loom omega6 part eng

STACOLOOM SL 6

SL 6

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INTRODUCTION Page 1

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The purpose of this instruction manual is to facilitate the operation and maintenance of the machine. It will help to ensure a long working life as well as a maximum performance and efficiency, and at the same time contribute to accident prevention. That is why the following instructions should be read and observed very carefully. The operating manual has to be always available wherever the machine is in use. Every operator being in charge of the machine or performing work on it has to read it carefully and to act in accordance. In addition we can offer the assistance of our service engineers according to the general terms of services performed by our installation and commissioning personnel.

INDEX - OPERATING MANUAL Page 2

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1 Technological description: 5

2 Technical data: 9

3 Installation: 11

3.1 Installation plan: 11 3.1.1 Circular loom with surface winder 11 3.1.2 Circular loom with trolley winder (special equipment) 12 3.1.3 Circular loom with second surface winder, one above the other (special equipment): 13 3.1.4 Circular loom with surface winder and unfolding device (special equipment) 14

3.2 Location: 15

3.3 Assembly: 15 3.3.1 Supporting frame 16 3.3.2 Creel 20 3.3.3 Surface winder 23 3.3.4 Electrical connection 23 3.3.5 Compensators 24 3.3.6 Weaving ring 25 3.3.7 Circular guide and spreading system 26

4 Adjustments: 27

4.1 Tightening of belts and chain: 27 4.1.1 Tightening the belt to the V-belt pulley 27 4.1.2 Tightening the belt to the driving motor 27 4.1.3 Tightening the haul-off chain 28

4.2 Weaving ring: 29 4.2.1 Height adjustment 29 4.2.2 Centering the weaving ring 29 4.2.3 Dismounting the weaving ring 29

4.3 Circular guide: 30 4.3.1 Mounting the circular guide 30

4.4 Cloth spreading system: 31

4.5 Shuttle: 32 4.5.1 Mounting and dismounting 32 4.5.2 Adjustment of the weft insertion finger 33 4.5.3 Weft tape brake 35

4.6 Modification of weft insertion: 36

4.7 Weft break: 37

4.8 Tape lubricator: 38


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4.9 Shedding units: 39 4.9.1 Control of the shedding units 39 4.9.2 Tightening the shedding units 39 4.9.3 Measuring the grommet band tension 39

5 First start-up and normal operation: 41

5.1 Functions of the control switches: 41 5.1.1 Control elements on the machine: 41 5.1.2 Control elements on the switch cabinet: 42 5.1.3 Control elements winder (Option): 42

5.2 Test run: 43

5.3 Distribution of the warp tapes to be threaded: 44 5.3.1 Calculation of the total number of warp tapes 44 5.3.2 Creel bobbins 46 5.3.3 Inlet combs 48 5.3.4 Pulling up the tapes 49 5.3.5 Threading into eyelet bow and bending spring compensator 50 5.3.6 Threading through shedding unit and reed 51 5.3.7 Pulling up of the tapes over the inlet 53 5.3.8 Preparing the shuttles 54 5.3.9 Insertion of the shuttles 54 5.3.10 Start weaving 55 5.3.11 Intermediate roller 55

5.4 Number of picks and weft density: 55

5.5 Normal operation: 56 5.5.1 Warp break detecting system 56 5.5.2 Weft break detecting system 56

5.6 Changing the cloth roll: 57

5.7 Changing the bobbins on creel: 57

5.8 Checks to be carried out by the operator: 58

6 Lubrication and maintenance: 59

6.1 Lubrication chart: 60

6.2 Lubricant list: 61

6.3 Maintenance work: 62 6.3.1 Daily preventive maintenance work 62 6.3.2 Weekly preventive maintenance work 63

7 Directions for fault diagnosis: 64

7.1 Electrical troubles: 64

7.2 Mechanical troubles: 66


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8 Annex: 67

8.1 Application of a finishing agent: 67

8.2 Denier table: 67

8.3 Tape specification: 68

8.4 Weaver’s knot: 68

8.5 Special accessories: 69 8.5.1 Electrically controlled inlet system with balancer 69 8.5.2 Trolley winder 70 8.5.3 Stacosonic cutting device: 71 8.5.4 Ultrasonic cutting device: 73 8.5.5 Thermal slitting device 75 8.5.6 Unfolding device with surface winder 77 8.5.7 Gussetting device 78 8.5.8 Monitoring device for weft tape end with colour sensor and black bobbin core 79 8.5.9 Monitoring device for weft tape end with light barrier and reflector tape core 80

1. TECHNOLOGICAL DESCRIPTION Page 5

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1 Technological description:

The heavy duty circular loom was specially designed to weave endless tubular or flat cloth out of PP, HDPE, LLDPE tapes or other blends of polyolefines.

The warp tapes are taken from two creels via rollers to the loom, which ensures uniform warp tension, excellent cloth quality and trouble-free handling.

During production the warp bobbins can be changed easily and quickly without shutdown of the loom: tape ends are simply tied in.

The weft is inserted by six shuttles running in a reed constructed for this purpose.

By using sturdy materials specially developed for the heavy duty circular loom, the mass of the moving parts has been reduced to a minimum, thus ensuring high output capacity as well as a long working life and reduced spare parts consumption.

The cloth width can be modified by simply changing the weaving ring.

The tubular cloth is taken past a calibrating and spreading system to two continuously driven draw-off rollers and subsequently batched onto a cloth winder.

Thanks to the superior construction of the heavy-duty circular loom and to the fact that no sliding elements are used, no central lubrication system is necessary, and the loom therefore achieves high speeds while minimizing energy consumption and maximizing efficiency.

The standard version of the loom includes:

• Two creels: to be fitted with warp bobbins

• Warp infeed system: consisting of intake and intermediate rollers to ensure a smooth inlet of the tapes into the machine as well as to maintain an even warp tension.


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• Warp break detecting system: Each tape is passing through a compensator which is responsible for tape length compensation and which shuts down the machine automatically if a broken tape makes a contact; the warp break is indicated by one of the pilot lamps arranged in the sectors of the loom’s circumference.

• Weft break detecting system: A magnetic sensor monitors the continuous tape supply. In case of an eventually broken weft tape the machine is stopped and the haul-off speed is automatically reduced in order to avoid a visible weft fault.

• Three manual control units: consisting of inch button, stop button (with lock-down) and start button. The control units are easily accessible to the operating personnel from every point around the loom.

• Main drive system: A central shaft is driven via V-belts by an AC motor. Two speeds can be selected. The rotating cam controls the shedding motion and drives the shuttles.

• Cloth haul-off: Speed of the cloth haul-off is infinitely variable. The desired weft density can be adjusted by means of keys on the loom control and can also be modified during the operation of the machine. When threading the loom you can operate the haul-off by depressing the button without starting the machine.

Accessories included with the standard model:

• Automatic weft cramming device: In case of a weft break the haul-off speed is automatically reduced in order to avoid visible weft faults in the fabric.

• One weaving ring with circular guide: is supplied with the dimension required.


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• Loom control: The central computerized control unit of the loom serves for

1. adjustment of weft density,

2. setting the desired running meters to be wound on the cloth roll;

3. it allows the manual control of the haul-off speed without starting the machine, and

4. it is provided with following indications of machine data:

• 4-shift meter counter including summation counter

• weft speed indicator

• operating hour meter

• indication of haul-off speed

• indication of roll change

• fault indication

• Efficiency in percent

5. Machine evaluation system. This module determines for each shift the following additional data and evaluates them:

• cutting-in period of the machine

• operating time of the machine

• number of broken warp tapes

• number of broken weft tapes

• efficiency in percent

The indications can be called up in various languages and in the metric or the British (inch) system.

• Surface winder: designed for winding up the tubular cloth or length of fabric on cores. The drive rollers with slip-resistant coating ensure the production of fabric rolls free from creases. The winding tension can be controlled progressively.

• Bobbin storage above the intake


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SPECIAL ACCESSORIES:

Electrically driven inlet system with balancer: To be used with the version for large tapes. A magnetic sensor keeps the balancer in horizontal position by controlling the motor of the inlet roller and maintaining in this way the tape tension at a constant value.

Trolley winder: specially designed for easy transportation and further processing of the cloth without special auxiliary device. The winding tension can be adjusted with infinite variability.

Second surface winder, one above the other: designed for winding up both lengths of single lay flat cloth on cardboard cores. The drive rollers with slip-resistant coating ensure the production of fabric rolls free from creases. The winding tension can be controlled progressively.

Stacosonic welding device, using cold-cutting: designed for slitting a tubular fabric having smooth reinforced edges. It is welded by ultrasonics and subsequently is cold-cut. Thereby, a clean, neat edge of the fabric is guaranteed without heat being developed.

Ultrasonic welding device, using cold-cutting: designed for slitting a tubular fabric. It is welded by ultrasonics and subsequently is cold-cut. Thereby, a clean, neat edge of the fabric is guaranteed without heat being developed.

Thermal slitting device: with adjustable temperature control designed for longitudinal cutting of polyolefine tubular fabrics and simultaneously sealing the fabric edge.

Unfolding device with surface winder: A specially designed device unfolds the tubular fabric to flat fabric. Subsequently, the unfold flat cloth is wound up on cores. The drive rollers, with slip-resistant coating, of the surface winder ensure the production of fabric rolls free from creases. The winding tension is adjustable with infinite variability.

Gussetting device: for folding gussets on both sides of the fabric. The gussetting depth can be adjusted with infinite variability.

Monitoring device for weft tape end with colour sensor: the colour of the core has to make a contrast with that of the tape. The machine is stopped automatically before weft tape end.

Monitoring device for weft tape end with light barrier: with light barrier and core with reflector tapes. The machine is stopped automatically before weft tape end.


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2 Technical data:

Working width, double flat 300 – 850 mm

With reduced weft insertion 700 – 850 mm

Number of shuttles per machine 6

Weft density 20 – 75 picks/10 cm

Weft insertion 900 picks/min

Speed 150 rpm

Weft bobbin:

Inside diameter of core 35 mm

Core length 218 mm

Max. diameter of weft package 115 mm

Traverse length 200 mm

Warp bobbin

Inside diameter of core 35 mm

Core length 218 mm

Max. diameter of warp package 160 mm

Traverse length 200 mm

Number of tapes 720 pcs

Creel positions 720 pcs

Surface winder (standard equipment)

Cloth width 850 mm

Max. roll diameter 1200 mm

Motor torque at standstill 1,1 Nm

Cloth trolley (special equipment)

Cloth width 850 mm


Motor torque at standstill 1,3 Nm


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Second surface winder, one above the other (special equipment)

Cloth width 850 mm


Motor torque at standstill 1.1 Nm Surface winder for unfolding device (special equipment)

Cloth width 1700 mm


Motor torque at standstill 2.5 Nm

Space required

Length with surface winder (standard) 10560 mm

Length with trolley winder (special equipment) 10620 mm

Length with second surface winder, one above the other (special equipment)

10770

mm

Length with surface winder for unfolding device (special equipment)

10680

mm

Width (with single installation) 2800 mm

Spacing with installation of several machines 2200 mm

Height 2920 mm

Height with second surface winder, one above the other (special equipment)

3020

mm

Electrical data

Nominal rating of main motor 3 kW

Average power consumption approx. 2.2 kW

Connected load 5 kVA

For electrical supply (voltage, frequency and cross section of wires) refer to the electrical circuit diagrams.

Noise being produced

Noise level 92 dB(A)

Our machinery is not suitable for an outdoor installation!

Ambient temperature for the production and storage facilities between 18°C and 40°C.

3. INSTALLATION Page 11

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3 Installation:

3.1 Installation plan:

3.1.1 Circular loom with surface winder


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3.1.2 Circular loom with trolley winder (special equipment)


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3.1.3 Circular loom with second surface winder, one above the other (special equipment):


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3.1.4 Circular loom with surface winder and unfolding device (special equipment)


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3.2 Location: The area for machine installation should be horizontal and suitable for supporting the pressures applied as well as for avoiding any transmission of vibrations caused by the machine operation. The load carrying capacity of said area has to be 1000 kg/m2 minimum.

The installation of the machine has to be carried out according to the lay-out plan (see supplement).

3.3 Assembly: With the exception of some loose parts, the circular loom is supplied completely assembled.

We recommend to arrange the packages on the place of installation before unpacking the equipment.

Pay attention to the winding direction: Winder side = the side facing the main motor.

Open the packages and put the loose parts separately to one side.

Stock the spare parts immediately in the parts store.


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3.3.1 Supporting frame On the supporting frame are provided recesses for a fork-lift truck by means of which the machine can be taken from the pallet.

When unloading the machine pay attention to its components.

Adjust the four machine feet at 135 mm and mount them on the supporting frame.

When assembling secure all screws and nuts with Loctite 243 included in our scope of supply.


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Alignment: Unevenness of the floor can be compensated by means of the machine feet. Level the machine by a spirit level to be positioned on the cam. Readjust the position of the feet (8 pieces per machine) so that they are charged with the same load and tighten them. When installing several machines align them by means of a cord. Parts of the inlet side: Mount the parts of the inlet side (1) on the supporting frame (2). Adjust the machine feet at 135 mm and attach them to the parts of the inlet side.

ATTENTION: On the gear motors you have to replace the transport screws by the vent screws.

Haul-off support:

The haul-off supports (3) have to be mounted on the parts of the inlet side (1). Screw the bridge supports (5) as well as the control cabinet supports (4) to the haul-off supports (3).

Mount the control cabinet (9) on the control cabinet supports (4).


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Haul-off frame:

The haul-off carriers (20) are attached to the bridge support (5) and to the control cabinet support (4). Subsequently, mount the deflection roller (21) with the moving plate (22) and the haul-off roller (23). When doing so, push the compensating washer (24) and the distance sleeve (25) onto the axle of the haul-off roller (23) and fasten them with the screw (26).

During installation, please make sure that the bearing (27) is arranged so as to be free from play!


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On the opposite side, push the distance sleeve (28) onto the axle of the haul-off roller (23) and fasten it with the screw (29).

Then, mount the distance piece (30) and the cable duct (31).

The motor (7) has to be fixed on the right side, in the direction of the fabric winder.

Subsequently, tighten the screws for the bridge supports and the control cabinet supports.

Further, the platform brackets (8) can be mounted on the parts of the inlet side (1).

Afterwards, mount the distance piece (10), the intermediate rollers (11), supporting tubes (12) with the threaded gratings (13), inlet rollers (14) with brake support on the haul-off supports (3).

Attach the combs (15) and (16) and the wetting tub (17) on the inner side of the haul-off supports (3).

With the exception of the screws for fastening of the combs (15) you now can tighten all screws. Check the easy motion and truth of rotation of all rollers.

When assembling secure all screws and nuts with Loctite 243 included in our scope of supply.

After installation, the electrical equipment is connected and a test run is performed (refer to item 5.2).


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3.3.2 Creel Start the creel assembly outside of the installation area of the machine.

Creel structure:

Assemble the individual spindle supports (1) with the vertical supports (2) to form complete creel rows and stack them.

Provide wooden supports under the stack so that the spindles will not be loaded and cannot be deformed or bent.

After having preassembled the creel, complete it according to the installation plan (refer to item 3.1). For this purpose draw under the loom a center line (vertically to the machine row) and position the creel. Slide the creel rows onto the creel feet (4). After having aligned the creel sections with regard to the machine, interconnect them with the tubular elements (5) and mount the creel braces (6) laterally on the rear supports. Additionally mount on both sides braces from the haul-off supports of the machine to the creel.


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Mount the creel eyelets (3) on the side facing the machine.

Position the creel eyelets in such a way (as to the height) that the tapes of the rear bobbins will not get into contact with the bobbins of the lower row.


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Bobbin adapters

Start immediately the assembly of the bobbin adapters.

Before sliding the bobbin adapters (1) onto the creel spindles (2), clean the spindles and thread the spacer sleeves (3).

Now put on the bobbin adapters and fix them with two circlips (4) in such a way that approximately 2 mm clearance will remain available. Subsequently check them for easy motion.

ATTENTION: Do not lubricate the creel spindles (2)!


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3.3.3 Surface winder Mount the surface winder and the accompanying components. The cloth winder has to be positioned centrically to the loom and fixed to the floor by means of bolts.

Pay specially attention to the exact installation of the cloth winder, otherwise the cloth web will run laterally of the surface winder.

Mount the fabric winder to form a right angle with the machine center line. Also care for the horizontal alignment of the rollers!!!

3.3.4 Electrical connection

ATTENTION: The machine number on the loom and on the control cabinet must always be identical!!

The electrical connection has to be executed according to the electrical circuit diagram, but only by specialists.

Subsequently the electrical cables for the cloth winder have to be laid.

The electrical circuit diagrams correspond to the specific machine version and are enclosed to the unit.


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3.3.5 Compensators The number of compensators results from the cloth construction (see item 5.3).

If you already know the number of compensator springs (1), you can mount them already.

The gaps between the compensator springs have to be filled with the spacers (2) and the bending spring separators (3) included in our scope of supply.

ATTENTION: The compensators must always be parallel and the number of spacers and bending springs per segment must always be

identical!!


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3.3.6 Weaving ring After tightening the nuts (3) the weaving ring (1) is supported by the weaving ring holders (2) (for adjustment see item 4.2).


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3.3.7 Circular guide and spreading system Put the circular guide (1) onto the threaded bar (2) and screw it with the preassembled spreading system (3) into the shaft (4), which is already mounted in the cam (7). Fasten the spreading system (3) with the nut (5) and the circular guide (1) with the nuts (6).

The spreading system can be adjusted immediately to the intended width, which should exceed the cloth width by 2 cm.

4. ADJUSTMENTS Page 27

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4 Adjustments: ATTENTION: When performing setting work on the machine, always put the

main switch to the OFF position!

4.1 Tightening of belts and chain:

4.1.1 Tightening the belt to the V-belt pulley The belt (3) from the intermediate gear (2) to the belt pulley (4) can be tightened after undoing the screw (1) and rotating the intermediate gear (2). For this purpose loosen the screws (7). By tightening the screw (1) the intermediate gear (2) is fixed again.

The belt is tightened correctly, if it can be deflected by 5 mm at the testing point (a) when applying a testing force of 70 N (see illustration on next page).

4.1.2 Tightening the belt to the driving motor The belt (5) from the motor (6) to the intermediate gear (2) can be tightened after undoing the screws (7) and swiveling the motor (6). Subsequently tighten the screws (7) again that the motor (6) will be fixed in this position.

The belt is correctly tightened, if it can be deflected by 5 mm at the measuring point (b) when applying a testing force of 30 N (see illustration on next page).


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Tension check:

4.1.3 Tightening the haul-off chain The haul-off chain (1) can be tightened by undoing the screws (2) and displacing the motor (3). After having tightened the chain fasten again the screws (2) and mount the chain guard (4).


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4.2 Weaving ring:

4.2.1 Height adjustment The height of the weaving ring (1) with regard to the weaving ring support (4) can be adjusted by loosening the nuts (3). The distance between the lower edge of the weaving ring and the cam shall be approx. 103 mm.

4.2.2 Centering the weaving ring After loosening the screws (2) you can center exactly the ring supports (4) together with the weaving ring (1). Additionally check the distance with regard to the reed race (x) over the complete circumference. It may not differ by more than 3 mm.

4.2.3 Dismounting the weaving ring Turn out the spreading system with the assembled circular guide by rotating the shaft and remove it through the cut open fabric width. Now you can remove the weaving ring. After having unscrewed the nuts (3) and (5) as well as after having removed the threaded bar (6) the weaving ring (1) ring has to be lowered and then taken out through the cut open fabric width.


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4.3 Circular guide:

4.3.1 Mounting the circular guide You have to cut open the fabric in order to be in a position to remove the spreading system with the mounted circular guide.

Loosen the nuts (8), turn out the spreading system (7) with the assembled circular guide (5) by rotating the shaft (2) and remove it through the fabric. Subsequently loosen the nuts (9) and dismount the circular guide (5). Then slide the new circular guide onto the threaded bar (6) and fix it again with the nuts (9). Push the spreading system with the new circular guide into the shaft (2) and attach it with the nut (8) (see item 3.3.7).


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4.4 Cloth spreading system: When changing the weaving ring, the spreading system has also to be adapted to the new cloth width.

The upper edge of the spreader rolls (1) has to be set 30-40 mm below the center line of the haul-off roller. After undoing the nut (2) this adjustment can be done by turning the threaded bar (3).

The spreading width can be set after undoing the nut (4) and turning the connecting piece (5). It depends on the weaving ring diameter and should exceed the desired bag width by 20 mm. Subsequently retighten the nut (4).

The support sleeve (6) serves for setting the spreading force in such a way that the cloth runs to the haul-off roller without forming creases.

When adjusting the spreader (7), pay attention that the fabric is drawn off by the haul-off roller (8) exactly in the center of the machine, as is illustrated below.


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4.5 Shuttle:

4.5.1 Mounting and dismounting For mounting and dismounting the shuttles both tapered rollers (1) have to be removed.

After having mounted the shuttles in the reed, both tapered rollers have to be adjusted. This will be obtained by turning the bolt (3) and subsequently tightening the screw (2) which will lock the tapered rollers in position. For adjustment observe the clearance between the roller and the reed race.

The rollers (1) have to be adjusted in such a way that it is still possible to rotate them easily by two fingers and that the tapes pass the roller (1) without being damaged.

The cam bolts (3) have always to show opposite to the running direction.

Check this adjustment one hour and once again five hours after setting into operation of the machine, because the clearance of the rollers (1) can vary at operating temperatures.

Should it no longer be possible to rotate the rollers (1) easily with two fingers at operating temperature, correct the adjustment.


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4.5.2 Adjustment of the weft insertion finger Take the tape directly from the weft bobbin through the weft compensator (4) and via the wire insertion finger (10) to the weaving ring.

All insertion fingers should be adjusted at one marked place in the machine (reed)! The insertion finger shut-down with weft compensation is mounted on the insertion tube (2) by tightening the screws (1). The complete insertion finger can be displaced after having undone the screws (3), i.e. it can be extended and shortened.

In case of a broken weft tape, the weft compensator (4) folds into position (5) and the machine is stopped by the magnetic sensor.

Pay attention that the wire insertion finger (10) is mounted centrally to the weft bobbin and that the distance between the wire insertion finger (10) and the weaving ring is about 3 mm. This adjustment must be identical for all shuttles.

The inclination (7) of the insertion tube (2) can be adjusted after loosening the screw (6). After having finished the adjustment tighten the screw (6) again.


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Insertion ranges for the various insertion tubes:

from 20cm to 45cm dfl. from 45cm to 70cm dfl. from 70cm to 90cm dfl.


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4.5.3 Weft tape brake The tape tension can be set by loosening the screw (3) and displacing the spring plate (2). The tape tension can be measured downstream of the insertion finger by means of a spring balance. The value indicated should be 500 g. This adjustment must be identical for all shuttles.

ATTENTION: The tension of weft tape depends on the tape quality.

If the brake leather is worn, proceed as following:

• Clean the adhesion surface (1) with a solvent

• Paste the brake leather onto the brake and press it strongly on

• Bevel the lateral edges (5)

ATTENTION: Use the brake only after one day so that the glue has hardened sufficiently.


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4.6 Modification of weft insertion: The main motor is equipped with a belt pulley having two different diameters. The weft insertion can be modified by changing the belt to the other diameter and by reversing the belt pulley of the motor (180°).

Before starting the modification put the main switch on the control cabinet to position 0 (to avoid any setting into operation of the machine by unauthorized persons).

Loosen the belt to the driving motor, change it over to the other diameter and tighten it again according to item 4.1.2. Do not perform any work on the intermediate gear!


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4.7 Weft break: Mount the support (11) of the magnetic sensor (12) on the weaving ring support (13). The magnetic sensor (12) has to be placed in the area of the recess for take-up (9) (see ill. item 4.5.2). The distance between the magnetic sensor (12) and the weft compensator (14) may be maximum 40 mm. For checking the correct adjustment a luminous diode on the magnetic sensor (12) will be lighted when the weft compensator (4) is entirely folded out (see item 4.5.2).


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4.8 Tape lubricator: On the tape lubricator the number of drops can be exactly regulated.

Put the lever (2) into the vertical position. After loosening the screw (1) you can adjust the flow rate (approx. 1 drop per min) by turning the lever (2).

Subsequently fix the screw (1) again.

With the lever (2) in horizontal position, the drip oiler is out of operation.


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4.9 Shedding units:

4.9.1 Control of the shedding units The control of the shedding units has been adjusted in our works. When carrying out a repair on the shedding units, you have to readjust them.

4.9.2 Tightening the shedding units After undoing the nuts (4) the grommet bands can be tightened by turning the setting screws (2) on the bearing block (3).

After having set the correct tape tension you have to fasten the nuts (4) again.

4.9.3 Measuring the grommet band tension Turn the machine in such way as to position the rear and the front grommets at the same level.

Attach a spring scale in the center of a round steel bar used as support behind the grommets and pull the grommet band 20 mm to the front. The balance shall indicate a value of 5 kg.

After having adjusted the correct band tension check, if the grommet band is running in the center of the deflecting roller (5), i.e. it has also to be in the center of the upper bearing block (3).


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5. FIRST START-UP AND NORMAL OPERATION Page 41

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5 First start-up and normal operation:

5.1 Functions of the control switches:

5.1.1 Control elements on the machine: Each loom is equipped with key units by which the operator can stop, start or inch the machine.

Inching:

This key has no holding contact, i.e. the operator has to depress it as long as he wishes to inch the loom.

Stop:

This key is provided with an interlocking device, i.e. if one of the keys is depressed, it remains in stop position, and the machine cannot be started by any other key. Restarting is only possible if the interlocking has been reset by turning the stop key.

SAFETY INSTRUCTION: Pay attention that this key is depressed during any adjusting work on the machine.

On:

This key with holding contact ensures continuous operation.


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5.1.2 Control elements on the switch cabinet:

1

2

3

Fabric tension at winder

Loom controller

Main switch

5.1.3 Control elements winder (Option):

10 2. Winder on/off

11 Fabric tension during operation

12 Fabric tension during standstill


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5.2 Test run: After having finished the machine installation according to the installation plan, the assembly, the adjustments and the inspection of the lubricating points (refer to item 6.1) you can perform a test run.

The test run speed of the machine has to be 720 picks/min (i.e. the belt has to be on the small motor pulley). Make the machine run at this speed for at least 8 hours. The number of picks can be modified by changing the belt over to the other pulley diameter (see item 4.6).

Cut in the main switch (3).

All stop keys have to be unlocked by turning them.

Check the sense of rotation by depressing the key „Inch“. The machine has to rotate clockwise.

Make the machine run for a longer period by maintaining the „Inch“ button manually in depressed position. Watch for truth of rotation and pay attention to anomalous operating noise.

After the test run you have to perform the following checks:

• Check the position of the grommet bands with regard to the deflecting rollers and correct it if necessary (see item 4.9.3).

• Check the oil level at the winder motor (see information on components)

• Chain tension at haul-off motor and winder motor as well as of inlet motors (Optional equipment)

• Sensors for broken weft and warp tapes

• Functional test of the controlled inlet system (Optional equipment)

• Check the distance between the main ring sensor and the belt pulley

• Check the bending spring shut-down

• Check the V-belt tension

If all is o.k., start with the loom threading.


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5.3 Distribution of the warp tapes to be threaded:

5.3.1 Calculation of the total number of warp tapes The machine design determines the maximum number of warp tapes with 720 positions which due to the cloth specifications is rarely fully needed. Therefore you have to calculate the required total number of warp tapes before starting the loom threading.

The threaded warp tapes have to run as straight as possible to the machine thus forming a neat and symmetrical inlet. The time required for modification of the cloth specification or for finding out and repairing weft breaks is optimized in such way.

Example:

Assumed cloth width for sewn sack: 62 dfl

Weaving ring has to be 1 cm smaller = 61 dfl

Weaving ring for 61 cm dfl with inner diameter 388.3 mm

Tape width: 3 mm with full cloth cover

The theoretical number of tapes is calculated from the intended cloth circumference divided by the tape width.

620 mm dfl x 2 : 3 mm = 413.3 warp tapes

As the circular loom is equipped with 36 shedding units, the warp tapes must be distributed to two machine halves having 18 shedding units each.

413.3 warp tapes : 2 = 206.65 warp tapes / machine half

206.65 : 18 = 11.48 warp tapes / shedding unit

The shedding units may only be supplied with an even number of tapes (always round down tape number)!

11.48 ~ 10 warp tapes / shedding unit


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When you supply all 18 shedding units with 10 warp tapes, you need 180 tapes. The remaining 26.65 warp tapes have to be distributed in such a way that the number of tapes/shedding unit is even (always 2 tapes/shedding unit).

18 x 10 = 180 warp tapes

206.65 - 180 = 26.65 warp tapes

26.65 : 2 = 13.32 ~ 14 shedding units

(always round up shedding unit number to a whole number)

This means that you need:

14 shedding units with 12 tapes each

4 shedding units with 10 tapes each

This results in a total number of 208 warp tapes required per machine half.


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5.3.2 Creel bobbins After having calculated the total number of warp tapes you can put the corresponding number of bobbins (max. 720) onto the creel. The creel has to be filled from the lower side to the upper side. With less than 720 bobbins the remaining positions on the upper side will be left free. Then the individual tapes of each row have to be pulled up to respectively through the creel eyelets. The above-calculated number of 208 warp tapes/machine half corresponds to the number of the creel positions.

Inlet diagram:


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The drop wires will be suspended on the tapes between the creel eyelets as illustrated below. The short end of the drop wires shall point to the opposite side of the machine.


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5.3.3 Inlet combs Now the tapes will be simply and regularly distributed to the passages on the inlet comb.

This is necessary for obtaining a neatly spaced inlet.

The small combs (1), the comb (2) and the threading tube (5) are attached to the inlet roller (3) by means of the threading device (7). Subsequently the tapes are threaded individually through the three combs and attached to the threading tube (5) with a double-faced adhesive tape.

The inlet comb is designed for a maximum number of 360 warp tapes per machine half and divided into 18 modules having 20 gaps each.

With a smaller total number of warp tapes, the tapes per shedding unit are evenly distributed to the 20 gaps.


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5.3.4 Pulling up the tapes This means the simultaneous passing through of all tapes of one machine side.

The tapes attached to the double-faced adhesive tape are fixed by an additional adhesive tape to ensure that all tapes will be pulled from the inlet roller to the reed.

Two operators pull the threading tube (with the pasted on tapes) over the inlet roller (3), below the intermediate rollers (4) up to approx. 50 cm above the upper bearing blocks where it is subsequently put down. The small combs (1) have to be fitted to the points provided for them.


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5.3.5 Threading into eyelet bow and bending spring compensator After having worked out a regular threading system for the following operation, you can start tape threading.

The pulled-up tapes are always cut off individually, drawn through the eyelet bow and compensator and knotted together per segments. The tapes are cut one after the other from the outside to the inside.

For mounting of the compensators refer to item 3.3.5.

With a total number of 416 warp tapes, 208 warp ends are assigned to one machine half.

For distribution refer to illustration under item 5.3.1!

Each eyelet on the grommet band is assigned to one position of the bending springs and to one eyelet on the eyelet bow!

The tapes/segment are individually threaded on the eyelet bow as shown below:


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5.3.6 Threading through shedding unit and reed

The course of the tapes from the bending springs, through the grommet bands and to the reed must be straight!

The warp tapes are threaded through the grommet bands and the reed.

When threading them through the reed, take care that there is only one tape in a reed gap and that only the absolutely necessary number of gaps is left open.

Shedding unit: The machine is equipped with 36 shedding units having 20 positions each.


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For distributing the warp tapes on the grommet band it is necessary to pull a warp tape through the outer eyelets on the left and the right side. The remaining tapes have to be distributed onto the free eyelets. The dimension x on the bending-springs may exceed the dimension on the grommet-band by max. 10 mm.

Reed: 720 gaps are provided on the reed’s circumference. The tapes are taken via the 36 shedding units to the reed ring.

720 : 36 = 20 open gaps per shedding unit

The open gaps shall be distributed in such a way that the warp tapes run as straight as possible from the compensator through the grommet band to the reed.


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5.3.7 Pulling up of the tapes over the inlet Now the loom is completely threaded and the warp tapes can be joined to a piece of tubular cloth which has been arranged over the haul-off and which connects the weaving zone with the cloth winder. Just above the weaving ring the tubular cloth will be cut into vertical strips by means of a knife (with approx. 400-500 mm length) and the tapes of 2 shedding units will be joined to a strip (Number of the strips is half the number of the shedding units).

Tension of the warp tapes is ensured by the vertically aligned compensators.

If the tension of some warp tapes is not sufficient, you have the possibility to operate manually the haul-off drive on the loom control (see description of the loom control).


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5.3.8 Preparing the shuttles Check the weft tension with a spring balance. The value indicated shall be approx. 500 g and must be identical for all shuttles.

Mount the insertion finger being appropriate for the weaving ring.

ATTENTION: The weft tension depends on the type of tapes.

5.3.9 Insertion of the shuttles The reed ring is designed with tapered reed races tilted towards the center. This construction was specially built according to the principles of the rolling motion. The conical design of the shuttle rollers ensures a long working life of the rollers as well as a very smooth treatment of the tapes. In addition this construction keeps the shuttle in the reed and prevents it from leaving the race.

When inserting the shuttles into the tapered race, both upper shuttle rollers have to be removed.

For adjustment of the shuttle rollers see item 4.5.1.

At the beginning insert only two shuttles one after the other, adjust the weft insertion fingers with regard to the weaving ring, mount the weft bobbins and thread the weft tapes.

For adjustment of the insertion finger refer to item 4.5.2.

Then turn the machine shortly by hand and check the correct position of the shuttles. The drive rollers should be in contact with the shuttle rollers.

Now start the machine and weave about 20 cm cloth above the weaving ring in order to distribute the warp tapes on the weaving ring.

Subsequently mount the remaining shuttles and adjust them.


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5.3.10 Start weaving Adjust the circular guide and spreading system according to the cloth width required (see item 4.4).

Weave until the cloth reaches the intermediate roller and care that it passes the circular guide and spreading system without hooking.

5.3.11 Intermediate roller Adjust the intermediate roller on the creel bridge in such a way that the continuous length of fabric reaches the winder in the center.

5.4 Number of picks and weft density: After an 8 hours test run with 720 picks/min you can modify the weft insertion by changing over the belt to the other diameter (see item 4.6).

Independently from the weft insertion (no. of picks) you can modify the weft density on the loom control during operation.

The optimum weft insertion depends on the fabric width, the fabric specification and the tape quality.


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5.5 Normal operation:

ATTENTION: During the operation do not reach into the weaving area, to the tapes and the shuttles!

The machine is equipped with a warp and weft tape monitoring system as well as with pilot lamps.

5.5.1 Warp break detecting system The tapes are threaded through compensators which maintain the tension of the warp tapes on the one hand as well as indicate immediately loose and broken tapes (pilot lamp) on the other hand.

If one of the tapes gets loose or breaks, the compensator arm makes a contact with the external ring, the machine stops and the red pilot lamp on the control unit of the sector in which the fault has occurred, lights up. This facilitates localizing of the broken tape. In such a case the machine cannot be cut in, it can only be inched.

After having joined the broken tape, extinguish the lamp by depressing the red stop key, and the machine can be cut in again.

5.5.2 Weft break detecting system If the pilot lamps of each control unit are illuminated, the shut-down of the loom can only be due to the weft break detecting system. Either a broken weft tape or an empty bobbin has been the cause.

In case of a broken weft tape the haul-off speed is automatically reduced so that no visible weaving fault occurs in the fabric.

For insertion of a new weft bobbin the operating personnel has to go to the shuttle. Do not depress the „Inch“ key, because this will increase the tension of the weft tape as well as the tolerance of the cloth width.

When changing the weft bobbin always replace two bobbins at a time so that one bobbin with a bigger diameter will follow a bobbin with a smaller diameter.


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5.6 Changing the cloth roll: On the loom control you can adjust the length of fabric per roll. As soon as this length has been reached, the loom is automatically stopped and the cloth roll can be changed.

Laterally on the cloth winder motor a switch is arranged. By setting the switch to position 2 tension of the cloth run is released and the roll is turned back. Now cut the fabric with a hot knife and attach it to a new core by means of an adhesive tape.

Subsequently reset the switch again to position 1.

Depress the stop key on the machine and reset the cloth length on the loom control (see description of loom control).

After having unlocked the stop key, you can continue the fabric production.

5.7 Changing the bobbins on creel: When the creel bobbins are empty, they can be changed during production.

The tapes have to be joined by a weaver’s knot (For description of weaver’s knot see item 8.4).


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5.8 Checks to be carried out by the operator:

When changing the weft bobbin, make sure

• that the weft bobbin is in good condition

• that the bobbin is correctly fixed in the shuttle

• that the weft end is correctly threaded

Should any trouble occur on the machine, shut it down and inform the foreman.

At each shift change the machine has to be handed over properly and the personnel of the oncoming shift has to be informed about the machine’s condition.

Important remark for the operator:

It is absolutely necessary to perform the maintenance work; refer to item 6.3.

6. LUBRICATION AND MAINTENANCE Page 59

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6 Lubrication and maintenance:

We wish to draw your special attention to the importance of lubricating our heavy duty machines appropriately.

The correct application of the most suitable lubricants will contribute to a large extent to a long working life as well as a high efficiency and eliminate operating troubles. The following chart includes the different oil and grease qualities of which have proved to render satisfactory lubrication of the machine components.

We assume the warranty of our machines only if these lubricants or demonstrably equivalent lubricants are used.


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6.1 Lubrication chart:

Lubricating points Lubricating interval/lubricant change

Lubricant no. /Qty

Drip oiler Check daily White oil Paralia P40 Company Klüber

Bushing at shedding lever

Oil every two weeks No. 10

Haul-off chain Lubricate it every 1000 h and retighten it. Heat it in chain

grease once a year.

No. 7

Gear motor on surface winder

Change every 20.000 hours, after three years latest

No. 5

Fabric roll support on surface winder

Lubricate at first start-up (see item 6.2)

no. 7

Gear motor on trolley winder


No. 5 / 0,8 ltrs

Gear motor on surface winder with unfolding device


No. 5

Gears Every 1000 hours No. 7

Chains Lubricate every 1000 hours and retighten them. Heat it in

chain grease once a year

No. 7

Avoid in any case mixing of different oil or grease types!

As far as the special instructions referring to a correct lubrication and maintenance are concerned, the information on the nameplates or in the enclosed documentation of the manufacturer have priority and generally have to be observed.


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6.2 Lubricant list:

No. Lubricant AGIP ARAL BP CASTROL DEA ESSO KLÜBER MOBIL SHELL TEXACO

1 Liquid transmission lubricant GP 00

Autol Liquid lubricant ZSA

Aralub FDP 00

Energrease HT-EP00

Grease CLS Glissando 6833 EP00

Beacon EP 0

Microlube GB 00

Mobilplex EP 004

Special gear lubricant H

Multifak EP 0

2 Liquid transmission lubricant GP 00

Autol Liquid lubricant ZSA

------ Energrease ZS 00

Grease CLS Glissando 6833 EP00

Liquid lubricant S 420

Syntheso D 220 EP

Glygoyle GREASE 00

Tivela Compound A

------

3 Transmission lu-bricant CLP 220

Blasia 220 Degol BG 220

Energol GR-XP 220

Alpha SP 220 Falcon CLP 220

Spartan EP 220

Lamora 220 Mobilgear 630

Omala oil 220 Meropa 220



Energol GR-XP 100


Spartan EP 100



5 Transmission lu-bricant PGLP 220

Blasia S 220 Degol GS 220

Enersyn SG-XP 220

------ Polydea PGLP 220

Circulating oil S 220

Syntheso D 220 EP

Glygoyle 30 Tivela oil WB ------

6 Machine oil CLP 68

Radula 68 Vitam GF 68 Energol HLP-D 68

Hyspin SP 68 Astron HLP 68

Nuto H 68 Lamora HLP 68

DTE 26 Tellus oil 68 Rando HDC 68

7 Bearing grease 2

GRMU 2 Aralub HL 2 Energrease LS 2

Spheerol EPL 2

Glissando 20

Beacon 2 Centoplex 3 Mobilux 2 Alvania R2 Multifak 20

8 Bearing grease 3

GRMU 3 Aralub HL 3 Energrease LS 3

Grease LMX Glissando 30

Beacon 3 Staburags NBU 8 EP

Mobilplex 47 Alvania R3 Multifak 30

9 Hydraulic oil HLP 32

OSO 32 Vitam GF 32 Energol HLP-D 32

Hyspin SP 32 Astron HLP 32


DTE 24 Tellus oil S 32 Rando HDA 32

10 Machine oil C 100

Radula 100 Dural MR 100

Energol CS 100

Magna 100 Sera 100 Nuto 100 Crucolan 100 Vactra oil heavy

Vitrea oil 100 Omnis 100


Blasia S 460 ------ Enersyn SG-XP 460


------ Syntheso D 460 EP

Glygoyle HE 460

Tivela SD ------

12 Transmission lu-bricant APIGL4

Rotra HY DB SAE 80W

Gear oil EP 80

Gear oil EP SAE 80

Gear oil EP 80

Deagear EP-A SAE 80W

Gear oil GP-D 80W

Lamora 100 Mobilube GX 80W-A

Spirax EP 80W

Geartex EP-A 80W


Blasia S 150 Degol GS 150

Enersyn SG-XP 220


Spartan Synthetic EP 150

Syntheso D 150 EP

Glygoyle 22 Tivela oil WA ------

14 Hydraulic oil HLP 46

OSO 46 Vitam GF 46 Energol HLP-D 46

Hyspin AWS 46

Astron HLP 46


DTE 25 Tellus oil S 46 Rando HDB 46



Energol GR-XP 320


Spartan EP 320




Blasia 150 Degol TU 150

Energol GR-XP 150

Alpha ZN 150 Falcon CLP 150

Spartan EP 150





Energol GR-XP 460


Spartan EP 460




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6.3 Maintenance work:

At the first start-up the fabric soll support (1) on the surface winder has to be lubricadet in the lower area for about 20 cm.

6.3.1 Daily preventive maintenance work

ATTENTION: These are important maintenance operations, which have to be carried out every day!

• Check the easy motion of weft compensator on the insertion finger

• Check the cover of the shuttle wheels

• Check the easy motion of the shuttle, drive and brake rollers

• Suck off the weaving dust from the shuttles and the reed (Do not work with compressed air. This would force the fine weaving dust into the bearings and sliding elements which will result in a quick wear of the parts!)

• Clean the stop ring at the compensator

• Check the oil level in the drip oiler

• Check the function of the wetting roller, free it from tape residues (must rotate easily)

• Clean the insertion finger from weaving dust

• Check the drop wires on the creel

• Clean the cutting tip of the thermal slitting device and check the easy motion of the press rollers.

• Pay attention to the cleanliness of the fan cowlings of all motors mounted near to ground


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6.3.2 Weekly preventive maintenance work • Grommet band play shall be less than 3 mm, otherwise the cam rollers have

to be changed.

• Clean the machine completely (suck it off). Use in any case a vacuum

cleaner. • Main ring • Cam (clean it on both cam sides)

• Dismount the shuttle and clean it; dismount the rollers and clean also the

bottom side, upon request regrease the shuttle; clean the bobbin support from tape residuals

• Clean the grommet band and the deflecting rollers, check the sealing felt • Clean the floor under the machine

• Remove the tape residuals from all moving parts, especially from the rollers at the intake

• Check the easy motion of the creel adapters and clean the axles with a solvent once a month

• Check the bending spring mails and the eyelets in the grommet band for wear and tear

• Check if there is dust in the electric control cabinet, suck it off if necessary. • Check the rollers and their coating • Check the chain and belt tensions; first inspection one week after the first

setting into operation, subsequently every 1000 hours. • Clean the wetting tubs

7. DIRECTIONS FOR FAULT DIAGNOSIS Page 64

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7 Directions for fault diagnosis:

7.1 Electrical troubles:

Fault Cause Remedy

The machine cannot be started

No supply voltage Check supply voltage

Fuses have cut out Check the fuses

Motor protection relay has tripped

Check the adjustment for power supply

Stop button has not been reset

Turn it clockwise and reset it by doing this.

Fault message on the loom control

See description of the loom control

Machine stops after some time

The weft tape has broken Join the weft tape

The warp tape has broken Join the warp tape

No supply voltage available

Check the supply voltage

Fuses have cut off Check the fuses

Motor protection relay has tripped

Check the adjustment of power supply

Check the easy motion of the machine

Check the temperature of the main motor

Wrong adjustment of the magnetic sensor

Readjust acc. to item 4.7


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Fault Cause Remedy

Machine stops too late in case of a weft break

Wrong adjustment of the magnetic sensor

Adjust according to item 4.7

Warp break monitor does not stop the loom

Compensator spring is stressed or broken

Replace the spring

Compensator or com-pensator ring is dirty

Clean it

Connecting cable on the compensator ring is defective

Check cable and replace if necessary

Module for warp tape monitor is defective

Check module

Jerky start of the machine The timing block on con-tactor K1M is misadjusted

Readjust between 6 and 8 seconds

Timing block is defective Replace the timing block

Change over time in the loom control is out of adjustment


Loom control indicates a weft break

Wrong adjustment for reduction of weft break


Weft density of fabric does not correspond to the adjustment

Wrong weft density Set the correct parameters (check the transmission)

See description of Loom control

For fault indication on the loom control refer to annex for loom control.


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7.2 Mechanical troubles:

Fault Cause Remedy

Machine squeaks during start-up

V-belt is loose Tighten the V-belt

Faulty concentric running of the machine

Different diameters of weft bobbins

Mount weft bobbins of the same diameter

Repeated broken warp tapes

Shuttle rollers turn with difficulty

Readjust the rollers

Shuttle roller bandage is defective

Replace the shuttle rollers

Tapes at the inlet are not supplied straight to the machine

Check the tape inlet

Shuttle bracket has a contact with the brake roll

Check the reed mounting height or correct the position of shuttle bracket

Excessive chain tension Check easy motion of the inlet rollers

Clean the creel bobbin take-ups

Operating noise Defective cam rollers Replace the cam rollers

Shuttle roller bandage is defective

Replace the shuttle rollers

No winding tension, rollers are slipping

Roller coating is deteriorated

Replace it

8. ANNEX Page 67

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8 Annex:

8.1 Application of a finishing agent: When using a finishing agent for the weaving operation we recommend the product STANTEX S 6051 (food-safe, approved by FDA) diluted with water at a mixing ratio of approx. 1:100, i.e. 1 portion STANTEX S 6051 and 100 portions of water.

Suitable biocide: Henkel Resista 4102, mixing ratio 0,2 % of the ready finishing agent.

8.2 Denier table: This table applies only to smooth tapes (not applicable to profiled tapes).

Tape thickness (µ) Tape width (mm)

2,2 2,5 3,0 4,0

40 717 815 977 1303

42 753 856 1026 1369

45 807 917 1099 1466

48 860 978 1172 1564

50 896 1019 1221 1629

52 932 1060 1270 1694

55 988 1121 1343 1792

58 1040 1182 1417 1889

60 1076 1223 1466 1955

80 1435 1630 1956 2610

1 Denier means: 9000 meters weigh 1 gram

e.g. 692 Denier mean: 9000 meters weigh 692 gram

Specific weight of PP: approx. 0,91 kgs/dm³

These values are not applicable to profiled tapes.

8. ANNEX Page 68

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8.3 Tape specification: Our recommendation:

• Calcium contents max. 2%

• NO titan dioxide

• Tensile strength minimum 5,6g/den

• Elongation maximum 30%

8.4 Weaver’s knot: Simple weaver’s knot:

In case of a broken tape or an empty bobbin you have to join the tape by means of a weaver’s knot.

1. Put the right end behind the left end.

2. Put the right tape over the thumb of the left hand by forming a loop and place it from the rear side through the center of both tapes.

3. Take the left end with the thumb of the right hand through the loop of the right tape.

4. Hold the left end back and tighten the knot by the right tape.

Double weaver’s knot:

Thin tapes and yarns have to be joined with a double weaver’s knot.

When forming this knot take the right tape according to item 2 by forming twice a loop around the thumb of the left hand, and place it from the rear side through the middle of both ends.

8. ANNEX Page 69

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8.5 Special accessories:

8.5.1 Electrically controlled inlet system with balancer The intermediate roller (2) presses on the warp tapes via a pivoted balancer (1). A magnetic sensor (3) keeps the balancer (1) in horizontal position by controlling the motor (4) of the inlet roller (5) and maintains in this way the warp tape tension at a constant value. The warp tape tension is adjusted by means of a weight. By turning the grip for clamp screw (7) the balancer (1) is moved up or down via the threaded bar (8) and the lever (9). Weight adjustment: Direction machine center = higher warp tension Direction creel = lower warp tension

ATTENTION: Adjustment of the weight or the warp tension must be identical on both sides of the machine!

The magnet support (10) must not touch the magnetic sensor (3). The minimum distance of 1 mm between the sensor (3) and the support (10) must be maintained.

8. ANNEX Page 70

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8.5.2 Trolley winder Mount the trolley winder and the accompanying parts acc. to item 3.1. The attaching frame has to be installed and fastened to the floor with bolts in such a way that the trolley winder is arranged centrically to the machine.

Installation of the trolley winder has to be done with special care and accuracy otherwise the cloth to be wound up would run laterally of the cloth winder.

The winding tension can be controlled with infinite variability.

8. ANNEX Page 71

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8.5.3 Stacosonic cutting device: With infinitely variable frequency control for welding the reinforced fabric edge and subsequent cutting of tubular fabric woven out of polyolefine tapes.

The ultrasonic unit, controlled via a generator, produces vibrations between the sonotrode (1) and the welding wheel (2) by which the reinforced fabric will be welded. Subsequently the sealed fabric is cut by a ceramic knife. In this way a neat edge of weld and cut of the fabric is ensured without generation of heat.

ATTENTION: For cooling the slitting device, dry air is absolutely necessary!! Oil and water have to be separated!!!

8. ANNEX Page 72

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Adjustment:

• The adjustment depends on the thickness and structure of the fabric to be cut.

• Turn the cutting device upside down and remove the fork head (3) of the cylinder (4).

• Position the sonotrode (1) in such way that it will form a right angle with the welding wheel (2).

• Position the fork head (3) of the cylinder (4) slightly above the center of the swivel arm bore (5) and hang it on again. This procedure will grant that the sonotrode (1) will always apply a pressure onto the welding wheel (2).

• The contact pressure of the sonotrode (1) to the welding wheel (2) depends on the fabric and will be adjusted by means of the air pressure of the cylinder. The standard adjustment is 2 bar and can be modified on the pressure regulator close to the control cabinet.

• For obtaining a good cutting performance the ceramic knife (6) has to be turned on to the next cutting edge as soon as it gets blunt.

For this purpose loosen the screw (7) and turn the ceramic knife (6) on to the next cutting edge with the screw (8) by using an Allen key.

Additionally you can turn the knife (6) by 180° and mount it again. This measure allows to use the knife 10 times. For this purpose remove the screw (7) and dismount the ceramic knife (6) with the knife supports (9) and (10). Subsequently dismount the support (10) and turn the knife (6) by 180°. Then mount the ceramic knife (6) again with the assembled supports (9) and (10).

ATTENTION: There is a danger that you cut yourself! Please wear protective gloves!

8. ANNEX Page 73

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8.5.4 Ultrasonic cutting device: With infinitely variable frequency control for cutting of tubular fabrics woven out of polyolefine tapes and simultaneously welding the fabric edge. The cutting head, controlled via an ultrasonic generator, produces vibrations between a piston and the counter-wheel. In this way a neat edge of weld and cut of the fabric is ensured without generation of heat.

ATTENTION: For cooling the slitting device, dry air is absolutely necessary!! Oil and water have to be separated!!!

8. ANNEX Page 74

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Adjustment:

• The adjustment of the cutting device depends on the thickness and structure of the fabric to be cut and on the angle of the tool.

• For introducing the fabric, the cam bolt (1) has to be turned round.

• Loosen pressure-adjusting screw (2).

• Establish contact between cutting tool (3) and sonotrode (4) by turning the cam bolt (1).

• Slowly tighten pressure-adjusting screw (2) until the fabric is cut through while the machine is running; then, further turn it so as to accomplish half a turn. If the pressure is too low, the fabric is not cut through; if the pressure is too high, the cutting tool gets blunt and the sonotrode gets worn out.

• The tool (3) must be rigidly fixed. If the tool is blunt, the sonotrode gets worn out and the cutting performance is low.

• For obtaining a good cutting performance the cutting tool has to be turned on when it gets worn out. ATTENTION: Do not change the pressure!

• For obtaining a good cutting performance the ceramic knife (5) has to be turned on to the next cutting edge as soon as it gets blunt.

For this purpose loosen the screw (6) and turn the ceramic knife (5) on to the next cutting edge with the screw (7) by using an Allen key.

Additionally you can turn the knife (5) by 180° and mount it again. This measure allows to use the knife 10 times. For this purpose remove the screw (6) and dismount the ceramic knife (5) with the knife supports (8) and (9). Subsequently dismount the support (9) and turn the knife (5) by 180°. Then mount the ceramic knife (5) again with the assembled supports (8) and (9).

ATTENTION: There is a danger that you cut yourself! Please wear protective gloves!

8. ANNEX Page 75

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8.5.5 Thermal slitting device The thermal slitting device is equipped with two cutting units. A specially shaped cutting tip with electrical heating cuts the cloth and seals the cloth edges at the same time. For obtaining a smooth selvedge the cloth runs through pressure rollers. A knife blade serves as additional cold cutting device.

The cutting tip is automatically put out of the cutting position in case of an eventual power failure.

Mount the thermal slitting device in such a way that the continuous length of fabric can run through it without deflection.

The cutting temperature depends on the quality of cloth to be cut and can be modified by turning the regulator of the control system.

The height of the cutting tip (1) with regard to the guide element (2) has to be adjusted in such a way that the cloth is cut through at operating temperature and sealed .

After undoing the screws (4) the distance between the cutting tip (1) and the pressure rollers (3) should be adjusted in such a way that the sealed cutting edges are pressed together. Set the contact pressure by means of the spring (5) after having undone the nut (7) and turned the nut (6).

The knife blade (8) serving as cold cutting device, can be changed after removal of the screws (9).

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Maintenance work:

The slitting device has to be inspected at least twice per shift and the cutting tip (1) has to be cleaned with a wire brush, if necessary. Check the easy motion of the pressure rolls (3) and clean them from tape remainders as far as necessary.

In case of failure of the thermal slitting device the knife blade of the cold cutting device is subject to a more important wear. In addition the cutting edges are not sealed.

ATTENTION:

Modification work has to be performed only with cut off main switch.

Cable length for the cutting tips must not be shortened, and with the double side thermal slitting device the cables for the cutting tips must be of equal length.

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8.5.6 Unfolding device with surface winder A specially designed frame of trapezoidal shape causes the unfolding of the tubular fabric cut in the center to flat cloth.

The surface winder serves for winding up flat cloth on cores. The drive rollers with slip-resistant coating ensure a cloth roll free from creases. The winding tension is infinitely variable.

Mount the surface winder and the accompanying parts according to the installation plan item 3.1.

Pay attention that the cloth winding system will be installed with special accuracy, otherwise the continuous length of fabric will run laterally of the winder.

The unfolding device is screwed to the surface winder.

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8.5.7 Gussetting device The gussetting device is required for providing gussets on both sides of the tubular fabric. The double spreading system has to be installed instead of the single spreader. Screw the setting spindles (1) together with the gussetting supports (2) and mount them on the haul-off structure (3). Subsequently mount both folding swords (4) and (5) with the supports (6) and (7) on the ring holder (8).

The gusset depth can be adjusted with infinite variability. By loosening the nuts (9) and (10) as well as by turning the tension lock (11) the desired gusset depth is reached. Then tighten the nuts (9) and (10) again.

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8.5.8 Monitoring device for weft tape end with colour sensor and black bobbin core Black bobbin cores (2) are used to avoid that weft bobbins run empty. The colour sensor (1) reacts to contrast difference, i.e. with white or coloured tapes you have to use black weft cores (2) and with black tapes you can use standard cores. By recognizing the contrast difference at running empty of the weft core (2) the machine is switched off.

On the belt pulley there are six cast bosses, which correspond to approx. 100 mm on the weft bobbin (2). 100 mm. Exactly within this area the colour sensor (1) is activated. The sensor switching the colour sensor (1) is fixed on a support (3) below the belt pulley. As soon as a casted boss reaches the sensor area, the colour sensor (1) is activated. This will be cut in approx. 70 mm after beginning of the weft bobbin and after 100 mm it will be cut off.

Setting:

The colour sensor (1) is mounted on a support (3) fixed on the bridge.

The distance between the colour sensor (1) and the empty weft bobbin (2) shall be 120 mm.

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8.5.9 Monitoring device for weft tape end with light barrier and reflector tape core Weft cores with sticked on reflector tapes are used to avoid that weft bobbins are running empty.

The infrared light sensor has to be adjusted to the weft bobbin core.

The infrared light is reflected by the reflector of the weft bobbin core, and the machine is shut down.

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