transport, place the jack as above to remove the trolleys, then lay down the machine by putting the rubber shims and tar paper supplied between the feet and the flooring

N N

Fig. 7

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UNLOADING THE SWITCHBOARD

WARNING DANGER: Maximum attention must be paid and at least two persons must be present in o rder to avoid tilting (the switchboard weighs approx. 250 kg). After positioning the machine on the floor, unscrew the screws attaching the switchboards to the red colour supports A.

B

A

Keep the eyebolts B mounted on the switchboard.

Fig. 1

4.1

UNLOADING THE SWITCHBOARDS BY MEANS OF HOISTING TOOLS

Hoist the switchboards by means of the eyebolts B found on them, using suitable ropes to hoist a minimum load of 500 Kg. Now remove all the switchboard’s supports (coloured red) from the machine and place the switchboard in its working position

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REMOVAL OF THE ANTI-RUST PROTECTION

No more than 24 hours before starting up the machine, the anti-rust protection applied to certain parts of the machine must be partially removed with a cloth soaked in detergent, leaving a thin residual film of product as a permanent protection of the treated areas.

ATTENTION

Carefully read the information shown on the RASOIL PLUS data sheet instructions for use, attached to the loom, before handling the product

The areas to be treated are: Rectified surfaces, before the eyebolts are applied, on the right and left frame (1), support surface of the right frame regulator drive guard (2), support surface of the left frame take-up roller(3), sley shaft (4) and fast shaft (5), right and left joints of sley shaft (6), positive back roller drive shaft end (7), back roller shaft head and right and left mechanism pin (8).

1 1

2 Fig. 1

3 5

6

4

5 6

7-8 7-8

Fig. 2 81

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LEVELLING (figures 1 - 2 - 3 - 4 - 5) For the smooth operation of the machine, the following operations must be carried out carefully. Six months after starting up the machine, the levelling must be checked again

The levelling operations are carried out on an unloaded machine as follows: - lift the feet of the machine following the procedure described in section 2 - chapter 3; - position the felt shims A between the floor and the iron plates B screwed down to the foot of the side frame; - check that levelling is correct by resting a spirit level C on the front machined surface D and on the rear one E of the right and left-hand side frames; - if you need to correct the levelling, loosen all four nuts F (with beam dia 1000, all the screws V) and lift the machine the minimun amount necessary to insert the shims G. The shims G are supplied with the loom

G

F

F

B A

G B A BEAM DIAMETER 1000

82

Fig. 1

29 - 02 - 2012

BEAM DIAMETER 1100



C Fig. 2

E

C D

Fig. 3

ATTENTION

Due to certain characteristics of the floor, self-levelling rubber shims A may be required and must be used in the following way:

- take the four self-levelling rubber shims A and immerse them in a vessel of water for at least 60 minutes; - afterwards remove the protective film from the surface of both rubber shims A; - position the rubber shims A between the floor and the iron plates B screwed down to the foot of the side frame; - now follow the same procedure as that for the felt shims.

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LOOMS WITH BEAMS FITTED WITH 1000 OR 1100 DIAMETER FLANGES

In order to enable the use of beam flanges with such diameter, the loom has been lifted and metal blocks have been placed under its four feet. These components cause the loom to be higher in the rear pa rt. As a result the frames, where the spirit level is to be placed, are no longer horizontal. This inclination can be eliminated by placing a special gauge (L), code ERZ013B, supplied with the loom accessories, between the side frame and the control instrument (C).

C

L

fig. 4 After placing the loom in the correct horizontal position, for wide machine with single beam it is necessary to adjust the central support M (figure 5): •

Loose the 4 screws F and put the central support on the floor

•

Insert the felt shim G and press gently by using the screws H on both sides

•

Fasten the 4 screws F.

F M

H G

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fig. 5



ELECTRICAL CONNECTION Only carry out this operation after checking that there is no voltage on the power supply line. Use only authorized personnel.

ATTENTION: DANGER! Before connecting the switchboard, check that the network voltage corresponds to that given on plate A on the switchboard (figure 1). B The sizing of the supply lines and their safety devices must comply with data shown on the plate of the switchboard; the supply line must consist of a four-pole cable with minimum cross section of each wire of:

A

- 6 mm² for voltages higher or equal to 346 Volts; - 10 mm² for voltages lower than 346 Volts. These minimum cross-sections are valid for connections that are a C

maximum of 10 - 15 metres long. For longer lengths the crosss ections have to be increased in order to avoid a voltage drop during the main motor’s inrush phase.

Fig. 1

Pay attention, in particular to that described in paragraph 2.4 of section 1 Insert the power supply cable in the cable gland B (figure 1) fastening it correctly. For different requirements, the power supply cable can be connected in the lower part of the switchboard using the optional hole C. The power supply cable is introduced into a permanently live area, in which the phases R, S and T are directly connected onto the terminals of the main switch D (fig.3); connection of the neutral wire, if present, can be of three types

PE N R S T N1 D E Fig. 2

85

Fig. 3

29 - 02 - 2012



1) f the external socket E is present, connect the neutral N to

R

the blue terminal.

S

T

PE

2) If an external winder is present, connect the neutral N directly to the main four-pole switch N1 3) If a 220V socket and the winder are present, the neutral wire is connected to the main four pole switch N1. The terminal N is then connected to the switch with the blue terminal Fig. 4 (4) using a wire with a cross section of 2.5 mm2. In all cases there is an electrical protection terminal to which the yellow/green earth wire (5) must be connected:

ATTENTION

ATTENTION

The earth wire (Y/G) can be use as a neutral wire only on type “TN-C” electrical systems in which there is specifically only one “PEN” wire ìsized for the two functions: earth and neutral. In this case, if the neutral is requested for the external socket and/or winder option, the “TN.C” system must be transformed internally into a “TN-S” system for the electric system of the loom, positioning a jumper between terminal PE and N as illustrated in the following diagram. ITEMA will not be deemed responsible for any malfunctioning or d amage to the the loom electronic equipment, if the electrical connection of the loom is provided with a common conductor (PEN conductor) for both netural and electrical protection functions and this conductor is not properly adapted for the two functions

- With 220 V external socket R

S

T

R

N PE

TN-S

TN-C

TN-S

TN-S

- With external winder N R S T

R

PE

TN-S

TN-C

TN-S

TN-S

Fig. 5

86

S

29 - 02 - 2012

PEN

T

S

T

PEN



- With external winder and 220 V socket N

R

S

T

R

PE

TN-S

TN-C

TN-S

TN-S

Fig. 5a

87

29 - 02 - 2012

S

T

PEN



MANUAL MOVEMENT OF THE MACHINE (figure 1 - 2 - 3 )

ATTENTION DANGER: Operation to be carried out with powered swithcboard. Only use authorized personnel. The switchboard must be powered while moving the machine manually in order to prevent the console from losing the encoder position

ATTENTION

when it is powered, the machine ’s parking brake is engaged.

For setting or preparation operations it is possible to manually move the machine as described here below: 1) Stop the machine 2) press the emergency pushbutton A on the switchboard, to disconnect the power section of the electric system; 3) Turn the lock B mounted on the parking brakeC (fig. 2) 180° clockwise in order to access the manual movement shaft; 4) Insert a wrench W10E in the appropriate hole D (fig.3) and turn it until the machine reaches the required position; 5) Once finished remove the wrench W10 and return the lock B to its srcinal position. If the step 5 is not properly followed, the machine cannot be started as the safety micro-switch is not enabled.

C A

B

D

Fig. 2

Fig. 1

Fig. 3

88

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PNEUMATIC CONNECTION (figura 1- 2)

Connect the machine to the main pneumatic system with a rubber hose A, able to withstand a pressure of at least 20 Bars, with an inside diameter of 19 mm (3/4 inches) and an outside diameter ìof 30 or 32 mm (1.18 or 1.26 inches). See detail "A". Tighten the end of the hose with a steel clamp B, suitable for pressure tubes, onto the air connection located at the entrance of the filter. Open the stop valve C to introduce air into the machine's pneumatic system.

B

A

C

Fig. 1

19 mm 3/4 inch.

30 / 32 mm 1,18 / 1,26 inch.

Fig. 2

89

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ENCODER AND GRADUATED DISK (figura 1 - 2 ) ATTENTION DANGER: This operation can be carried out only when the power section is on. The operator must therefore take all due precautions for his own safety and warn away any other people before acting. All adjustment and control operations must be performed with the machine at a standstill and in manual mode, following the instructions given in SECT. 2 paragraph 8

The encoder, whose function is of crucial importance to the machine’s operation, is integrated in the main machine motor. The value given by the encoder must correspond to the real position of the machine as indicated by the graduated disk, mounted on the left-hand side of the machine, whose function is to serve as a reference to be used when testing. In order to synchronize the encoder, proceed as described in the Console Manual, after having manually positioned the machine with the reed in the beat up position dead at center to 0° (zero degrees). Check the graduated disk A is at 0°. If necessary turn the disk, after loosening screw C, until the needle marks the zero degree (to do that is necessary to remove the cover D). At the end move the machine in slow motion for two or three complete turns to verify the correct functioning of the encoder, after having repositioned the cover D.

D

B

A

C

Fig. 1

Fig. 2 90

29 - 02 - 2012

USER AND MAINTENANCE MANUALE

SECTION 3 PREPARATION FOR START UP

91

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92

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Preparation for start up 1

WARP BEAM

1.1

SIMPLE BEAMS


The simple beams for the machine conform to the current ISO-DIN regulations. The twin beams are specific for this machine. The constructive characteristics of the cylinders and the flanges must be adequate for the warp yarns used, paying particular attention if using synthetic yarns. The adjusting lateral flanges must be attached to the beams when mounting them to the machine, as shown in figures 1 and 2.

Eitherway, we do not recommend using be ams with a cylinder diameter less than 219 mm.

1.1.1 DIAGRAM FOR MOUNTING SIMPLE BEAMS CONFORMINGTO ISO-DIN REGULATIONS

STANDARD BEAM VERSION

Right flange with gear and bearing

left flange with bearing

SBM BEAM VERSION

cod. 2552022

cod. QELL008

left flange

right flange

Fig. 1

93

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Preparation for start up 1.2

USER AND MAINTENANCE

POSITIONING OF THE FLANGES On new machines, when flanges are already mounted on the machine on their cylinder, there are no 1 mm shims at screws C. In the case of spare flanges, the 1 mm shims (between flanges E and L and small flange D) must be eliminated when mounting the flanges on their cylinder.

During beam warping, the flanges must be positioned on the beam cylinder whilst referring to the type of weaving width reduction.

1.2.1 REDUCTION FROM THE RIGHT-HAND SIDE The ISO DIN beam for machines from 1900 to 3600 width (figure 3) Position the flange E 183 mm from the edge of the beam cylinder H. It will also remain in this position for future warping operations. Value B gives the possibility for reducing the width and corresponds to a maximum of 800 mm. This is obtained by moving the mobile flange L. Distance A between the two flanges must be equal to the reed width by excluding, if present, the right-hand waste selvedge if this is warped on the independent small beam. Value A may have an additional tolerance of 10 ~ 20 mm.

C

D

E

L

D

C

H

B = MAX 800 mm 183 mm

A Fig. 3

EXAMPLE: reed width (excluding the righ-hand waste selvedge) = 1770 mm. Value A can therefore be between 1780 ~ 1790 mm

The 183 mm value refers only to the beam cylinder without t he side buffers M - N and P shown in figures 9 and 10 of paragraph 1.5 Screws C have a tightening torque of 40 Nm.

1.2.2 SYMMETRICAL REDUCTION FROM BOTH SIDES (figure 4) Position flanges E and L centred on the beam cylinder H. Value B gives the possibility for reducing the width and 94

29 - 02 - 2012

Preparation for start up


corresponds to a maximum of 400 mm. Distance A between the two flanges must be equal to the reed width, excluding, if present, the r ight-hand waste selvedge if this is warped on the independent small beam. Value A may have an additional tolerance of 10 ~ 20 mm.

EXAMPLE: reed width (excluding the right-hand waste selvedge) = 1770 mm. Value A can therefore be between 1780 ~ 1790 mm C

D

L

E

D C

H

A

B = MAX 400mm

B = MAX 400mm

Fig. 4

If the beams supplied are without holes for warp thread anchorage, fasten these threads to the cylinder by means of the adhesive tape or double-sided adhesive tape.

1.3

THE CLOTH ROLLER BEAMS

The cloth roller beams comply with the ISO-DIN regulations (figure 5).

Fig. 5 NOMINAL

95

WIDTH

1900 2100 2300 2600 2800 3400 3600

A

2306 2506 2706 3006 3206 3806 4006

B

2110 2310 2510 2810 3010 3610 3810

29 - 02 - 2012



1.4 SAFETY REGULATIONS FOR TRANSPORTING, LOADING AND UNLOADING BEAMS ATTENTION: DANGER! Use the appropriate trolleys to move the beam The transportation and loading/unloading of the beams (and fabric winding cylinders) must be carried out by trained personnel using the appropriate trolleys built for this purpose by specialized manufacturers. The type of trolley depends on the type of machine and the production cycle adopted in the weaving room: - check the maximum carrying capacity of the trolley referring to the total weight of the beam plus warp; - check that the correct beam lifting mechanism is used (forks or cradle type) (figures 6 and 7); - check whether both the beam and the heald frames are to be transported together (figure 8); - make sure that the trolleys have the required safety devices; - check the width of the corridors and that these are free of obstacles when the trolleys are used

Fig. 6

Fig. 7

Fig. 8

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SIMPLE BEAM ASSEMBLY

ATTENTION DANGER: Use the appropriate trolleys to move the beam.

1.5.1

SBM BEAM VERSION

- Mount the lateral buffers M and N on the beam cylinder H. Mount also the buffers P only on wide machines;

N

H

M

Fig. 9

- unlock the crank R and place it in high position inside its housing (see figure 11);

- loosen the screw G and pull out the clutch P, using the handle Q; - using the special moving trolleys, lift the beam with the warp; - insert the lateral buffer P into the flange M and tighten the screw G; - lock the crank R in contact with the lateral buffer M ;

97

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R

G P Q

Fig. 10

Fig. 10

1.5.2

STANDARD BEAM VERSION

- Mount on the cylinder H the right buffer N and the gear Z;

N

Z H

Fig. 11

98

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- loosen the screws U and open the jaws V on both sides - to keep the jaws V opened use the hooks T; - loosen the handle L and lower the spool S; - using the special moving trolleys, lift the beam with the warp and lay it down to the supports, paying attention to engage smoothly the gear Z with the let off pinion; - close the jaws V and fasten the screws U; - reposition the spool S by engaging its pinion with the gear Z and lock the handle L;

T V

U

Fig. 12 S

L 99

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1.6 MOUNTING THE BEAMS ON THE WARPING MACHINES Suitable adapters are available for mounting the beams on the warping machines and on the beamer of the sizing machines (figure 12).

- simple beams

cod. 2580063

cod. 2580798

Remove code QELL008 from the right hand side.

cod. 2580063

cod. 2580798

0 4

0 4

ø

ø

90

90 A

Fig. 12

NOMINAL WIDHT

1900 2100 2300 2600 2800 3400 3600

A±2 (mm) 2550 2750 2950 3250 3450 4050 4250

100

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2

HEALD FRAMES AND HEALDS

2.1

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

492.5

B

492.5

B

C

492.5

D

492.5

A

Profile 140 x 9

10 7.8 9.8 STÄUBLI CONNECTION DRC10

sez.X-X

101

NOMINAL WIDHT

A

B

C

D

1900

2075

545

480

610

2100

2275

645

580

710

2300

2475

745

680

810

2600

2775

895

830

960

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

A D

E

F

G

H

I

O C

P

Z

622.5

L

M

N

B

Z = Central support that can be shifted 160 mm from the centre in order to fit the central leno device Profile 140 x 9

10 7.8 9.8 STÄUBLI CONNECT DRC10

sez.X-X NOMINAL WIDHT 2800

A

B

C

D

E

F

G

2975

1537.5

1437.5

682.5

805

805

682.5

3400 3600

3575 3775

1837.5 1937.5

1737.5 1837.5

310.5 310.5

650 677

827 900

827 900

H

I

L

M

N

O

P

NOMINAL WIDHT 2800

---

---

800

930

622.5

---

---

3400 3600

650 677

310.5 310.5

690 780

410 420

540 550

690 780

622.5 622.5

102

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HEALDS

When using healds with eyes in asymmetric position, remember that the shorter side must be placed over the warp threads We recommend the use of healds with J-type connections as shown in figure 1. Remember that the openings of the connection eyes must be directed towards the weaver and not towards the beam WEAVER’S

SIDE

Fig. 1 Type J (extra)

103

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Preparation for start up 3

REED

3.1

FEATURES


The reeds must be exactly as shown in figures 1 and 2. - The standard reed is recommended for dobby and tappet motion machines, for styles requiring ìtwo weft nozzles (figure 1).

TOTAL WIDTH

. X A M ,5 5 1

REED WIDTH

. X A M 6 2

SEZ. B-B SECTION CONSISTING OF PROFILED DENTS SECTION CONSISTING OF STRAIGHT DENTS

SEZ. K-K

Fig. 1

104

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SEZ. C-C



- The bicone-type reed is recommended for dobby and tappet motion machines, for styles requiring four or more weft nozzles and for all jacquard machines (figure 2).

SEZ. A-A

VIEW FROM C TOTAL WIDTH

. X A M 5 , 5 1

REED WIDTH

. X A M 6 2

SECTION CONSISTING OF PROFILED DENTS SECTION CONSISTING OF STRAIGHT DENTS

SEZ. K-K

Fig. 2

Table 1 A 40 mm

4

6

COLOURS COLOURS X

60 mm

X X

The table 1 refers to the dimensions of the bycone, according to the number of the colours of the launch nozzle. For the choice of the correct thickness of the blades remember the style (cotton or synthetic).

105

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There are three different ways to use the reed: a) – CUT REED(figure 3): the total reed width is equal to the width taken up by the warp ends, including the leno ends.

WARP ä

Fig. 3

b) – CUT REED WITH WASTE SELVEDGE (figure 4): the total reed width is equal to the width taken up by warp ends including the leno ends, plus the reed space used for the waste selvedge.

AUXILIARY REED

WARP ä

ä

Fig. 4

c)

–

FULL WIDTH REED WIDTH WITH WASTE SELVEDGE (figure 5): the total reed width is equal to the nominal

width of the machine or the total width of the reed equal to the nominal machine width plus 150 mm. This method should be adopted by those who change the reed width often keeping the same dent reduction per cm. This means you have to use the threads for the waste selvedge, fitting the machine with the relevant devices

WARP ä

Fig. 5

106

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CALCULATING THE TOTAL REED WIDTH AND THREADING UP

As far as the reed width is concerned we mean the width occupied by all the warp threads including the leno device (splitz) threads. When defining the total width of the reed it is necessary to pay attention to the chosen solution.

a) - total width of the reed equal to the fabric width (figure 6). When defining the total reed width, bear in mind the methods of threading the leno device. Execute the threading, starting from the left-hand side and leaving the space that is between the 1 mm support and the first blade free from threads. On the right-hand side the space between the last blade and the 2 mm support must remain free.

WARP ä

Fig. 6 b) - total width of reed equal to the fabric width plus the waste selvedge (figure 7). Execute the threading, starting from the left-hand side leaving the space between the 1 mm support and the first blade free from threads. On the right-hand side in the auxiliary reed supplied in the spare accessories, thread the first waste selvedge thread, after leaving the first 8 dents, that is a space of about 10 mm, empty AUXILIARY WARP ä

10 mm

ä ä

ä

REED 10 mm

Fig. 7 107

29 - 02 - 2012



c) - total width of the reed equal to the nominal width of the machine plus 150 mm (figure 8) Execute the threading, starting from the left-hand leaving the space between the 1 mm support and the first blade free from threads. On the right-hand side, thread the first waste selvedge thread, after leaving the reed dents empty for 10 mm from the last warp thread.

WARP

ä

ä

10 mm 10 mm ä

Fig. 8

3.3

REED CLEANING

It is very important, for the good machine running, to check the condition and clean the reed at each beam change. For cleaning, we recommend you use specific products that may be requested from the reed manufacturers.

EXAMPLE: product RC 30, company SCHOCH - 30 litre contain er - applied with brush. If you use high pressure or compressed air devices to clean the reed, pay attention that sufficient distance is maintained between the dispenser nozzle and the reed in order to avoid possible deformations to the reed dents.

108

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4

SELVEDGES AND WASTE SELVEDGES

4.1

SELVEDGES

The binding of the fabric selvedge may be carried out in two different ways: a) using the leno device (also called the splitz); b) using the weft selvedge device (also called the tuck-in device).

For machines with tappet motion or dobby, when preparing the number of heald frames with which to produce the style, it is necessary to bear in mind the type of selvedging device in use.

4.1.1 LENO DEVICE SELVEDGES (figure1) The function of the leno device (splitz) binding threads A and B is to keep the selvedges of the fabric compact and to prevent the loosening of the outer threads.

A

B

Fig. 1

This type of binding is carried out with the heald device with independent, electronic control.

4.1.2 TUCKED-IN SELVEDGES (figure 2 - 3) The weft selvedge or tuck-in device D allows the weft ends C, protruding from the sides of the fabric, to be tucked in with the aim of obtaining a selvedge similar to that produced by a shuttle machine

109

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C Fig. 2 This equipment can be mounted on the machine, provided that it is set up for this.

pneumatic tuck-in device D

110

Fig. 3

29 - 02 - 2012



4.2

WASTE SELVEDGES

4.2.1

WASTE SELVEDGES FEED

The feed of the waste selvedge yarn may be obtained by warping the threads of the waste selvedge E on the small beams supplied F (figure 4).

F

E

Fig. 4

111

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112


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SECTION 4 MECHANICAL A ND TEXTILE ADJUSTMENTS

113

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114

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MECHANICAL AND TEXTILE


ADJUSTMENTS

1 1.1

FABRIC SUPPORT STANDARD SUPPLY

(figures 1 - 2 - 3 - 4) Machines operating with fabric that is not centred - fixed left-hand side:

All adjustment and control operations must be performed with the machine at a standstill and in manual mode, following the instructions given in SECT. 2 paragraph 8.

a) The left end of the fabric support A (figure 1) is already positioned at the fixed distance of: - for 1700 - 2100 - 2200 - 2300 width machines = 300 mm; from the beginning of the rail P on the left-hand side of the machine.

Fig. 1 Machines operating with centred fabric - variable right and left-hand sides: 1) the left end of the fabric support A (figure 2), must be positioned at a distance K, from thebeginning of rail P on the left-hand side of the machine, which is the result of the followingformula(for 1900 - 2100 - 2300 width machines):

X -Y K = ————— + 300 2 where: X = nominal width of the machine; Y = total reed width (included waste selvedge); K = distance between the cloth support plate and the beginning of the rail on the left-hand side of the machine. Example: X = 1900 and Y = 1700 1900 - 1700 K = —————————— + 300 = 400 Fig. 2

2

115

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MECHANICAL AND TEXTILE ADJUSTMENTS


b) insert and lock the 4 gauges B, (code QEH1167) supplied with the machine, in the sley, bypositioning two of them at the two ends and two at a 1/4 and 3/4 of the length respectively of the fabric support A; c) bring the machine manually to 0°; d) loosen all the screws C and bring the fabric support in contact with the gauges B; e) with the spare shims D, adjust the fabric support A height with respect to the pins E of gauges B. The distance can vary according to the type of fabric thickness that has to be produced. The standard value is from 0.6 to 0.8 mm (the machine is delivered with this adjustment). Important : for filament warp yarns, in case of pilling formation on the auxiliary nozzle this value can be reduced up to a minimum of 0.3 mm.

Fig. 4

116

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Fig. 3



ADJUSTMENTS

1.2

SUPPLY OF CUT FABRIC SUPPORT (LIP IN THE REED)

a) the left end of the fabric support A (figure 5) is already positioned at the fixed distance of 300 mm,from the beginning of the rail P on the left-hand side of the machine (refer to fig. 1 of paragraph 1.1). a1) for machines that operate with centred fabric, refer to point a1 of paragraph 1.1 b) measure the width of the style that you have to weave (from the first thread on the left-hand side to the last thread on the right-hand side), adjust the block piece G (figure 6) so that distance L (figures 5 and 6) is exactly the same as the reed width of the fabric; c) insert and lock the 4 gauges B, (code QEH1167) supplied with the machine, in the sley, at the two ends of the block pieces A and G (figures 6 and 7); d) bring the machine manually to 0°; e) loosen screws C and H, bring the two block pieces A and G in contact with the gauges B. f) with the spare shims D, adjust the fabric support A and G height with respect to the pins E of the gauges B; the distance can vary according to the type of fabric thickness that has to be produced. The standard value is from 0.6 to 0.8 mm (the machine is delivered with this adjustment). Important: for filament warp yarns, in case of pilling formation on the auxiliary nozzle this value can be reduced up to a minimum of 0.3 mm. g) Tighten the screws C, while keeping fabric support A in contact with gauges B; h) insert and lock a gauge B in the sley at the support N of the block piece F; i) with shims D, adjust the block piece F height at the same distance between the pin E and the gauge B. Tighten the screw H of the support N. j) Perform the same operation for the other supports N.

Fig. 6

Fig. 5

117

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1.3


SUPPLY OF TELESCOPIC FABRIC SUPPORT (LIP IN THE REED)

a. the left end of the fabric support A (figure 7) is already positioned at the fixed distance of 300 mm,from the beginning of the rail P on the left-hand side of the machine (refer to fig. 1 of paragraph 1.1). a. a1) for machines that operate with centred fabric, refer to point a1 of paragraph 1.1 b. measure the width of the style to be woven (from the first thread on the left-hand side to the last thread on the right-hand side), adjust the block piece G (figure 6) so that distance L (figures 5 and 6) is exactly the same as the reed width of the fabric; c. insert and lock the 4 gauges B (code QEH1167) supplied with the machine, in the sley, in line with the ends of the two block pieces A and G (figures 5 and 6); d. manually bring the machine to 0°; e. loosen the all screws C, bring the two block pieces A and G in contact with the gauges B; f. with the spare shims D, adjust the height of the two block pieces A and G in relation to the pins E of the gauges B; the distance can vary according to the type of fabric thickness that has to be produced. The standard value is from 0.6 to 0.8 mm (the machine is delivered with this adjustment). Important: for filament warp yarns, in case of pilling formation on the auxiliary nozzle this value can be reduced up to a minimum of 0.3 mm Tighten the screws C, while keeping fabric support A in contact with gauges B (figure 7); g. insert and lock a gauge B in the sley in line with the central support of the side block piece F; h. with the shims D, adjust the height of the side block piece F, keeping the same distance between the pin E and the gauge B. For the other supports of the block piece F, insert the same number and type of shims D as those mounted on the central support. i. insert and lock a gauge B in the sley in line with the central support P of central block piece R (figures 6 and 7); j. with the shims D, adjust the height of the central block piece R, keeping the same distance between the pin E and the gauge B. For the other supports of the central block piece R, insert the same number and type of shims D as those mounted on the central support. See table 1 for the selection of block pieces according to the reduction in height.

Fig. 7

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Fig. 8

119

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2


FASTENING THE REED

(figures 1 - 2) The reed must be fixed using the special wedges A. These wedges must be blocked between the reed B and the


Before fastening the reed, make sure the wood protection of the packaging has b een removed.

reed-holder extruded piece C by means of the relevant screws. The torque wrench setting for these screws must be 5.5 Nm. Align the left support D (1-mm) with the left end E of the fabric support (figure 2) crosswise. It is necessary to check that the reed is of the proper size and shape, in order to ensure the perfect operation of the machine (see section 3 chapter 3).

Fig. 1

Fig. 2

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ADJUSTMENTS

3

MOUNTING AND POSITIONING THE AUXILIARY NOZZLES

The auxiliary nozzles A, screws B and nuts C are mounted on the loom and are adjusted only when the weaving


width is reduced. Insert the fastening screws B in groove D of the sley, passing the head of the screw as shown in figure 1. Fasten the auxiliary nozzle assembly A with the screw B using the self-locking nut C. To hold the auxiliary nozzle A in position, tighten the screw using nut C with a torque of 5 Nm. In this way the head of the screw rotates in a clockwise direction (figure 1), becoming locked inside the T-shaped groove. With this fastening system, a single auxiliary nozzle can be removed by loosening nut C, without working on the other nozzles installed. Hoses E should be connected after the auxiliary nozzles A have been positioned, whose number depends on the working machine width.

Fig. 1

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Configuration with 1 solenoid valve every 4 auxiliary nozzles:

a) solenoid valve for straightener nozzle

last auxiliary nozzle used

Fig. 2

solenoid valve for straightener nozzle (if present)

a) solenoid valve for weft optical sensor

Fig. 3 last auxiliary nozzle used

solenoid valve for optical sensor

122

29 - 02 - 2012



Any unused auxiliary nozzle supply hoses should be closed with the special plugs supplied with the accessories. The distance between the first auxiliary nozzle and the end of the fabric support F is 10 mm* (*as a condition of supply, the machine is delivered with this adjustment); ** for special weaving requirements, with styles that shrink greatly, it is possible to position the first auxiliary nozzle even at 50 mm, at the window H; Starting from the first auxiliary nozzle A on the left, the other auxiliary nozzles should be positioned using the special gauge F (code FRW007B) supplied as a spare, with the machine accessories, at a constant pitch of 74 mm that allows them to enter the windows L of the fabric support F

Fig. 4

Fig. 5

123

29 - 02 - 2012



we recommend having 2 or 5 auxiliary nozzles close together on the right-hand side of the machine to keep the weft taut when the shed closes, so that no weft threads are slack. Using the gauge G position these 2 or 5 auxiliary nozzles at a pitch of 37 mm. The distance between the last auxiliary nozzle and the last thread on the right-hand side must be minimum 70 mm and maximum 100 mm (* without straightener nozzle min. 40 mm). In case of a style change involving a change in reed width, move the machine slowly by hand and check that the auxiliary nozzles of the right-hand side of fabric support F enter the corresponding openings L without any problems. Correct the position of the auxiliary nozzles if required.

Fig. 6

Fig. 7

Fig. 8

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29 - 02 - 2012



ADJUSTMENTS

4

TEMPLES


The temples must be fitted “pressing on the fabric ”. Before fitting the temples, make sure that the needles of the rings are not broken or crooked. Furthermore, make sure that the rings run free in their seats.

4.1

POSITIONING

(figure 1) Check that the abbreviations LH or RH, or S or D are engraved on each temple A. These abbreviations indicate whether the temple should be mounted on the left or right. Place the temples so that these abbreviations are visible from above: - fit the small plate B into the indentation on plate C; - fit the rear end of the temple A into the small plate B; - attach the tip of the temple A to the plate C inserting the spacer D.

Fig. 1

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29 - 02 - 2012



4.2

ADJUSTMENT

a)

Lengthwise positioning (figure 2): - place support A aligning its inside edge X (marked in figure 2) with the end of the fabric; - according to the shrinkage in width of the style, it may be necessary to make small lengthwise adjustments of the temple, using the cam B.

b)

Positioning in depth (figures 2 - 3): - place temple C, 1 mm from the edge of the fabric support D using the screws E.

c)

Positioning in height (figures 2 - 3): - place temple C, 1 mm from the fabric support D using the cam F. In the case of styles with a minimum shrinkage, this distance can be increased vertically for less temple hold. Once height positioning is adjusted, place the nut S. This will avoid to readjust the temple height in case of temple disassembling (beam or article change, temple maintenance, etc)

Fig. 3

In order to get more or less temple hold depending on the weaving requirements, it is possible to turn the temple cylinder on its axis by loosening the two screws G ( figure 2). When turning towards the reed, you have more hold; turning towards the weaver, you have less hold.

Fig. 2

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ADJUSTMENTS

5

LATERAL SCISSORS


5.1

BLADE PRELOADING ADJUSTMENT

(figures 1 and 2)

This operation must be carried out with the machine turned off or by removing the scissors from the machine and executing the adjustment on the bench.

Equipment for checking the blade preloading adjustment: code QARZ005. Proceed as follows: -loosen the screw A of the motor clamp; -loosen the screw B; -align the mobile blade C to the fixed blade D without preloading; position the rod E of the dial gauger F on the mobile blade C and set it to zero by means of the rotating ring nut; -remove the fixed blade D, by means of the screws G; -act on the mobile blade C in the indicated direction (figure 1 for left scissors, figure 2 for right scissors), up to reach a value 0.2 mm on the dial gauger F; Fig. 1 Left-hand scissor

-tighten the screw B; -reposition the fixed blade D, placing the mobile blade C on it; -on the dial gauger F check if the preload value is set to zero.

Fig. 2 Right-hand scissor

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5.2


ADJUSTMENT OF BLADE OPENING

(figures 3 - 4 - 5 - 6)

All adjustment must be carrier out with the scissor assembled on the machine and can be executed only with the power section actuated. For his reason the operator must look out for himself and move other people away from the machine.

Fig. 3 Left-hand scissor

Fig. 4 Right-hand scissor

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ADJUSTMENTS Adjustment of "limit switches": - switch on the machine;

- touch in sequence the icons on the console

- on the DEVICES TEST page, at Fixed test, insert YES

- on the icon

touch LH for "LEFT-HAND CUTTER" and

RH for "RIGHT-HAND CUTTER" and the mobile blade C automatically moves to the closing position; - loosen the nut O and position plate P 0.1 to 0.3 mm from the head of screw F. This measurement must be taken with the feeler gauge. Tighten the nut O again; - touch

to end the TEST.

Fig. 5 Left-hand scissor Fig. 6 Right-hand scissor Cutter functioning control: - switch on the machine; - touch in sequence the icons on the console

- on the DEVICES TEST page, at Fixed test, insert YES

- on the icon

touch LH for "LEFT-HAND CUTTER" and RH for "RIGHT-HAND CUTTER"

and the mobile blade C automatically begins to execute the cutting cycles; - touch

129

to end the TEST.

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5.3


LENGTHWISE ADJUSTMENT AND ADJUSTMENT IN DEPTH

(figure 7) The lateral scissors are fastened to the machine by means of screws R that allow lengthwise adjustment. Screws Q and S, instead, allow adjustment in depth and height.

Fig. 7

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a) Left-hand scissors (figures 8 - 9) - bring the machine to 0° (zero degrees); - for lengthwise adjustment, the fixed blade D must be set at a distance of 1.5 to 2 mm from the end of the reed dent U; - for adjustment in depth, using a ruler as a reference, set the tip of the fixed blade D at a distance of 25 mm from the back edge of the reed dent U; - for adjustment in height, position the scissors so that the edge of the fi xed blade D is 1 mm below the level of the fabric support T.

Fig. 8

Fig. 9

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b) Synchronous right-hand scissor (figures 10 - 11 ) - bring the machine to 0° (zero degrees); - for lengthwise adjustment, the moving blade C must be set at a distance of 1.5 - 2 mm from reed dent U; - for adjustment in depth, the edge of the fixed blade D must be set at a distance of 0.2 - 0.5 mm from the edge of the fabric support T level. Make sure that the moving blade C does not hit fabric support T surface during the cutting stage; - for adjustment in height, set the scissors so that the moving blade, at its maximum opening, is at a distance of 0.5 mm from the cloth support.

Fig. 10

Fig. 11

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6


MAIN NOZZLE AND TANDEM NOZZLE GROUP

All adjustment and control operations must be performed with the machine at a standstill and in manual mode, following the instructions given in SECT. 2 paragraph 8. Pay attention when handling these equipments. They can be set up with two and four colours (figure 1).

Fig. 1

Tandem-nozzles and main nozzeles - 2 colours

Tandem-nozzles and main nozzeles - 4 colours

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6.1


NOZZLES

(figures 2 - 3 - 4 - 5 - 6) Check, with the centesimal gauge, that the adjustment screws H, placed on the support D, protrude 4.5 mm out of the lower surface of the support D. This adjustment centres the nozzle group with the reed gap. Fig. 2 Insert the nozzle assembly L complete with support D in the same housing as the reed-holder extruded piece and: - position the end of the nozzle L, 3 mm from the mobile blade T (fig.4) of the left-hand scissors; - using the wedge M (fig.3) fasten the nozzle support in the reed-holder extruded piece, tightening screws N at 5.5 Nm (0,55 Kgm).

Fig. 3

Fig. 4

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For a further check on nozzle centring with the reed gap, you can use a gauge P which can be requested from PROMATECH CUSTOMER SERVICE: - place the gauge P in the reed gap; - gently move the gauge P in the direction of the nozzle L; - adjust the nozzle with the screws H (fig.2), placed on the support D, so that the gauge P can be found exactly in the following positions: 2 colour nozzle - the gauge P must be centred in the nozzle No. 2; 4 colour nozzle - the tip of the gauge P must match the tangent point between the nozzle N° 3 and the nozzle N°4.

Fig. 5

Air hose connection (figure 6) - connect the air hoses Q to the sleeves R and fasten them by means of the ring-nuts S, paying attention to the number of nozzles as per the of references in figure 1.

Fig. 6

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6.2


PRE-NOZZLES

(figure 7) Position the support bracket A of the pre-nozzles in support B and secure it with screws C. Adjust the crosswise, horizontal and vertical position of the pre-nozzles as follows: vertical and crosswise position - with the machine positioned at 90°, the pre-nozzle must be aligned with the matching nozzle so that the weft thread has the most linear route possible; horizontal position - loosen the screws D, position the plate B so that it is 110 - 120 mm from the main nozzles; tighten the screws D air hose connection - connect and fix the air hoses to the sleeves H and F, paying attention to the number of nozzles as per the references in figure 1.

Fig. 7

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For weaving particular weft yarns, the pre-nozzle position can be changed as follows: crosswise position for weaving fine, weak wefts with low resistance - with the machine positioned at 90°, the tandem-nozzle must be moved in the weaver's direction with respect to its own nozzle; horizontal position for weaving fine, delicate and weak wefts with low resistance - move the tandem nozzles support plate B towards the left-hand side (prewinder side); crosswise position for weaving twisted or elastic wefts - with the machine positioned at 90°, the tandem-nozzle must be moved in the direction of the beam side with respect to its own nozzle; horizontal position for weaving twisted, thick and heavy wefts - move the tandem nozzles support plate B towards the right-hand side (towards the centre of the machine).

6.3

USE OF NOZZLES AND PRE-NOZZLES

Table 1 summarizes the different nozzle options available according to the type of pin W coupled with the t ype of lance V.

Table 1: possible couplings (see mark)

LANCE

PIN

P

P 1.5

T

T2 T2.5 T3 T4

Fig. 8

Textile instructions: The launch nozzle obtained by coupling Promatech pin P 1.5 with lance P ensures the best performance with low count yarns. It is essential with very low count yarns and with yarns which are not easily transported by air (yarns with smooth continuous filaments). The launch nozzle obtained by coupling pin T 2.5 with lance T is the customar y version and therefore more widely used. It can be used with medium to low count yarns remembering that, as the weft count decreases, the efficiency of nozzle transport is reduced. In order to partially remedy this tendency, when weaving low count yarns without nozzle P 1.5 – P, a combination of pin T 2 and lance T can be adopted. With high count yarns, the nozzle obtained by coupling pin T 3 with lance T must be used. Whenever the yarn requires particular assistance to enter the nozzles – this becomes evident when launching chenille wefts – the nozzle obtained by coupling pin T 4 with lance T can be used.

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7


PHOTOCELLS AND STRAIGHTENER NOZZLE GROUP

(figures 1 - 2 - 3)


These parts are supplied with the spare accessories to avoid damage during transport. Pay attention when handling.

7.1

PHOTOCELLS

OPERATION The first photocell A and the second photocell B can both stop the machine: - photocell A has the function of checking weft arrival; therefore, if photocell A does not detect the weft passage, the machine will stop due to short weft; - photocell B has the function of checking whether the weft is long; therefore, if photocell B detects the weft, the machine will stop due to long weft. When the weft thread crosses the straightener nozzle C tunnel, you find that: - the nozzle blow T pushes the weft into the small tube L to keep it stretched until the reed reaches the beat-up position and at the same time the right-hand scissors cut.

Fig. 1

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ADJUSTMENTS POSITIONING

Photocells A and B must be positioned correctly on the straightener nozzle in order to avoid false detection and damage to the photocells due to excessive rubbing by the weft. FIRST PHOTOCELL – A Position the photocell by means of the screws V, so that there is no upper slack between the screws and the holes of the straightener nozzle S (see detail A). In this way the weft tensioned by the straightener nozzle is prevented from damaging the upper external edge of the photocell with an excessive rubbing. A build-up of dust is not normally seen on the first photocell (or it occurs more slowly) because the passage of the weft keeps the sensor clean. SECOND PHOTOCELL – B Position the photocell by means of the screws W, so that there is no lower slack between the screws and the holes of the straightener nozzle S (see detail B). An incorrect position could cause an excessive build-up of dirt in the photocell area, which could be shadowed.

Fig. 1a

Detail A

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Detail B

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7.2


STRAIGHTENER NOZZLE GROUP

Insert the pre-assembled straightener nozzle unit including the first photocell A, second B and the straightener nozzle C in the same housing as the reed-holder extruded piece and: - position the first photocell A, at a distance of 1.5 - 2 mm from the fixed blade Z of the right-hand scissors; - using the wedges D (fig.3) fasten the assembly in the reed-holder extruded piece, tightening the screws E to 5 Nm (0.5 Kgm); - connect the hose F coming from the solenoid valve G to nozzle and fasten it with the special ringnut T ; - using the fastening accessories M , lay out the route for the hose F until it connects to the solenoid valve G; - using the fastening accessories N, lay out the route for the two cables O and P of the photocells until they reach their connectors Q and R, paying attention to the references marked on their cables.



Photocells A and B are interchangeable and can therefore be replaced one with the other.

Fig. 2



If photocells A and B are replaced, keep the arrangement of the

cables P and O as showed in fig. 3.



According to the height adjustment, fill all sley threads with the

fastening accessories N, to fix the cables P and O p roperly.

Fig. 3



The photocells will last longer if the cable fastening is checked

periodically.

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8


WORKING WITH THE REED AT FULL WIDTH (on request)

In order to weave with a reed longer than the actual reed width of the fabric or of the same length as the nominal machine width, the machine needs to be fitted with the waste selvedge device on the right-hand side (see section 4 - chapter 12), weft control photocells and a special straightener nozzle.

 

When using the full cloth support, centre the sensors in the relevant windows.

Fig. 1

 

141

WARNING: keep the cables stretched as much as possible to make sure they don't break.

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8.1


WEFT STRAIGHTENER NOZZLE

(figures 1 e 2) Place auxiliary nozzle M for the weft blow, 50 ÷ 74 mm from the first photocell A and fix it to the sley with screw F. WARNING To connect the photocell supply cables and the straightener nozzle blowing tube, use the same parts and the same system shown in section 4 - chapter 7.

8.2

POSITIONING THE BENDING BEAM PHOTOCELLS

(figures 1 e 2) The first photocell A is positioned in the centre inside the space between the last warp thread and the first thread of the waste selvedge. The second photocell B is positioned 170 to 230 mm from the first photocell A. a) fasten photocells A and B on the sley with the screws C; position the photocells so that they correspond to the openings in the cloth support. b) position the devices D on the rear of the reed on a level with the photocells A and B and fasten them to the upper edge of the reed with screws E. The devices D serve to prevent vibrations of the reed blades.

Fig. 2

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8.3


ITN STRAIGHTENER NOZZLE (option)

(patent)

Inside Tunnel Nozzle is a special straightened nozzle for full reed weaving system. It is fitted on the reed.

Mechanical settings •

Adjust the fabric table to the drawing-in width (drawing-in

•

Position photocell A within the range of the last gap of the

plus 24 mm or more). fabric table. Check whether the sensor touches on the fabric table (in foremost loading position). •

Draw in the auxiliary selvedge on the right side of photocell A. As near to the weft monitor as possible will result in less weft wastage. Minimum of 16 mm from the fabric edge.

Fig. 1

•

Mount the temple along with the auxiliary selvedge bushing. Bushing flash with end of fabric table.

•

Fix the holder with the in-tunnel nozzle on the sley (M3 screws must not yet be tightened). Distance from nozzle body to fabric table C of 1 –2 mm (Fig. 2). Push the nozzle in the tunnel base backwards, so that the position rib reaches a leaf gap, determine the height and then tighten the M3 screws. If necessary, realign the nozzle at the fastening screw, so that it is parallel to the leaf channel.

•

Install and fasten the compressed air hose and the weft monitoring cables correctly on the sley (Fig. 1): Distance photocells A and B= 180 mm Distance between the tube holder and photocell B at least 14 mm (Fig. 1):

WARNING •

ITN device require a cut fabric support version (see section 4, chap-

•

FAR device is notavailable with ITN

ter 1.2 and 1.3)

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8.4


FASTENING THE PHOTOCELL CABLES

(figures 1 e 3) After the photocells have been positioned, fasten their cables respecting the distances shown in figure 1.



. Photocells A and B are interchangeable and can therefore replace one another if one breaks.



. According to the height adjustment, fill all appropriate sley threads with the fastening accessories N,

in order to properly fasten the cables.



The photocells will last longer if the cable

fastening is checked p eriodically.

Fig. 3

MAINTENANCE AND CLEANING OF THE WEFT CONTROL PHOTOCELLS When to clean the photocells There are no pre-fixed times for cleaning the photocells, they should be cleaned whenever the following situations occur: - the console indicates that they should be cleaned; - false weft stops occur or weft stops fail to occur, or however when there are doubts regarding weft control operation. How to clean the photocells - Remove the photocells from the straightener nozzle, or in the case of a full reed, remove the optic photocells from the reed support; - Use only neutral detergents: the optical part of the photocell, being made of Plexiglas, can be damaged by thinners or alcohol; - Use a damp cloth and wipe the optical parts, checking that there are no deposits caused by the release of glue or other substances present on the transported weft. - Replace the clean photocells on the support, checking that they are correctly mounted and fastened.

. Cleaning may not be effective if the photocells are not removed from their support. Protect or remove the photocells when cleaning the reed to prevent them from being damaged.

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9


AIR INLET (cut reed looms)


The function of inlet A is to collect the weft ends that come out of the small tube of the straightener nozzle C (see section 4 - chapter 7) and then divert them to the weft waste collector. - Move the support B in a longitudinal direction in order to position the inlet A at a distance of 3 - 5 mm from the second photocell D; - loosen the support E in order to position the flat surface L of the inlet A, 1 mm from the fabric support F; - connect the tube G coming from the waste collector to the inlet A.

Fig. 1

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10


F.A.R. DEVICE - on request

(figures 1 - 2 - 3 - 4 - 5) F.A.R. is the abbreviation of F " ILLING AUTOMATIC REPAIR”, which literally means: AUTOMATIC WEFT REPAIR. This device, supplied with the machine by specific request, allows for the repair of a broken weft in the shed (short or crimped weft) without the operator intervening. Functioning At machine stop due to short weft, the blow F of the FAR, placed at the beginning of the reed on the left-hand side, enters into action. The machine automatically executes a reverse pick to free the weft which has been beaten-up by the reed and stops at 180°. At this point, a number of insertions (that can be programmed on the console) are launched by the weft nozzle that caused the stop. If the second photocell registers the arrival of the launched weft, the m achine moves and positions itself at the cutter degrees for the FAR device, so the weft is cut. Following this, the machine moves in reverse and goes back to the 180° position. In this position the FAR sucks all the insertions free in the shed i.e. the one that caused the machine stop plus all the FAR launches. If the suction occurs correctly (the control is done with the two photocells), the machine moves back to the starting position and starts off again, automatically without the operator intervening. If the suction does not occur correctly the machine doesn’t sta rt up and the blue stop light due to weft lights up. Adjustment - Move the support B in a lengthwise direction until the F.A.R. A is 3 to 5 mm from the second photocell C; - position the machine at 180° and centre the F.A.R. hole A with the weft passage tunnel of the second photocell C. To adjust in depth, move support D, in height, use screws E;

Fig. 1

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ADJUSTMENTS

- position block F to make a slot on the front guide of the fabric suppor t and position it together with the air blow holes N ,1 mm from the end part of the nozzle G. Fasten it with the special screw H. Check that the thread slot formed by the blow is perpendicular to thread line (see figure 5), in order to avoid any knocks with the nozzles and the blades of the left-hand scissors; - connect tube Q to the solenoid valve P; - connect tube L, coming from the weft waste collector, to the F.A.R. reference A (fig.1).

Fig. 2

Fig. 3

Fig. 4

Fig. 5

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10.1


F.A.R. DEVICE FOR FULL REED WIDTH (on request)

(figure 6) When the "full width" reed A is present on the machine, then in addition to the auxiliary nozzles needed for the fabric, the auxiliary nozzles B, designed to cover the distance between the end of the fabric and the uptake inlet of the weft to be emptied, must be installed. The mounting pitch of the auxiliary nozzles is from 100 to 150 mm.

Fig. 6

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11


WEAVING WITH WASTE SELVEDGE

As a general rule, the waste selvedge should be in plain weave, though in special cases the style may accept a waste selvedge with different weaves. The following systems can be used to form the waste selvedge: a) passing the threads in the ground heald frames; b) passing the threads in two extra heald frames. This solution should only be used in exceptional cases when the ground weave cannot bind the waste weft ends. In this case the two extra heald frames should be placed in front (weaver's side). The number of warp ends of the waste selvedge differs depending on the type of yarn being used and the style being woven. Generally speaking, the following rules apply: - most styles 16/18 threads.

11.1

SELVEDGE CONVEYOR

The waste selvedge is wound in the direction shown by the arrow and, thanks to the tapered shape of the device U, the resulting waste selvedge coils move towards the outside and finally drop off into collection bin M below. Ring nut P is used to adjust the tractive force: tighten this and the force intensity increases. The tapered shape of the six fins Q can also be adjusted: loosen screw R and then adjust its position in slot S.

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12


SELVEDGES


12.1

SELVEDGE BINDING

The binding of the fabric selvedge can be performed with the following accessories: - leno device, called ELD SPLITZ ; - planetary leno device, called RLD SPLITZ

12.2

LENO DEVICE "ELD SPLITZ"

(figures 1, 2 e 3) The complete "ELD SPLITZ” set is made up of two devices (one on the right and one on the left). Its correct functioning is clearly described in the manual provided "console user manual". a) Positioning Fit the "ELD" device A on the support B: - so that the small guide bars C are in line with the healds of the firs heald frame; - adjust the device A in height so that the shed created by the two threads F and F1 is centred with the reed gap.

Fig. 1

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b) Threading up - the two threads F and F1 that come from the small supply creel G, pass through the thread guides H and L and in the drop wires of warp stop motion M; - using the special guiding slit, pass the two threads through the slotted hole of the device A; - pass one of the threads through the eyelet of the fin D and the other through the eyelet of the fin E; - both threads F and F1 must be passed through the same reed dent, normally the one that contains the end warp threads (the right threading gauge must be used, fig. 4).

Fig. 2

Fig. 3

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c) Type of yarn Choose the type of yarn according to type of fabric: Type of fabric

Yarn for leno device (splitz)

Filament

Polyester 20-60 den single filament Polyester 40-60 den multi-filaments, twisted (300 turns/m)

Cotton

Cotton Ne 80/2

d) Adjustment of the correct crossing position This adjustment should be carried out in the following situations: - positioning the leno device on the machine; - replacing the control belt. Proceed in the following way: - turn on the machine; - program and/or check the phases of the leno device in the relevant menu, see "CONSOLE USER MANUAL" in the "LENO DEVICE PROGRAMMING" chapter; - take the machine to the same PHASE degrees; - remove the cover N; - press the pushbutton fitted on the upper cross bar 1-2 second and then release; repeat this operation until the scew Q of the joint can be loosened; - following this operation the motor is in the crossing position; - loosen the joint which connects the drive shaft to the motor by means of the screw Q (weaverside); - keeping the pulley in the stop position, rotate it until the two thread guides D and E are at the crossing position; - tighten the joint screw. e) Replacing the drive belt •

WARNING By applying the correct periodic adjustment and maintenance procedures, the belt will last 6-8 months; to avoid loom useless stops, it is recommended to replace the belt after 6 working months of operation.

Proceed as follows: - loosen the screws R; - mount the new belt; - tension the belt and tighten the screws R; - repeat the adjustment as described above in the paragraph "Adjustment of the correct crossing position"; - if a leno thread breaks, reset the memory containing the number of turns by pressing push-button P for two second; - if the leno device is being moved manually with the machine switched off, in order to put the leno device back into phase, keep pushbutton P pressed until the thread guides D and E are back to the crossing position; then release the pushbutton immediately; - the card controlling the leno d evices is the ELD card. f) Cleaning: - connect the air pipe to the union S (fig.3).

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ADJUSTMENTS

13 13.1

BACK ROLLER ADJUSTING THE BACK ROLLER INCLINATION


(figures 1 and 2) According to the style woven, the inclination of the back roller mobile cylinder may be varied. - Position 1 (P1) for synthetic styles - Position 2 (P2) for cotton styles

Fig. 1

To perform this operation, proceed as follows: - Loosen the warp tension. - Loosen the screw N and E then extract the lever F(fig.2). - Set position P1 or P2 (fig.1). - Tighten the screw N with a 170 Nm torque wrench setting. - Loosen screws I. - Position the lever A and tighten the screw E with a 200 Nm torque wrench setting. - Tighten screws I with a 120 Nm torque wrench setting. - Follow the same procedure on the other side of the machine. - By loosening screws I, adjust the levers F (on both sides of the machine), so that the milling A1 is in line with the perpendicular surface of the pointer B1 (fig.1). - Tighten screws I with a 120 Nm torque wrench setting.

13.2

HORIZONTAL ADJUSTMENT (figure 2)

You can move the back roller horizontally depending on the requirements of the fabric being weaved. As a rough guide, the indications for use refer to indicator S placed inside and on both sides of the frame and are as follows: HEAVY-WEIGHT COTTON WARP: indicator S between values 70 and 90; MEDIUM WEIGHT COTTON WARP: indicator S between values 90 and 110; LIGHT-WEIGHT COTTON WARP: indicator S between values 100 and 120; FILAMENT WARP: indicator S between values 100 and 130.

Fig. 2

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

If the warp remains the same, the positioning values can vary according to the number of heald fra



With positive back roller (figure 2) it is necessary to loosen and then reposition the two screws I

mes used for the fabric. too.

13.3

VERTICAL ADJUSTMENT

(figure 2) To select the correct vertical position, the following indications should be used as a rough guide. To identify the vertical position of the back roller, refer to the index D placed inside the frame on either side. The vertical position of the back roller is adjusted as follows: - loosen the screw C; - adjust screw G to arise or lower the back roller unit then tighten screw C



At the end of the adjustment operation, check the back roller levelling with a spirit level. When adjusting the heigh t of the ba ck roller, you must operate gradually from both ends. In other words, one support at a time must be moved up or down by a small amount. This process should be repeated until the correct height has been reached. During adjustment, the difference between the respective heights of the two ends must not exceed 1 notch (10 mm).



If the back roller is empty or the load cell trips, follow the instructions given at paragraph 24 of this section.

13.4

SPRING POSITION

(figure 3) Depending on the style type, the end pins of the two springs M should be positioned as follows: - position 1: LIGHTWEIGHT FABRIC; - position 2: MEDIUM AND HEAVY-WEIGHT FABRIC; - position 3: VERY HEAVY-WEIGHT FABRIC

Fig. 3

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13.5


ADJUSTING THE SPRINGS

(figure 4) a) Recommended standard adjustment on starting up the style (with slack warp). 1) Buffer B to get 6 usable turns of spring M and to determine distance H: - loosen screws D and E; - loosen nuts A and C using the two keys supplied (code HRZ006B); - loosen screws F; - turn buffer B with the key inserted into screw F until distance H of 6 usable turns of spring M is reached; - tighten screw F and nuts A and C; 2) Lever L must be in a vertical position (figure 4): - using the two keys supplied (code HRZ006B), loosen nut A and turn nut C to get the vertical position of lever L; - tighten nut A and screws D and E. b) Varying the spring action of the ba ck roller When buffer B is shifted towards the end D, the spring action increases; towards the end E it decreases: - loosen screws D and E; - loosen screws F; - measure the distance G; - loosen nut A; - turn buffer B in the direction required; - tighten screws F; - turn nut C to get the distance G previously read; - tighten nut A and screws D and E.

Fig. 4

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13.6


TIMING OF THE DRIVEN BACK ROLLER

- In manual mode move the shedding machine to the shed crossing position. - Loosen the screw of the clamp L (right hand side) and M (left hand side). - Manually turn the back roller drive shaft R to reach the alignment as shown in figure 7. - Tighten the screws L and M.

Fig. 5

Fig. 6

Fig. 7 After carrying out the back roller mechanical adjustments correctly, you must first program theconsole with the specific data.

 TARE See the "Console user manual".  WARP TENSION See the "Console user manual".

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13.7


LOAD CELL ADJUSTMENT

(figures 8 and 9) The rear load cell doesn't need to be adjusted. To replace it, proceed as follows: - Loosen the screws M. - Extract the cell N to be replaced and insert the new one. - Tighten the screws M with a 70 Nm torque wrench setting. - Make sure that there are 8mm between the lever holder pin R and the back roller arm support S as shown in figure 9. - If not, loosen the screw Q and adjust the value to 8mm. Tighten the screw Q with a 140 Nm torque wrench setting.

Fig. 8

Without warp load on the back roller (i.e. warp tension equals z ero), check that the distance between the lever holder pin R and the back roller arm support S is 8mm.

Fig. 9

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14


SHED SIZE


The instructions given can change slightly depending on: - the type of heald frame used; - the healds used; - the weaving characteristics of the fabric to be produced.

Fig. 1

14.1 ADJUSTING THE LEVERS FOR Staubli cam motions (figure 2) - ensure that the warp beam has been loosened; - adjust the position of clamps B, bringing distance X to the value chosen in the table, following the instructions given in the shedding machine instruction manual. Fig. 2

158

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Model type 16xx

Model type 17xx



It is important that the unused heald connection ends that are governed by the cams are taken out so

as to prevent them being damaged.

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14.2


ADJUSTING THE LEVERS FOR Staubli dobbies

- Program a plain weave on the console; - move the machine until the blade levers C are perfectly aligned; - ensure that the warp beam has been loosened; - adjust the position of clamps B, bringing distance X to the value chosen in the table, following the instructions given in the shedding machine instruction manual.

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15


ADJUSTING THE HEALD FRAME TIE-RODS

The adjustment of the heald frame tie-rods of both standard and DRC10 models is carried out by placing the heald frames in their crossing position. For this operation, we recommend using the programmes managed by console as indicated.

15.1

Default setting for dobby

Touch the [Weaving machine] button followed by the [Weave]

button in the "Textile Area" menu. Touch the [Additional functions] button. Touch the [Plain weave 1/1] button. Back rest roller is in the "0" position. Adjust the tie-rods of heald frames B by means of the tie-rod locking clamps A so that the corresponding warp threads are tangent to the following devices: - fabric support extruded piece; - upper part of the healds eye 1; - upper part of the back roller set to position 0 (zero).

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15.2


MACHINES WITH TAPPET MOTION WITH LEVELLING

a) Switch on the machine; b) Press the [Pick finding] forwards buttons. c) the loom automatically brings the levelled heald frames to their crossing position; d) tension the warp threads; e) switch off the machine. Adjust the tie-rods of heald frames B by means of the tie-rod locking clamps A so that the corresponding warp threads are tangent to the following devices: - fabric support extruded piece; - upper part of the healds eye; - upper part of the back roller set to position 0 (zero).

15.3 MACHINES WITH TAPPET MOTION WITHOUT LEVELLING a) Move the machine to place the first heald frame in its crossing position and tension the warp threads; b) adjust the tie-rods of the heald frames B by means of the tie-rod locking clamps A, so that the corresponding warp threads are tangent to the following devices: - fabric support extruded piece; - upper part of the healds eye; - upper part of the back roller set to position 0 (zero); c) note the distance H on the first heald frame; d) in the case of a style with plain weave (1/1) adjust the tie-rods of the heald frames to obtain the same distance H noted on the first heald frame.

For other weaves, adjustment of the heald frame tie-rods to distance H is obtained by turning the machine to have each successive heald frame in the crossing position.

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ADJUSTMENTS

16

SHED CLOSING ADJUSTMENT

All adjustment and control operations must be \performed with the machine at a standstill and in manual mode, following the instructions given in SECT. 2 paragraph 8.

The relative position between the shedding machine and loom (shed closing) can be adjusted according to the type of style to be produced. - Move the heald frames to the crossing position; - loosen the screw B of the connection joint C of the dobby; - insert the wrench E in the housing F; - with a alley key on the screw F rotate untill the machine is positioned to the desired de grees of shed closing; - pull the joint C in the direction of the dobby then lock the screws B by means of the wrench with a 200 Nm torque wrench setting;

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17 17.1


CALIBRATING THE LAUNCH NOZZLES AND PRE-NOZZLES CALIBRATING THE INSTRUMENT WITH A PRESSURE GAUGE

(figure 1) To calibrate the launch nozzles and pre-nozzles, it is essential to clean them first, in order to remove any foreign bodies, and then to calibrate instrument D supplied with the machine. To do so, follow these steps: - place instrument D so that its magnetic base is on the top of the left-hand side frame; - connect tube E equipped with quick coupling and corresponding with letter ( A) of instrument D to connection G of the nozzle and pre-nozzle regulator H. 4.17.1.1 CLEANING - Connect the end of tube F to the connection (B) of instrument D; - put the other end of tube F near the discharge hole under letter (A) printed on instrument D to allow the air blast to remove any foreign bodies.

Fig. 1

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17.1.2 CALIBRATING (figure 2) - Connect the free end of tube F to the connection (C) of instrument D; - use pressure regulator H until the manometer indicates 2 bar. The instrument D is now completely clean and calibrated. With tube E still connected to connection G, calibrate the nozzles and pre-nozzles.

Fig. 2

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17.2


NOZZLES

(figure 3) The screws M and N are for adjusting the nozzle. - By loosening screw M and tightening screw N, the amount of air emitted by the nozzle is reduced; - by tightening screw M and loosening screw N, the amount of air emitted by the nozzle is increased. To calibrate each nozzle: - disconnect the tube that feeds the nozzle to be calibrated; - disconnect tube F from connection (C) of the instrument; - connect tube F to the connection of the nozzle P to be calibrated; - adjust the screws M and N until the manometer indicates the calibration values shown in the following table. See the paragraph 4.6.3. for the different pin-lance matchings.

Fig. 3

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17.3


PRE-NOZZLES

(figure 4) Repeat the same operations carried out for the nozzles, as per paragraph 17.2

 When replacing the nozzles or pre-nozzles, they must be calibrated again as previously described, making sure that instrument D is correctly clean and calibrated as described in paragraph 17.1

Fig. 4

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ADJUSTMENTS

18 18.1

PNEUMATIC ADJUSTMENTS CALIBRATING THE PRESSURES

Calibrating the pressures of different pneumatic parts is carried out: - on the main adjustment and distribution group (figure 1); - on the automatic launch adjustment and distribution group (figure 2) for AIR CONTROL functions (PPC).

18.1.1 CONTINUOUS BLOW (figure 2) The continous blow on the pre-nozzles and the nozzles is to guarantee that the wefts stay in position in their tubes at a specific tension. The tension must not be too great, so as not to damage the weft when the machine is at a standstill. - adjustment: adjust the air flow by means of the regulator B.

18.1.2 WEFT THREADING UP BLOW (figure 2) The threading up blow is used when you have to introduce the weft thread in the pre-nozzle and nozzle tubes, therefore the air that transports the weft must be sufficient to guarantee that threading up is carried out easily without breaking the weft. - adjustment: adjust the air flow with the regulator C screw. To thread up the weft, place the end part of the weft next to the pre-nozzle and nozzle hole and at the same time, press Fig. 1

the corresponding pushbuttons C1 until the thread has not been introduced completely into the tube.

1: Main nozzle valves

2: Tandem nozzle valves

Fig. 2

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18.1.3 AUXILIARY NOZZLE PRESSURE (figure 3) Use the pressure regulator A. Check the right pressure with the manometer D trough the quick connection A1.

18.1.4 STRAIGHTENER NOZZLE ADJUSTMENT PRESSURE To adjust the pressure of the straightener nozzle, use the regulator B. Start with a pressure of 4 bars and then adjust the pressure until the weft stretching device, after cutting, expels the weft tail correctly into the waste bin.

18.1.5 NOZZLE BLOW PRESSURE OF TUCK-IN DEVICES To adjust the nozzle blow flow rate of the tuck-in devices, use the regulator C. At first the pressure must be set to 4 bars; it must then be modified according to the type of weft being woven.

Fig. 3

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ADJUSTMENTS

18.1.6 ADJUSTING THE F.A.R. FLOW RATE (Broken weft extracting device with automatic loom restart) (figures 4 - 5) To adjust the flow rate of the F.A.R. device, use the regulators M (left hand side valve) and N (right hand side valve) for both the blow unit and the air inlet.

Fig. 4

Fig. 5

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19


WEFT DENSITY

There are three weft density ranges available, depending on the transmission ratio inside the takeup roller reduction gear and the warp let-off. The weft density ranges are also affected by the type of ETD and EWC motors, the machine speed, the diameter of the beam cylinder, the diameter of the beam flanges and the use of the regulator release. The minimum weft density limit refers to a machine speed of 550 picks/min. This limit can be increased, by doubling the speed, i.e.1100 RPM (picks/min), following this formula: Current density = Minimum density (indicated in the table) x Loom output speed ------------------------------------------------------------------------------------------------------550 See the Console Manual for details on the choice of three ranges and weft insertion density variations. picks/min 400 450 500 550 600 700 750 800

MIN density 5,1 5,8 6,4 7,0 7,7 8,9 9,6 10,2

MAX density 200 200 200 200 200 200 200 200

850 900 950

10,9 11,5 12,1

200 200 200

1000

12,8

200

19.1 CALCULATING THE CLOTH SPEED Calculating the cloth speed is carried out via the following formula: Loom speed (picks\minute) Vp = ------------------------------------------------------ = mm\sec 6 x Weft density (wefts\cm)

FURTHER HAZARDS: further hazards are possible when the cloth speed exceeds 10 mm per second.

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ADJUSTMENTS

20

PRODUCTION SPEED

The machine must be started up at a variable minimum speed depending on the nominal width of the machine as shown in the table below

WIDTH

START UP SPEED PICKS/MIN.

1900

656 ÷ 700

2100

656 ÷ 700

2300

656 ÷ 700

2600

540 ÷ 580

2800

540 ÷ 580

3400

400 ÷ 450

3600

400 ÷ 450

Under such conditions, the machine must weave for at least ten consecutive days to allow for an optimal running-in of the mechanical parts. The speed can then be increased gradually, until the optimal weaving value is reached depending on the styles to be produced. The maximum speeds allowed are variable according to: - the type of shedding machine; - the number of heald frames used; - the warp pick size, in the case of synthetic or cotton styles; - the type of fabric being produced; - the quality and preparation of yarns used for weaving.

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21


WINDING OF THE FABRIC

(figure 1) The way the fabric must be wound on the cloth roller and on the fabric pressing cylinders is illustrated in figure 1. A = Stretching bar B = Pressing cylinder C = Take up roller

Fig. 1

21.1

STRETCHING BAR

(figure 2)

The stretching bar is made up of three blocks as follows: - two lateral blocks which have their threads in opposite directions to permit distension of the fabric; - one smooth central block with a variable length. The mounting of the blocks on the machine varies according to the nominal width of the machine and the reed width of the fabric.

Fig. 2

left block

central block

right block

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ADJUSTMENTS

As shown in Table 1, the machines are supplied with blocks suitable for working with the maximum reed width. Table 1 Loom

Block

Table 2 Loom

Central Blocks

Width

Left

Central

Right

Width

supplied (mm)

1900

700

540

700

1900

90 -340

2100

700

740

700

2100

90 -540

2300

700

940

700

2300

90 -740

2600

1200

240

1200

2600

90 -140

2800 3400

1200 1200

440 1040

1200 1200

2800 3400

90 -240 90 -840

3600

1200

1240

1200

3600

90 -1050

Table 3

Central block available widths (mm) 90

140

240

340

440

540

640

740

840

940

1040 1140 1240 1340

. The codes relevant to the various central block lengths are found in the spare p arts catalogue . When the width of the fabric changes, the central block must be replaced. To find its exact length, use the following formula: for machine widths 1900 - 2100 - 2300 (fabric reed width + 50) - 1400 = central block length Example: nominal machine width

= 1900 mm

fabric reed width

= 1750 mm

(1750 mm + 50) - 1400

= 400 mm

for machine widths 2600 - 2800 - 3400 - 3600 (fabric reed width + 50) - 2400 = central block length Example: nominal machine width

= 3400 mm

fabric reed width

= 3200 mm

(3200 mm + 50) - 2400

= 850 mm

The choice of the length of the central block is made by rounding the value obtained up to the value immediately above it according to Table 3. Blocks, as described in Table 2, are supplied with the machine.

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For particular weaving requirements, it is possible to adjust the vertical position of the fabric stretching bar B: loosen the screws D and place the supports E in the required position with respect to the side of rail

Fig. 3

21.2

UPPER FABRIC PRESSING CYLINDER

(figure 4) The pressure of fabric pressing cylinder B can be adjusted according to the features of the style being woven. Adjustment: - turn screws M to adjust the pressure of the cylinder at the ends of the fabric; - turn screws N to adjust the pressure of the cylinder at the centre of the fabric. Do not exceed the limits given in figure 4. The fabric pressing cylinder B can be lifted rapidly by using the levers Y on both sides of the machine, thereby enabling the fabric to pass when loading and unloading the style.

Using lever Y while the machine is weaving could cause serious damage to the machine and the fabric being woven.

Fig. 4

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21.3


FABRIC ROLL CYLINDER

(figure 5)



These operations can also be performed while the machine is in movement. In this case, take great

care (WARNING: MOVING PARTS). The fabric roll is released by pushing the right and left pedals Q. The fabric winding tension can be increased or decreased by rotating the tool R (clockwise to increase).

Fig. 5

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22 Warp Stop Motion 22.1 WARP STOP MOTION WITH DROP WIRES (figure 1) To mount or dismount the warp stop motion on/from the loom, act on the levers M , right and left. The position in depth of the warp stop motion depends on the type of style being woven and the number of heald frames used. The adjustment is carried out by loosening the screws H of the left and right-hand lateral supports B.

Fig. 1

22.2

HEIGHT OF THE OVAL BARS OF THE WARP STOP MOTION

(figures 1 - 2 - 3) This setting usually offers two options: a) SHED CROSSING; in this case the two oval bars C are almost in touch with the warp threads when they are crossing. Under this condition the drop wires are at rest; b) WHEN LOWERED; in this case the two oval bars C just touch the threads when they are lowered. In this case the drop wires oscillate. Loosen screws A on the right and left-hand supports B (figure 1) and raise or lower the warp stop motion acting on the screw L (figure 1) and then tighten screws A again. Adjust the warp stop motion inclination to suit the position of the back roller, using screws G on the right and lefthand supports B (figure 1).

Fig. 2

Fig. 3

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22.2.1 HEIGHT OF THE WARP STOP MOTION ROWS (figure 4) This setting usually offers two options which we shall call HIGH and LOW. The setting is carried out by replacing the plastic spacer D which supports the rows, supplied with the warp stop motion. After replacing them, adjust lateral supports F using screws E.

HIGH Position: recommended to obtain an immediate machine stop when the thread breaks. To avoid possible defects in the fabric (cages). LOW Position: recommended for figured styles where some warp threads tend to loosen.

Fig. 4

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SECTION 5 LUBRICATION

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181

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Lubrication 1


GENERAL

The correct and effective lubrication of mechanical organs is essential for the m achine to operate correctly, avoiding premature wearing and possible damage to the various components. We therefore recommend that the following instructions are followed to the letter. The main mechanisms are oil-lubricated by a closed pressure circulation system. The lubrication system therefore only requires regular lubricant level checks, with top-ups when necessary. To replace the lubricant and filters see the instructions below. The fabric regulator and the warp let-offs are not in the pressure circulation system and operate in an oil bath. Here too, the lubricant level needs to be checked and replaced at set intervals. Other external mechanisms need to be oiled or greased by hand at the set intervals. In this case, all components where dust can build up should be cleaned thoroughly before lubricating these. See the relevant manuals for details of how best to lubricate the shedding machines, tie-rods and tuck-in devices.

1.1 SUPPLY CONDITIONS The machine is supplied already provided with lubrication. In any case, we recommend checking that the levels are correct before the first start-up. All greasing and oiling points have been lubricated during final testing. To avoid oil leaks during transit, shedding machines are not supplied pre-lubricated. Before starting the machine up, it is therefore essential that these are lubricated with the specific product provided and the level checked (see the shedding machine manual for details).

ATTENTION: DANGER! The lubrication oil can reach high temperatures; pay attention during replacement.

2

OIL LUBRICATION SYSTEMS

There are two different oil lubrication systems on the machine: a) Pressure circulation, closed circuits with pum p, tank and filters. b) Immersion of the working elements (oil bath). System a) is used for sley drive boxes and the main drive box. System b) is used for fabric regulator and warp let-offs

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Lubrication 2.1


LUBRICATION SYSTEM AND CONTROL DEVICE

The lubrication system uses pressure circulation with a gear pump, intake and drain filter units and a tank. The circuit is constantly controlled by electric pressure switches which detect the working conditions of the circuit. The complete circuit is shown in diagram form in figure 1

B A

C

Right command group

Left command group

E

D

Tank A = Minimum pressure switch N.O. 0.7 bar

Fig. 1

B = Maximum pressure switch N.C. 4.5 bar C = Drain filter D = Intake filter E = Pump N.C.= normally closed N.O.= normally open

2.2

MINIMUM PRESSURE SWITCH

The minimum pressure switch (1) (figure 2) is found on the left side frame. This switch trips when the oil pressure in the lubrication circuit drops below the minimum level and so is insufficient. This value is 0.7 bar. The microprocessor immediately stops the machine with the warning “Minimum pressure switch in alar m mode”. If this occurs, check that the pump works properly and that the tubes and fittings in the lubrication circuit are intact.

2.3

MAXIMUM PRESSURE SWITCH

The maximum pressure switch (2) (figure 2) is found on the head of the drain filter (3) (figure 2). This switch trips when the oil pressure in the lubrication circuit rises above the maximum level (4.5 bar). The microprocessor immediately displays the warning “Maximum pressure switch in alar m mode”, but does not stop the machine. 183

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Lubrication


Normally this means that the drain filter has become clogged and so needs to be replaced. If, after replacing the filter, the error message is still shown on the display, check that the lubrication circuit is not clogged.

2.4

PUMP MOTOR

The pump (4) (Figure 3) in the lubrication system is driven by an independent electric motor (5). After a normal machine stop, the pump motor stops automatically after a few minutes (this interval can be set from the Console - see the Console user manual) to limit the energy consumed by the machine. When this pump is stopped, when the machine is started up in Fast Speed mode, just the pump starts up and the warning lights start flashing. Wait about 7 seconds and then press the start buttons again to actually start the machine up in Fast Speed mode. This delay is needed to guarantee the correct lubrication of the machine.

1

Fig. 2 3

2

6

4

184

5

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Fig. 3

Lubrication 2.5


REPLACING THE FILTERS All operations must be carried out WITH THE MACHINE AT A STANDSTILL, POWER CUT OFF AND PADLOCK ON.

To replace the drain filter (3) (figure 3) or the intake filter (6) act as follows. a) Remove the filter from the head using a filter extractor. b) Lightly lubricate the seal on the new filter with the oil from the circuit. c) Manually tighten the new filter onto the head. d) If the filter is being replaced without an oil change, check the oil level in the tank and top up if necessar y.

2.6

CHECKING THE LUBRICANT LEVEL

To verify the level of the lubricant in the tank use the indicator (7) (figure 4).

This operation should be carried out at least 15 minutes after stopping the machine and switching off the oil pump motor.

CAUTION

Never start the machine up if the level of the lubricant is below the min mark.

6

7 Fig. 4

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Lubrication 2.7


REPLACING THE LUBRICANT (DRAINING AND FILLING)

All operations must be carr ied out WITH THE MACHINE AT A STANDSTILL, POWER CUT OFF AND PADLOCK ON.

We recommend carrying out this operation when the lubricant is at working temperature. To drain the lubricant, remove the drain cap (8) (figure 5) of the tank (9). To fill the lubricant, remove the filling cap (6) (figure 4) and pour in the lubricant.

9

8 Fig. 5

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Lubrication 2.8


TYPES OF LUBRICANT All operations must be carried out WITH THE MACHINE AT A STANDSTILL, POWER CUT OFF AND PADLOCK ON.

The tables below show the parts to be lubricated and the specifications and quantities of the lubricants to be used. We recommend using only the lubricants indicated in the tables. If it is not possible to find the lubricants listed here, contact our After-Sales Service. WARNING: The lubricants and necessary detergents can damage one's health, therefore in order to avoid contact with such substances, use gloves, glasses and anti-inhaling masks as prescribed by the relevant manufacturer. Lubricants are pollut ants. DO NOT DISPOSE OF I N THE ENVIRONMENT. Dispose of the used lubricant in accordance with prevailing laws and regulations.

2.8.1 SYMBOLS USED The symbols used in this section are the following:

= Fill

2.9

= Drain

= Level

UNITS TO BE FILLED WITH LUBRICATING OIL

2.9.1 PRESSURE LUBRICATION CIRCUIT TANK

Fig. 6 187

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Lubrication

USER AND MAINTENANCE MANUAL Change Frequency (hours) Lubrificant

Quantity (liters)

Mobilgear 600 XP100

15

First change

Following changes

1000

5000 (*)

(*) in any case not more than one year.

Fig. 7

Drain filter Intake filter

Change Filter

Type

Code

frequency (hours)

Drain

CS5000 M60-71 (blu)

Intake

CS5000-A 10-71 (bianco)

0483028

10000

(hours) 10000

0483031 5000 (*) 1000 (*) in any case not more than one year.

2.9.2 FABRIC REGULATOR AND LET-OFF UNITS

Fig. 8

188

First change

Fig. 9

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Lubrication

USER AND MAINTENANCE MANUAL Change frequency (hours) Quantity

First

Following

(liters)

change

changes

1000

5000

Unit

Lubrificant

Fabric Regulator (fig. 8)

Mobilgear 636

0,5

Let off (fig. 9)

Mobilgear 636

1,5

(*) in any case not more than one year.

For the type of lubricants to be used, refer to the following comparison tables:



BRAND

TYPE

MOBIL

MOBILGEAR 636

ESSO

SPARTAN EP 680

AGIP

BLASIA 680

IP

MELLANA 680

SHELL

OMALA OIL 680

TOTAL

CARTER EP 680

KLUBER

LAMORA 680

FINA

GIRAN 680

CASTROL

ALPHA SP 680

OPTIMOL

OPTIGEAR BM 680

WARNING WHEN TOPPING UP LUBRICANT: the same type of lubricant must be used to top up. The comparison tables shown previously are not tables for mixture compatibility, but for finding products with similar characteristics.

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Lubrication 3


GREASE LUBRICATION All operations must be carr ied out WITH THE MACHINE AT A STANDSTILL, POWER CUT OFF AND PADLOCK ON.

The parts listed below are to be lubricated with grease according to the procedure indicated in the following tables.

- the connection pins of the back roller springs and the back roller lever pin (both sides);

Lubrificant Agip GR MU 3 Klüber Centoplex 3

Fig. 1 - the back roller end (a greaser for each side);


Frequency

Monthly

Fig. 2 190

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Frequency

Monthly

Lubrication


- the pins, the chain, the drive shaft and the supports of the cloth winding cylinder;

Fig. 3a

Fig. 3b Lubrificant Agip GR MU 3 Klüber Centoplex 3

Frequency

Monthly

- The gears of the fabric regulator and the drive gear of the take-up cylinder;

Fig. 4a

Lubrificant Agip GR MU 3 Fig. 4b

191

Klüber Centoplex 3

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Frequency

Monthly

Lubrication


- The pins and the bushes of the press roller ;

Lubrificant Bellini Grease LI-EP-2-PT Klüber Microlube GL 262

Frequency

Monthly

Fig. 5 - The beam gear;


Frequency

Monthly

Fig. 6 192

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Lubrication


- the beam supports and connection (PBC version); Lubrificant Agip GR MU 3 Klüber Centoplex 3

Frequency

Monthly

Fig. 7

- The beam supports and connection (standard version); Lubrificant Agip GR MU 3 Klüber Centoplex 3

Frequency

Monthly

Fig. 8

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Lubrication


- The lateral heald frame guides felt; Lubrificant

Frequency

Mobilgear 600 xp100

Monthly

- The support pin of the rhs heald frame guide

Lubrificant

Frequency

Agip GR MU 3 Klüber Centoplex 3

Monthly

Fig. 9 - The wooden separators of heald frames

Lubrificant Lubropress

Frequency

Monthly

Fig. 10

4

TIE-RODS LUBRICATION

For the lubrication and maintenance of the undermotion, please refer to the Manual of the shedding machine supplied with the loom.

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SECTION 6 MAINTENANCE

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196

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Maintenance 1


REGULAR CHECKS (PREVENTIVE MAINTENANCE))

The aim of the regular checks and preventive maintenance described in this chapter is to keep the machine in a state of perfect efficiency. These checks are to be carried out at set intervals (daily, weekly, monthly, every six m onths or once a year). The intervals indicated here refer to a machine working at a norm al rate of production (24 hours a day, 6 days a week). Obviously, the frequency can be ad justed to suit the actual use made of t he machine.

The checks and operations required for each of the items described below must be carried out in full conformity with the instructions given in this manual. See paragraph 15 of section 4 for details on how to replace the lubricant and the filters

1.1

DAILY CHECKS (D) Description

Operation

Reference

Clean with compressed air the cooling fins D1

Main motor

and the fan cup. Remove any possible yarns

--

waste. Clean with compressed air the cooling fins D2

Suction device motor

and the fan cup. Remove any possible yarns

--

waste. D3

Main electric box

Clean with compressed air the outside and the heat sink.

--

D4

Intake filter

Emptying, clean and check efficicen.

--

D5

False selvedge bin

Emptying and pulling tension check.

--

1.2

WEEKLY CHECKS (W) Description

W1

Fabric support, beat-up and overall machine

Operation Clean with vacuum and compressed air.

Reference --

Check positioning, state of needles and free W2 Temples

197

rotation of the rings.

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Sec. 4 - Ch. 4

Maintenance

USER AND MAINTENANCE MANUAL Description

Operation

Reference

W3 Lateral cutters

Check cutting conditions.

Sec. 4 - Ch. 5

W4 Reed

Dents clearing with specific porducts.

Sec. 3 - Ch. 3

W5 Compactor device

Filter cleaning.

W6 ELD belt and pulleys

Compressed air cleaning and integrity check.

Sec. 4 - Ch. 12

Operation

Reference

1.3

--

MONTHLY CHECKS (M) Description

M1

Covering of electrical connections

Check integrity.

--

Check tightness of screws on the heald frame M2

Heald frames

couplings and lateral supports.Lubricate the

Sec. 5 - Ch. 3

wooden separators. M3

Sley

M4

Shedding machine and undermotion

M5

Warp stop motion

M6

False selvedge

M7

Fabric regulator

M8

Cloth roller

M9

Heald frames guide

M10

Backrest roller

M11

Fabric press roller

Clean area between cross bar and the struts on the sley shaft. Clean and lubricate. Clean and check efficiency.Check fastening and wear of rows. Clean. Grease and check lubricant level. Grease drive chain, toothed wheel and cloth roller pins. Lubricate felt and grease central pin. Grease bushes, rest points on spring rod and lever fulcrum points. Lubricate spring rod. Grease pins and bushes. Check level of lubricant and general state of

M12

Lubrication circuit

M13

Let-offs

Check for lubricant.

M14

Extra ends device

Grease pin.

M15

ELD belt

M16

Lateral and central cutters

Check tension. Check position and wear of blades.Grease the

198

circuit.

hooking points of the spring.

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-Sec. 5 - Ch. 4 --Sec. 5 Ch. 2.9.2 Sec. 5 - Ch. 3 Sec. 5 - Ch. 3 Sec. 5 - Ch. 3 Sec. 5 - Ch. 3 Sec. 5 - Ch. 2.6 Sec. 5 Ch. 2.9.2 Sec. 5 - Ch. 3 ---

Maintenance 1.4


FREQUENZA SEMESTRALE (S) Description

Operation

Reference See specific

S1

Shedding machine and undermotion

Check for play at joints.

S2

Take-up and fabric press rollers

Check state of covering.

--

S3

Cloth roller clutch

Clean and check take-up.

--

S4

Backrest roller (bearings)

S5

Safety devices

Check integrity of bearings and bushes and check for correct movement of levers. Check efficiency of the devices. Clean inside with compressed air and suck

manuals

---

S6

Electrical box

S7

Coling fans inside the main electrical box Check functionality .

--

S8

Compresse air filter

Check air leakages and clean.

--

S9

False selvedge take-up

Check the winding cone status.

--

S10

1.5

Pneumatic system

residues.

Pipes integrity visual check and search for air leakages.

--

--

YEARLY CHECKS (Y) Description

Operation

Reference

The machine must be subjected to yearly inspection by SKILLED PERSONNEL to make Y1

Check

sure that all safety devices are running smo-

--

othly and that the different parts of the machine are in a good state of repair. Check the existence and integrity of the gluing/

Y2

Installation

Y3

Lubrification

Y4

Relay nozzles

Clean with ultrasonic device.

--

Y5

Main and fixed nozzles

Clean with ultrasonic device.

--

Y6

Compressed air filter

Cartridge replacement.

--

199

fixing of the machine to the floor. Oil change for the lubrication system, the fabric take-up and let-offs.

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-Sez. 5 Cap. 2.9

Maintenance

200


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SECTION 7 APPENDIX

201

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202

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Appendix 1


USING THE FLOWMWTER (figure 1)

The flowmeter A is a device for measuring the quantity of air comsumption in "cubic metres/hour" necessary for weaving on the machine. On request the flowmeter may be supplied with an accessory kit for one to ten machines.

1.1

CONNECTION

- Close the general air supply; - the delivery/stop valve B must be open; - connect the tube to the flowmeter as indicated in the figure; - start the loom and slowly close the delivery/stop valve B (to avoid backflow to the flowmeter) to its fully closed position.

1.2

READING THE FLOWMETER

With the machine in operation, the flowmeter float D is positioned on the graduated scale with a minimum value of 15 Mc./hour and a maximum of 170 Mc./hour. While the machine is in operation, if the pressure indicated on the flowmeter manometer E is equal to 5 Bar then the value indicated by the float D will determine the actual air consumption, if however the pressure is inferior or superior, one must use the conversion table of the following page. .

E

D

A C B

203

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Fig. 1

Appendix


Pressure indicated by manometer (bar) 2

2,5

3

3,5

4

4,5

5

5,5

6

6,5

7

Correct air consumption value (Nmc/hour)

)r u o h / c m N ( le a c s d te a u d ra g r e t e m w o fl e h t o n d e t c e t e d e lu a v n o ti p m u s n o C

204

20

14

15

16

17

18

19

20

21

22

22

23

30 35

21 25

23 27

24 29

26 30

27 32

29 34

30 35

31 36

32 38

34 39

35 40

40

28

31

33

35

37

38

40

42

43

45

46

45

32

34

37

39

41

43

45

47

49

50

52

50

35

38

41

43

46

48

50

52

54

56

58

55

39

42

45

48

50

53

55

57

59

61

64

60

42

46

49

52

55

57

60

62

65

67

69

65

46

50

53

56

59

62

65

68

70

73

75

70

49

53

57

61

64

67

70

73

76

78

81

75

53

57

61

65

68

72

75

78

81

84

87

80

57

61

65

69

73

77

80

83

86

89

92

85

60

65

69

74

78

81

85

88

92

95

98

90

64

69

73

78

82

86

90

94

97

101

104

95

67

73

78

82

87

91

95

99

103

106

110

100

71

76

82

87

91

96

100

104

108

112

115

105

74

80

86

91

96

101

105

109

113

117

121

110

78

84

90

95

100

105

110

114

119

123

127

115

81

88

94

100

105

110

115

120

124

129

133

125

88

95

102

108

114

120

125

130

135

140

144

130

92

99

106

113

119

124

130

135

140

145

150

135

95

103

110

117

123

129

135

141

146

151

156

140

99

107

114

121

128

134

140

146

151

157

162

145

103

111

118

126

132

139

145

151

157

162

167

150

106

115

122

130

137

144

150

156

162

168

173

155

110

118

127

134

141

148

155

161

167

173

179

160

113

122

131

139

146

153

160

167

173

179

185

165

117

126

135

143

151

158

165

172

178

184

191

170

120

130

139

147

155

163

170

177

184

190

196

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Appendix


2 SHARPENER FOR WEFT CUT BLADES (on request) (figures 2, 3, 4 and 5) In order to correctly operate the shar pener for the weft cut blades (on request), refer to the relevant instructions supplied with the device. The following information describes how to use the device with the A9500 loom.

The device is fitted with two different kinds of clamping devices according to the type of blade to be sharpened: code QARZ003 and code QARZ008. D C

C - clamp for blade locking D - locking screw E - blade positioning template F - "fork" system to hold the template E

F QARZ003 E

Fig. 2

To position the blade, lift the template E till it rests on the "fork" F, so that the small tooth G protrudes and the blade rests on it.

G

E

QARZ003

Fig. 3

205

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Appendix


Place the blade to be sharpened so that it adheres perfectly to the small tooth G of the template E. Tighten the clamp C by acting on the screw D. D C

G

Fig. 4 E

Fig. 6

Fig. 5

Once the blade has been locked in place, move the template E to the side so that it can be rotated downwards, exposing the part of the blade to be sharpened.

Fig. 7

E

Fig. 8

206

Fig. 9

29 - 02 - 2012

Appendix


The following figures show the right orientation of the blades in the clamping device. The part of the blade with the holes for the positioning on the loom cutter must be placed opposite the grinding wheel of the device.

QALT10A

QALT09A Fig. 10

Fig. 11

QALT014 Fig. 12 For the blade, code QALT003, the clamping device, code QARZ008, must be used. Place the blade on the device (using the pin P) and fasten it by rotating the bracket S (using the screw T ). T S

QARZ008 P Fig. 13

Fig. 15

207

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Fig. 14

Appendix 3


ADJUSTMENT SHEETS

208

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Appendix

209


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Appendix

210


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Appendix 4


SCREW TIGHTENING TORQUES

The tightening of screws is carried out in accordance with th read resistance class standards, with the exception of the specific cases noted in this manual. The resistance class of the screws is marked on their heads. If they have no marking, the resistance is 8.8 (8G). The tightening values are shown in the spare parts catalog.

RESISTANCE CLASS SCREW THREAD

KEY WIDTH

6.9 (6G)

8.8 (8G)

10.9 (10K)

12.9 (12K)

MM

Nm

Nm

Nm

Nm

M5

9

4,12

4,91

6,97

8,33

M6

10

9,80

10,78

13,72

16,67 40,20

M8

13

21,57

25,49

34,32

M10

17

44,13

48,05

67,66

81,39

M12

19

73,55

84,33

117,60

142,10

M14

22

112,70

132,30

186,30

235,50

M16

24

156,90

205,90

289,20

348,10

M18

27

235,30

284,30

397,10

475,60

M20

30

304,00

402,00

568,70

676,60

M22

32

431,40

539,30

794,90

912,00



1Nm = 1Newton meter = 0,102 Kgm

211

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Appendix

212


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A9500 User and Maintenance Manual ENG_120710009

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