Service Instructions

Summary of main chapters

E-26.04.2004

Information 1

Safety 2

Customer informations 3

Service instructions

E-26.04.2004

Index of complete terminal manual1 Information

1.1 Information concept . . . . . . . . . . . . . . . . 1.1-5

1.2 Using the Operating Instructions . . . . . . . . . 1.2-7

1.3 Third-party documentation . . . . . . . . . . . 1.3-11

1.4 Copyright . . . . . . . . . . . . . . . . . . . . . 1.4-15

1.5 Validity of the operating instructions . . . . . . 1.5-17

2 Safety

2.1 General information . . . . . . . . . . . . . . . . 2.1-5

2.2 Fundamental safety instructions . . . . . . . . . 2.2-9

2.3 Hazard symbols and warning notices . . . . . 2.3-13

2.4 Safety equipment . . . . . . . . . . . . . . . . 2.4-19

3 Customer informations

3.1 CCP PCB customer information . . . . . . . . . 3.1-5E-26.04.2004

Index of complete terminal manualE-26.04.2004

Main chapter1 InformationE-26.04.2004

E-26.04.2004

Main chapter index1 Information

1.1 Information concept . . . . . . . . . . . . . . . . . . . 1.1-5

1.2 Using the Operating Instructions . . . . . . . . . . . . 1.2-7

1.2.1 About this manual . . . . . . . . . . . . . . . . 1.2-7

1.2.2 Symbols used . . . . . . . . . . . . . . . . . . 1.2-7

1.2.3 Descriptive elements . . . . . . . . . . . . . . . 1.2-8

1.2.4 Guidance elements . . . . . . . . . . . . . . . . 1.2-9

1.2.5 Machine positions . . . . . . . . . . . . . . . . 1.2-9

1.3 Third-party documentation . . . . . . . . . . . . . . 1.3-11

1.3.1 Suppliers . . . . . . . . . . . . . . . . . . . . 1.3-11

1.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . 1.4-15

1.4.1 Patents . . . . . . . . . . . . . . . . . . . . . 1.4-15

1.4.2 Copyright . . . . . . . . . . . . . . . . . . . 1.4-15

1.5 Validity of the operating instructions . . . . . . . . . 1.5-17

1.5.1 Picking points . . . . . . . . . . . . . . . . . 1.5-17

1.5.2 Type key . . . . . . . . . . . . . . . . . . . . 1.5-18E-26.04.2004

Main chapter indexE-26.04.2004

1.1 Information concept1.1 Information concept

The documentation for Sulzer Textil weaving machines is made up of Operating Instructions and Supplements.

Fig. 1.1-1

The operating instructions consists of the Installation Guide, User Manual and Adjustment Manual.

The installation guide contains detailed information about how to set up a weaving machine prior to commissioning.

The user manual describes the control and display elements and the control cabinet.

The adjustments and maintenance work that become necessary during operation are described in the adjustment manual, which will help suitably qualified personnel keep the weaving machine running smoothly.

The electronic spare parts catalog, "Elspace", contains a de-tailed listing of all spare parts.

The "Circuit diagram" is always located in the box with the red corners so that the appropriate documentation for each machine type is always close at hand for the mill electrician.

The "Machine Software" configuration CD-ROM contains the Terminal Help texts, all error messages (these can be printed), the terminal simulator, circuit diagram, machine software, etc.

The "External suppliers documentation" provided by our vendors E-26.04.2004 1.1-5

1.1 Information conceptcontains information regarding additional bought-in equipment1.1-6 E-26.04.2004

1.2 Using the Operating Instructions1.2 Using the Operating Instructions

We advise you to read the following before using the Operating Instructions.

In addition, read the chapter entitled "Safety" carefully.

1.2.1 About this manual

The operating instructions are structured in the form of a book. Page numbering starts again at the beginning of each main chapter.

The following signposts will direct you to the chapter you require.

Main chapter front sheet shows the individual main chapters

General contents page shows the chapter heading and the sections it contains

Main chapter contents shows the sections and the subsections they contain

The header at the top of each page contains the name of the cur-rent section.

The footer at the bottom of the page contains the section number, followed by a dash and the page number within the sec-tion.

1.2.2 Symbols used

The symbols used in the operating instructions are explained here.

For an explanation of the safety symbols, refer to the chapter en-titled "Safety".

Cross-references within the operating instructions or to other documents or vendor manuals are indicated thus:

1.2 Using the Operating InstructionsE-26.04.2004 1.2-7

1.2 Using the Operating Instructions1.2.3 Descriptive elements

) NotesUsed to highlight information. Have more or less the same function as the Explanation element

9 Authorised personnelIndicates which personnel are authorised to carry out the tasks in the subsequent section.

Options are:

i SignpostsBrief "signposts" that describe how to find your way around a chapter. Normally to be found at the beginning of a chap-ter.

Angle dataThe angle data shows the angle that must be adopted by a component during the operation being described.

warp gaiter

Weaver

Weaveroom foreman

Mill electrician

Service technician1.2-8 E-26.04.2004

1.2 Using the Operating Instructions1.2.4 Guidance elements

Maintenance interval: used to indicate that the following se-quence of operations is to be performed regularly.

9 RequirementsLists all the requirements that must be fulfilled before starting the operation.

> Actions to be performedthese are the actions that have to be peformed and tell the user what has to be done.

ExplanationsThe user is given some initial guidance regarding complicated operations. This section will contain some background informa-tion and explain how various features interact.

1.2.5 Machine positions

Angle dataA number of settings must be made in various machine po-sitions depending on the picking point of the projectile.

Picking point [] - - 95 100 105 110 120 135

Machine position [] - - 66 71 76 81 91 104E-26.04.2004 1.2-9

1.2 Using the Operating InstructionsWarning!Severe personal injury and damage to property.Unintentional start-up of the weaving machine during adjustment work (with the sole exception of adjustments that according to the operating instructions have to be carried out while the ma-chine is running).S Before commencing adjustment work, switch the main motor

over from automatic to manual operation at the terminal.

> Select [Settings] from the main menu.

> Press the [Main Motor] button.

> Select the [Settings] sub-menu.

> Switch the service switch to [Manual operation].

> Then turn the weaving machine to the required angle at creep speed or by hand using the handwheel.

) From now on, all references in the operating instructions to the above procedure for switching the main motor from au-tomatic operation [I] to manual operation [0] (or vice versa) will be indicated by the following symbols:1.2-10 E-26.04.2004

1.3 Third-party documentation1.3 Third-party documentation

The following list contains the most important documentation re-lating to ancillary equipment.

The amount of additional documentation (operating manuals, spare parts catalogues, diagrams, etc.) provided with each ma-chine varies depending on the specific version of the weaving machine.

Technical advice regarding these items of equipment or addi-tional copies of the documentation can be obtained directly from the manufacturer.

1.3.1 Suppliers

Operating instructions, user guides, spare parts catalogues

Address

Dobbys Stubli AGSeestrasse 240CH-8810 HorgenSwitzerlandTel. +41 (0)1 728 61 11Fax +41 (0)1 728 62 11Mail marcom@staeubli-ag.ch

Weft feeders IRO Sweden ABKarlsnsvgen 7S-52322 UlricehamnSwedenTel. +46 321 29 700Fax +46 321 29 800Mail info@iro.se

L.G.L. Electronics S.p.A.Via Foscolo, 156I-24024 GandinoBergamo - ItalyTel. +39 035 733 408Fax +39 035 733 146Mail lgl@lgl.ithttp://www.lgl.itE-26.04.2004 1.3-11

1.3 Third-party documentationWeft detectors Gebrder Loepfe AGKastellstrasse 10CH-8623 WetzikonSwitzerlandTel. +41 (0)1 930 32 32Fax +41 (0)1 930 31 00

Heald shafts Grob AGSeestrasse 80CH-8810 HorgenSwitzerlandTel. +41 (0)1 727 21 11Fax +41 (0)1 727 24 59

Schmeing GmbH & CoHolthausener Strasse 9D-46325 Borken WesekeGermanyTel. +49 28 623 010Fax +49 28 623 012 65

Warp stop motions Grob AGSeestrasse 80CH-8810 HorgenSwitzerlandTel. +41 (0)1 727 21 11Fax +41 (0)1 727 24 59

Controls SIG PositecAutomationen GmbHBreslauer Strasse 7D-77933 LahrGermany

Batch winders Willy Grob AGAlte SchmerikonerstrasseCH-8733 EschenbachSwitzerlandTel. +41 (0)55 286 13 40

Operating instructions, user guides, spare parts catalogues

Address1.3-12 E-26.04.2004

1.3 Third-party documentationMotors Landert Motoren AGCH-8180 BlachSwitzerlandTel. +41 (0)1 863 51 11Fax +41 (0)1 860 65 22

Dietz Motoren GmbHEisenbahnstrasse 67D-73265 Dettingen unter TeckGermanyTel. +49 702 157 020Fax +49 702 157 02 64

Lubricating equipment

Cleaning equipment

Schnitzler GmbHHffgeshofweg 26D-47807 KrefeldGermany

Programming units EATElektronische Ateliertechnik Textil GmbHIndustriering Ost 64D-47906 KempenGermanyTel. +49 (0) 21 52 / 20 07-0Fax +49 (0) 21 52 / 51 99 86

Transportation equipment

Warp beam lifting trucks

Genkinger Hebe- undFrdertechnik GmbHPostfach 1120D-72521 MnsingenGermanyTel. +49 81 18 60Fax +49 73 81 186 49

Operating instructions, user guides, spare parts catalogues

AddressE-26.04.2004 1.3-13

1.3 Third-party documentationJacquard machines Stubli Lyon SAF-69680 Chassieu/LyonFranceTel. +33 4 72 47 39 39Fax +33 78 90 28 36

BonasMachine company LimitedDukeswayTeam Vally Trading EstateGateshead NE11 OLFEnglandTel. +44 191 491 04 44Fax +44 191 491 09 99

Eltex of Sweden ABBackgatan, 6Box 608S-343 24 ElmhultSwedenTel. +46 476 48 800Fax +46 476 13 400Mail public@eltex.se

GrosseWebereimaschinen GmbHRapsweg 9D-89233 Neu-UlmGermanyTel. +49 731 979 610Fax +49 731 713 143

Operating instructions, user guides, spare parts catalogues

Address1.3-14 E-26.04.2004

1.4 Copyright1.4 Copyright

1.4.1 Patents

Sulzer Textil weaving machines are protected by the following patents:

1.4.2 Copyright

Reproduction in any form of technical documentation for Sulzer Textil weaving machines, including individual text passages, il-lustrations or tables, and its translation into other languages is prohibited, except with the permission of Sultex Ltd.

All rights, especially copyrights, are retained by Sultex Ltd. CH-8630 Rti.

US patent numbers

4,534,386 5,355,912 5,630,449

4,957,403 5,386,855 5,649,569

4,974,639 5,423,355 5,666,998

5,014,756 5,439,034 5,684,255

5,058,628 5,441,084 5,711,352

5,063,971 5,450,880 5,729,114

5,090,453 5,483,997 5,755,267

5,199,466 5,520,224 5,826,625

5,205,377 5,568,826 5,827,975

5,244,164 5,575,314 5,890,519

5,259,422 5,613,525

5,348,053 5,628,346E-26.04.2004 1.4-15

1.4 Copyright1.4-16 E-26.04.2004

1.5 Validity of the operating instructions1.5 Validity of the operating instructions

These operating instructions are for weaving machines in the P7300 HP range.

1.5.1 Picking points

Projectiles have different picking points depending on the nomi-nal width of the machine.

Fig. 1.5-1

The picking point is displayed on the machine type plate 1, on the picking unit 2 and on the receiving unit 3.

Nominal width [cm] Picking point []

190 / 220 135

280 120

330 110

360 105

390540 100E-26.04.2004 1.5-17

1.5 Validity of the operating instructions1.5.2 Type key

The type of weaving machine is also indicated on the type plate 1.

Type specification P 7300HP B 190 4 EP D12 R

Weaving system

Model

Fibre

B CottonW WoolS SyntheticsP PolypropyleneH Hard fibre

Nominal width [cm]

190 / 220 / 280 / 330 / 360 / 390 / 430 / 460 / 540

Colour selector

4 Electronic four colour

Shed formation

EP Cam motionSP DobbyJ Jacquard machine

Supplement

R Equipment for heavy fabricsD12 Small cross-section steel projectile with large gripper1.5-18 E-26.04.2004

Main chapter2 SafetyE-26.04.2004

E-26.04.2004

Main chapter index2 Safety

2.1 General information . . . . . . . . . . . . . . . . . . . 2.1-5

2.1.1 Liability. . . . . . . . . . . . . . . . . . . . . . 2.1-5

2.1.2 Authorized application . . . . . . . . . . . . . . 2.1-5

2.1.3 Alterations to the machine . . . . . . . . . . . . 2.1-5

2.1.4 Damage to the machine . . . . . . . . . . . . . 2.1-5

2.1.5 Obligations of the user . . . . . . . . . . . . . . 2.1-6

2.1.5.1 Operating instructions . . . . . . . . . . . . . . . 2.1-6

2.1.5.2 Personnel . . . . . . . . . . . . . . . . . . . . . 2.1-6

2.1.5.3 Competencies and responsibilities . . . . . . . . . 2.1-6

2.1.5.4 Access to weaveroom, visitors . . . . . . . . . . . 2.1-6

2.1.6 Additional directives and standards . . . . . . . 2.1-7

2.2 Fundamental safety instructions . . . . . . . . . . . . 2.2-9

2.2.1 Safety-conscious working . . . . . . . . . . . . 2.2-9

2.2.1.1 Protective equipment . . . . . . . . . . . . . . . 2.2-9

2.2.1.2 Working with harmful materials . . . . . . . . . . . 2.2-9

2.2.1.3 Hair and clothing . . . . . . . . . . . . . . . . 2.2-10

2.2.1.4 Before starting the machine . . . . . . . . . . . 2.2-10

2.2.1.5 Button operation/starting the machine . . . . . . 2.2-10

2.2.1.6 While the weaving machine is running . . . . . . 2.2-10

2.2.1.7 Scissors and tools . . . . . . . . . . . . . . . . 2.2-10

2.2.2 Working on the machine . . . . . . . . . . . . 2.2-11

2.2.3 Working on the electrical equipment . . . . . . 2.2-11

2.2.3.1 Before working on the electrical equipment . . . . 2.2-11E-26.04.2004

Main chapter index2.2.4 Working with the stroboscope . . . . . . . . . 2.2-12

2.2.5 Working with compressed air . . . . . . . . . 2.2-12

2.2.6 Noise hazards . . . . . . . . . . . . . . . . . 2.2-12

2.3 Hazard symbols and warning notices . . . . . . . . 2.3-13

2.3.1 Danger notices . . . . . . . . . . . . . . . . . 2.3-13

2.3.2 Warning notices . . . . . . . . . . . . . . . . 2.3-15

2.3.3 Caution notices . . . . . . . . . . . . . . . . 2.3-17

2.4 Safety equipment . . . . . . . . . . . . . . . . . . . . 2.4-19

2.4.1 Stickers, signs and notices. . . . . . . . . . . 2.4-19

2.4.2 Safety equipment. . . . . . . . . . . . . . . . 2.4-19

2.4.2.1 EMERGENCY STOP switch . . . . . . . . . . . 2.4-19

2.4.2.2 Safety circuit . . . . . . . . . . . . . . . . . . 2.4-20

2.4.2.3 Close safety circuit . . . . . . . . . . . . . . . 2.4-21

2.4.2.4 Open safety circuit . . . . . . . . . . . . . . . . 2.4-21

2.4.2.5 Main switch ON . . . . . . . . . . . . . . . . . 2.4-22

2.4.2.6 Main switch OFF . . . . . . . . . . . . . . . . 2.4-22

2.4.2.7 Main switch OFF and secured . . . . . . . . . . 2.4-23

2.4.3 Cabinet doors and covers . . . . . . . . . . . 2.4-24

2.4.3.1 Function . . . . . . . . . . . . . . . . . . . . 2.4-24

2.4.3.2 Weaving machine in operation . . . . . . . . . . 2.4-24

2.4.3.3 Weaving machine stopped . . . . . . . . . . . . 2.4-24

2.4.3.4 Checks, repairs, settings . . . . . . . . . . . . . 2.4-25E-26.04.2004

2.1 General information2.1 General information

2.1.1 Liability

Your weaving machine is state-of-the-art and meets all the re-quirements in respect of safe operation.

Despite this, some risks are involved when operating the ma-chine. The safety instructions and warning symbols in these op-erating instructions are intended to help you protect yourself against these risks.

Sultex Ltd. CH-8630 Rti, will deny any liability for damage re-sulting from non-compliance with these safety rules and warn-ings in these operating instructions.

2.1.2 Authorized application

Your weaving machine is designed to produce fabrics solely within the agreed range.

Always observe the operating conditions specified by Sultex Ltd.

2.1.3 Alterations to the machine

Always inform Sultex Ltd. if you make any alterations to the me-chanical or electrical systems of the weaving machine.

Sultex Ltd. will deny any liability for damage resulting from fitting any other than original Sulzer Textil components.

2.1.4 Damage to the machine

In the event of damage to the machine, provide a detailed ac-count of how the damage occurred (with photographs and draw-ings).

Notify Sultex Ltd. CH-8630 Rti, immediately of any damage.E-26.04.2004 2.1-5

2.1 General information2.1.5 Obligations of the user

2.1.5.1 Operating instructions

Keep these operating instructions ready to hand at the weaving machine.

2.1.5.2 Personnel

Employ only trained personnel on the weaving machine; these personnel must have read and understood these operating in-structions, at least the chapter Safety rules and the information relating to their particular job.

Keep personnel continuously informed about safety rules and measures and make sure these are complied with.

Ensure that personnel are familiar with the location and function of all the safety equipment on the machine.

Make sufficient personnel protective equipment available to per-sonnel. Protective equipment includes:

Hearing protection Work wear Safety shoes and gloves Safety goggles Hairnet

2.1.5.3 Competencies and responsibilities

Clearly define areas of responsibility and specify who has overall responsibility, especially when several people are working on the machine at the same time.

Specify which employees are authorized to open the control cab-inet. The key may be entrusted to these persons only.

2.1.5.4 Access to weaveroom, visitors

Keep unauthorized persons away from the weaveroom.

Inform visitors about safety behaviour. If necessary, make per-sonal safety equipment also available to visitors.2.1-6 E-26.04.2004

2.1 General information2.1.6 Additional directives and standards

Please also observe the regulations and standards currently in force in your country, e.g.:

Legislation, directives and standards Trade union regulations Installation and maintenance regulationsE-26.04.2004 2.1-7

2.1 General information2.1-8 E-26.04.2004

2.2 Fundamental safety instructions2.2 Fundamental safety instructions

2.2.1 Safety-conscious working

2.2.1.1 Protective equipment

Always wear personal protective equipment:

Hearing protection Work wear Safety gloves and shoes Safety goggles Hairnet, etc.Take the necessary additional precautions if you are working with materials, such as asbestos, which are injurious to the health.

Always wear enclosed safety goggles during all work involving risk to the eyes.

2.2.1.2 Working with harmful materials

The following materials can cause irritation to the skin and eyes:

Lubricants Paint Adhesives and sealing materials Cleaning agents and solventsComply with the maker's instructions when handling these mate-rials.

When working with these materials, wear gloves and enclosed safety goggles.

In the event of contact with the skin or eyes, rinse off at once with water. If necessary, contact a doctor without delay.

When working with cleaning agents and solvents, make sure that the room is adequately ventilated.E-26.04.2004 2.2-9

2.2 Fundamental safety instructions2.2.1.3 Hair and clothing

Do not wear:

Loose items of clothing Long sleeves with buttons Open-heeled footwear Work wear with buttons at the front (exception: covered press

studs)

Hair loose

2.2.1.4 Before starting the machine

Starting the machine must not endanger persons, the machine or material.

All safety equipment must be operational; all protective covers intact and fitted.

2.2.1.5 Button operation/starting the machine

Never touch the machine with your free hand when pressing but-tons or switching on the machine using the starting handle.

Never operate control buttons before ensuring that there is no danger to persons, machine or material.

Never rest your fingers on the control buttons.

Never reach into the working area of the machine after pressing a control button.

2.2.1.6 While the weaving machine is running

Never touch moving machine parts.

Never lift or remove protective covers.

Never remove yarn remnants/fibre fly.

Never touch the fabric or move your hands close to rotating com-ponents.

2.2.1.7 Scissors and tools

Scissors and tools should never be allowed to drop into the ma-chine while it is running.2.2-10 E-26.04.2004

2.2 Fundamental safety instructionsNever carry scissors and tools in open breast pockets.

Never place tools on the machine.

2.2.2 Working on the machine

Before starting maintenance work, mechanical adjustments, re-pairs, etc.: make sure that the [main switch] is in the OFF posi-tion and secure against switching on with the personal padlock.

The personal padlock should only be removed by the person who put it there.

2.2.3 Working on the electrical equipment

Work on the electrical equipment may only be carried out by skilled personnel (electricians).

When working on the electrical equipment, a second person must be present who is responsible for the safety of the first. The second person must know what to do in the event of electrical accidents.

Take particular care when working with live equipment, e.g. functional checks and trouble shooting.

Work only with properly maintained measuring probes and in-struments.

2.2.3.1 Before working on the electrical equipment

Disconnect the electrical equipment.

Check with the voltmeter that the power input terminals on the machine are in fact dead.

Caution!The electrical energy stored in the power electronics (drives, brakes, couplings) represents a potential overvoltage hazard, even after the control has been switched off.Disconnecting electrical connections while still under voltage re-sults in destruction of the electronic modules.S Before opening the control cabinet, and especially before dis-

connecting any of the electrical connections in the cabinet, observe the stipulated delay of 5 minutes.E-26.04.2004 2.2-11

2.2 Fundamental safety instructions2.2.4 Working with the stroboscope

Wear protective goggles (dark sunglasses).

Never look straight at the flash.

Protect other people from the flashes (e.g. by putting up screens).

Never reach into the weaving machine. The stroboscope shows still images of moving objects.

Take every care that the stroboscope lamp or cable does not touch any rotating components.

2.2.5 Working with compressed air

Never use compressed air to clean the skin or items of clothing.

Never direct compressed air towards other people.

For Switzerland: maximum admissible blowing pressure = 3.5 bar.

2.2.6 Noise hazards

The noise level in a weaveroom under normal industrial condi-tions is in excess of 85 dB(A) and can therefore cause perma-nent damage to your health.

Always wear your pesonal hearing protection when the weaving machine is running.2.2-12 E-26.04.2004

2.3 Hazard symbols and warning notices2.3 Hazard symbols and warning notices

For your own safety, you are urgently advised to take note of the hazard symbols and warning notices in these operating instruc-tions. We also draw your attention to the safety rules prevailing in your own country.

The hazard symbols are always used in conjunction with a warn-ing notice. The extent of the hazard is indicated by one of the three key words Danger, Warning or Caution. As far as these operating instructions are concerned, these key words can be in-terpreted as follows:

2.3.1 Danger notices

Danger!Suspended and raised loads!Suspended and raised loads can cause fatal injuries should they fall.S Ensure load and lifting equipment are secure and fastened

properly.S Ensure that nobody is standing under suspended and raised

loads or anywhere near the danger zone.

Danger High risk.

Denotes a dangerous situation that can result in death or severe personal injury if the safety in-structions are not obeyed.

Warning Medium risk.

Denotes a dangerous situation that can result in personal injury or extensive material damage if the safety instructions are not obeyed.

Caution Low risk.

Denotes a dangerous situation that can result in damage to material or the product if the safety instructions are not obeyed.E-26.04.2004 2.3-13

2.3 Hazard symbols and warning noticesDanger!Danger during transportation!Transporting components with damaged or unsuitable equip-ment can cause fatal injuries if the components work loose.S Ensure that all equipment and appliances are in perfect work-

ing order.S Do not use damaged or unsuitable equipment and applianc-

es.

Danger!Slipping of weaving machine on tilted surfaces!Uncontrolled sliding of the weaving machine is highly dangerous and can cause fatal injuries.S Ensure that nobody is standing in the danger zone on the tilt-

ed surface underneath the weaving machine.S Weaving machines on tilted surfaces are to be adequately se-

cured and transported slowly and carefully.

Danger!Electric shock!Touching live parts and wires is extremely dangerous and can cause fatal injuries.S Work on the weaving machine must only be carried out by

specialist personnel.S Do not open any covers, power supply cabinets, etc. These

have a sticker attached showing a yellow triangle with a light-ning symbol.

S For specialist personnel: always work with insulated measur-ing probes.

S For specialist personnel: set measuring instruments to the correct range.

Danger!Electric shock with main switch turned off.Even when the weaving machine is switched off, electrical mod-ules indicated by the appropriate warning symbols remain live.S Before removing these modules, completely disconnect and

isolate the incoming supply to the weaving machine on the connecting terminals.2.3-14 E-26.04.2004

2.3 Hazard symbols and warning noticesDanger!Moving parts!Moving parts can cause crushing injuries.S Never reach into the weaving machine while it is running.S Keep a safe distance from the weaving machine.

Danger!Moving parts!Moving parts can cause crushing injuries.S Never reach into the weaving machine while it is running.S Keep a safe distance from the weaving machine.

Danger!Rotating parts!Danger of injuries caused by rotating parts pulling in body parts, hair and clothing.S Never reach into the weaving machine while it is running.S Tie hair back and keep workwear done up.S Keep a safe distance from the weaving machine.

Danger!Fingers cut off!Sharp components can cause serious lacerations.S Switch off the machine before opening covers.S Secure the machine to prevent it being switched on inadvert-

ently.

2.3.2 Warning notices

Warning!Electric shock with main switch turned off.If live parts of the weaving machine are touched within 5 minutes of turning off the main switch, there exists a risk of electric shock and the risk of damage to the electronics of the weaving ma-chine.S After turning off the main switch, wait at least 5 minutes before

removing the cover.E-26.04.2004 2.3-15

2.3 Hazard symbols and warning noticesWarning!Heavy parts!The lifting of heavy parts can cause serious injuries (e.g. back in-juries, crushing as a result of the load slipping).S Wear safety clothing (gloves).S Heavy loads to be lifted and carried by suitable lifting equip-

ment or by calling for the assistance of several people.

Warning!Materials harmful to the health and chemical substances!Contact (touching, inhalation) with materials harmful to the health or chemical substances can result in poisoning, uncon-sciousness, skin damage and allergies.S Wear safety clothing (gloves, mouth & nose mask).S Avoid inhalation and contact with skin.S In the event of skin contact, rinse affected areas immediately

with copious amounts of water.S Consult a doctor immediately in case of nausea or skin rash-

es.

Warning!Fragmenting parts or sparks!Injuries to the eyes can result in blindness.S Wear safety goggles.S Ensure there is no one in the danger zone.

Warning!Burns!Contact with hot weaving machine parts causes burns.S Wear safety clothing (gloves, safety shoes); avoid contact

with hot parts.

Warning!Compressed air!Careless working with compressed air can result in injuries (e.g. embolism).S Do not direct compressed air at people.S Never use compressed air to remove splinters or other small

parts (vacuum up or brush away instead)S Do not use compressed air to clean skin or clothing.2.3-16 E-26.04.2004

2.3 Hazard symbols and warning noticesWarning!Noise!Excessive noise can cause hearing loss and damage your health.S Wear personal hearing protection.

Warning!Slipping!Spilt oil presents an acute risk of slipping and consequent injury.S Remove spilt oil immediately using bonding agents and dis-

pose of according to environmental regulations.

2.3.3 Caution notices

Caution!Damage to the machine!If the machine is subjected to extreme fluctuations of tempera-ture, the resulting condensation can cause damage to the ma-chine.S Do not remove the plastic cover from the machine when it is

delivered.S Let the weaving machine stand in the mill until it has reached

room temperature.S Remove plastic cover and clean the weaving machine.S Apply a thin layer of oil to bright parts.

Caution!Damage caused by poor levelling!Poor levelling of the machine adversely affects operational qual-ity. This can cause damage to the machine and increase wear and tear.S Level the machine according to the instructions (within toler-

ance).

Caution!Damage to the machine through inadequate maintenance!Inadequate maintenance causes damage to the machine, in-creased wear, loss of efficiency and inferior quality.S Carry out maintenance according to the instructions.E-26.04.2004 2.3-17

2.3 Hazard symbols and warning noticesCaution!Damage caused by low oil level!Too low an oil level can cause damage to the machine and in-crease wear and tear.S Check the oil level according to the instructions.

Caution!Damage caused by high oil level!Too high an oil level can cause damage to the machine and in-crease wear and tear.S Check and maintain the oil level according to the instructions.

Caution!Damage to the electronics!The plugging-in and removing of live electrical components can cause damage to the weaving machine electronics.S Before plugging-in or removing PCBs: Turn off the main

switch and wait 5 minutes.

Caution!Damage caused by electrostatic discharge!Electrostatic discharge can damage the weaving machine elec-tronics.S Touch a metal object before handling any electronic compo-

nents.2.3-18 E-26.04.2004

2.4 Safety equipment2.4 Safety equipment

2.4.1 Stickers, signs and notices

Never cover, remove or deface any stickers, signs or notices, etc. on the weaving machine.

Any temporary signs may only be removed by the person who put them there in the first place.

The following sign will be found on the weaving machine switch boxes.

This denotes: High voltage - danger of death.

2.4.2 Safety equipment

Never remove safety equipment (protective covers, notices, light barriers, etc.).

Never switch off any safety equipment.

2.4.2.1 EMERGENCY STOP switch

Caution!S Before resetting the [EMERGENCY STOP] switch, satisfy

yourself that doing so will not endanger anyone or the ma-chine itself.

i Pressing the [EMERGENCY STOP] switch turns off all the weaving machine drives and disconnects the units from the power supply.E-26.04.2004 2.4-19

2.4 Safety equipment> To reset the [EMERGENCY STOP] switch, turn the switch in a clockwise direction.

2.4.2.2 Safety circuit

The weaving machine has a safety circuit that controls all safety-related elements and the power supply to all power current con-sumers (voltages greater than 50 V).

When switching on the weaving machine, pressing an emergen-cy stop button or in the event of a safety-related fault on the weaving machine, the safety circuit is interrupted and all safety-related elements are switched dead.

Fig. 2.4-12.4-20 E-26.04.2004

2.4 Safety equipmentA Enabled by controlB1 Emergency Stop switchB2 Emergency Stop switchC External equipment (third-party equipment)D Safety buttonE Mains voltageF Safety-related elementsG Power current consumer

2.4.2.3 Close safety circuit

When all the conditions for the closing of the safety circuit have been met (no faults present, all emergency stop buttons reset), this is indicated by the Safety circuit open operating status.

> Press the [Safety button].All power current consumers are now live.

2.4.2.4 Open safety circuit

The safety circuit can be opened by third-party equipment or by pressing the Emergency Stop button on the weaving machine.

> Press [EMERGENCY STOP] button.All safety-related elements are immediately switched dead and the weaving machine performs an undefined Stop.E-26.04.2004 2.4-21

2.4 Safety equipmentDanger!Electric shock.Touching live parts and wires is extremely dangerous and can cause fatal injuries.S Work on the weaving machine must only be carried out by

specialist personnel.S Do not open any covers, power supply cabinets, etc. These

have a sticker attached showing a yellow triangle with a light-ning symbol.

S For specialist personnel: always work with insulated measur-ing probes.

S For specialist personnel: set measuring instruments to the correct range.

2.4.2.5 Main switch ON

> Turn [main switch] to position l.The weaving machine is connected to mains voltage.

2.4.2.6 Main switch OFF

Danger!Electric shock with main switch turned off.Even when the weaving machine is switched off, electrical mod-ules indicated by the appropriate warning symbols remain live.S Before removing these modules, completely disconnect and

isolate the incoming supply to the weaving machine on the connecting terminals.

Warning!Electric shock with main switch turned off.If live parts of the weaving machine are touched within 5 minutes of turning off the main switch, there exists a risk of electric shock and the risk of damage to the electronics of the weaving ma-chine.S After turning off the main switch, wait at least 5 minutes before

removing the cover.2.4-22 E-26.04.2004

2.4 Safety equipment> Turn [main switch] to position 0.The weaving machine is disconnected from mains voltage.

2.4.2.7 Main switch OFF and secured

Danger!Electric shock with main switch turned off.Even when the weaving machine is switched off, electrical mod-ules indicated by the appropriate warning symbols remain live.S Before removing these modules, completely disconnect and

isolate the incoming supply to the weaving machine on the connecting terminals.

Warning!Electric shock with main switch turned off.If live parts of the weaving machine are touched within 5 minutes of turning off the main switch, there exists a risk of electric shock and the risk of damage to the electronics of the weaving ma-chine.S After turning off the main switch, wait at least 5 minutes before

removing the cover.

> Turn [main switch] to position 0 and lock with your person-al padlock.

The weaving machine is disconnected from mains voltage and a personal padlock is being used to prevent it being switched on again.E-26.04.2004 2.4-23

2.4 Safety equipment2.4.3 Cabinet doors and covers

2.4.3.1 Function

Cabinet doors and covers prevent contact with moving parts while the weaving machine is running and prevent contact with live components, even when the machine has stopped.

Cabinet doors also act as dust covers for internal components. Some covers are deliberately used to collect controlled amounts of dust.

Cabinet doors and covers also help reduce noise levels.

2.4.3.2 Weaving machine in operation

The cabinet doors must not be opened during normal weaving operations. Covers must not be raised, lowered, moved aside or dismantled.

2.4.3.3 Weaving machine stopped

The following procedure must be followed before any cabinet doors are opened or covers removed:

> Stop the weaving machine.> Turn [main switch] to position 0 and lock with your person-

al padlock.

The weaving machine is disconnected from mains voltage and a personal padlock is being used to prevent it being switched on again.

i Even when a weaving machine is not in use, the cabinet doors must remain closed to prevent soiling of internal components.2.4-24 E-26.04.2004

2.4 Safety equipment2.4.3.4 Checks, repairs, settings

When carrying out checks or repair work, or when in setting mode, it may be necessary to start up the weaving machine with some barriers/cabinet doors open or casings/covers removed.

) This may only be done by specialist personnel under strict observance of the safety rules.Before recommissioning the machine, all barriers/cabinet doors must be closed and the casings/covers correctly refitted.E-26.04.2004 2.4-25

2.4 Safety equipment"2.4-26 E-26.04.2004

Main chapter3 Customer informationsE-26.04.2004

E-26.04.2004

Main chapter index3 Customer informations

3.1 CCP PCB customer information. . . . . . . . . . . . . 3.1-5

3.1.1 Introduction . . . . . . . . . . . . . . . . . . . 3.1-5

3.1.2 Important information . . . . . . . . . . . . . . 3.1-7

3.1.3 Procedure . . . . . . . . . . . . . . . . . . . . 3.1-9

3.1.3.1 Replacing the CCP PCB . . . . . . . . . . . . . . 3.1-9

3.1.3.2 Replacing the OPP PCB . . . . . . . . . . . . . 3.1-12

3.1.4 Backup copy . . . . . . . . . . . . . . . . . . 3.1-13

3.1.4.1 Create backup copy . . . . . . . . . . . . . . . 3.1-14

3.1.4.2 Load backup copy . . . . . . . . . . . . . . . . 3.1-14E-26.04.2004

Main chapter indexE-26.04.2004

3.1 CCP PCB customer information3.1 CCP PCB customer information

3.1.1 Introduction

Item no. 910000760

Important!Read this manual carefully and comply with the instructions it contains. Sultex AG is not liable for any damage arising through lack of regard for the instructions in this manual.

Equipment supplied:

CCP PCB (one of the 3 versions) Installation instructions

Tab. 3.1-1

If you are still experiencing problems after reading this manual or there is a different item number on the PCB, please contact Sultex AG customer service.

Version Item no. (1) Type Valid for WM no.

1 * 270.002.766 CCP/RK376 200028 - 200611

or

2 ** 270.006.991 CCP/RK376 200612 - 200953

or

3 270.008.437 CCP/RK376 200954 -

* If this version is not in stock, version 2 or 3 will be supplied.

** If this version is not in stock, version 3 will be supplied.

(1) The item number is at the bottom right of the CCP PCB (arrow).E-06.10.2004 3.1-5

3.1 CCP PCB customer informationFig. 3.1-13.1-6 E-06.10.2004

3.1 CCP PCB customer information3.1.2 Important information

Danger!Electric shock with main switch turned off.The mains filter 8 remains live, even when the [Main switch] is switched off!S Allow only qualified technical personnel to carry out work on

electrical equipment.

Fig. 3.1-2

Warning!Electric shock with main switch turned off.If live parts of the weaving machine are touched within 5 minutes of turning off the main switch, there exists a potential risk of electric shock and the risk of damage to the weaving machine electronics.S After turning off the main switch, wait at least 5 minutes before

opening the control cabinet doors.

Mill electricianE-06.10.2004 3.1-7

3.1 CCP PCB customer informationCaution!Damage to the electronics!The plugging-in and removing of live electrical components can cause damage to the weaving machine electronics.S Before plugging-in or removing PCBs: Turn off the main

switch and wait 5 minutes.

Caution!Damage caused by electrostatic discharge!Electrostatic discharge can damage the weaving machine electronics.S Touch a metal object before handling any electronic

components.

> Turn [Main switch] to 0 position.The weaving machine is disconnected from the mains.3.1-8 E-06.10.2004

3.1 CCP PCB customer information3.1.3 Procedure

3.1.3.1 Replacing the CCP PCB

9 Before starting work on the activities described in this section, the user must have read and fully understood the chapter entitled "Important information".

3.1.2 Important information9 Before removing the PCB, save the data to a memory card. 3.1.4 Backup copy

9 Turn [Main switch] to 0 position.9 OPP PCB removed. 3.1.3.2 Replacing the OPP PCB

Fig. 3.1-3

> Remove all connectors from the PCB 9.> Remove the screws 10.> Carefully tilt the PCB 9 forwards and pull out of the lower

locating lugs 11.E-06.10.2004 3.1-9

3.1 CCP PCB customer information> Locate the new PCB using the lower locating lugs 11 and insert.

> Carefully tighten the screws 10.

> Plug connectors onto the PCB 9, see: Fig. 3.1-1

Tab. 3.1-2

> The adapters shown are no longer used on any of the versions:

Fig. 3.1-4

Version Without adapter With adapter

1 X01; X07; X08; X25; X26; two off X32; X52; X63.1; X65

X11 and X81

2 X01; X07; X08; X11; X25; X26; two off X32; X52; X63.1; X65 and X81 33.1-10 E-06.10.2004

3.1 CCP PCB customer informationImportant!The adapters shown below for plug-in connection X 11 and X 81 must be used only on version 1.S In the case of version 2 and 3, remove these adapters!

Fig. 3.1-5

> Plug in all other connectors on the PCB 9.> Install OPP PCB. 3.1.3.2 Replacing the OPP PCBE-06.10.2004 3.1-11

3.1 CCP PCB customer information3.1.3.2 Replacing the OPP PCB

9 Before starting work on the activities described in this section, the user must have read and fully understood the chapter entitled "Important information".

3.1.2 Important information9 Turn [Main switch] to 0 position.

Fig. 3.1-6

> Remove all connectors from the PCB 6.> Remove the screws 7.> Carefully tilt the PCB 6 forwards and pull out of the lower

locating lugs 8.

> Locate the new PCB using the lower locating lugs 8 and insert.

> Carefully tighten the screws 7.> Plug in all connectors on the PCB 6.3.1-12 E-06.10.2004

3.1 CCP PCB customer information3.1.4 Backup copy

> Insert the [Memory card] into the terminal.The Memory card button appears in the main menu.

Fig. 3.1-7

) When the CCP module is replaced, all the data can be backed up on a Memory card and then restored to the new module.

Caution!A backup copy can only be restored to the same weaving machine, otherwise statistical information such as pick counts will be lost.E-06.10.2004 3.1-13

3.1 CCP PCB customer information3.1.4.1 Create backup copy

This button enables a backup copy of the current weaving machine settings to be made.A message from the control system shows that the data is being transferred.

3.1.4.2 Load backup copy

This button loads a backup copy onto the weaving machine.A message from the control system shows that the data is being transferred.3.1-14 E-06.10.2004

Sultex LimitedHead OfficeCH-8630 Rti ZHPhone +41 (0)55 250 21 21Telefax +41 (0)55 250 21 01www.sultex.com

Service instructions1 Information1.1 Information concept1.2 Using the Operating Instructions1.2.1 About this manual1.2.2 Symbols used1.2.3 Descriptive elements1.2.4 Guidance elements1.2.5 Machine positions

1.3 Third-party documentation1.3.1 Suppliers

1.4 Copyright1.4.1 Patents1.4.2 Copyright

1.5 Validity of the operating instructions1.5.1 Picking points1.5.2 Type key

2 Safety2.1 General information2.1.1 Liability2.1.2 Authorized application2.1.3 Alterations to the machine2.1.4 Damage to the machine2.1.5 Obligations of the user2.1.5.1 Operating instructions2.1.5.2 Personnel2.1.5.3 Competencies and responsibilities2.1.5.4 Access to weaveroom, visitors

2.1.6 Additional directives and standards

2.2 Fundamental safety instructions2.2.1 Safety-conscious working2.2.1.1 Protective equipment2.2.1.2 Working with harmful materials2.2.1.3 Hair and clothing2.2.1.4 Before starting the machine2.2.1.5 Button operation/starting the machine2.2.1.6 While the weaving machine is running2.2.1.7 Scissors and tools

2.2.2 Working on the machine2.2.3 Working on the electrical equipment2.2.3.1 Before working on the electrical equipment

2.2.4 Working with the stroboscope2.2.5 Working with compressed air2.2.6 Noise hazards

2.3 Hazard symbols and warning notices2.3.1 Danger notices2.3.2 Warning notices2.3.3 Caution notices

2.4 Safety equipment2.4.1 Stickers, signs and notices2.4.2 Safety equipment2.4.2.1 EMERGENCY STOP switch2.4.2.2 Safety circuit2.4.2.3 Close safety circuit2.4.2.4 Open safety circuit2.4.2.5 Main switch ON2.4.2.6 Main switch OFF2.4.2.7 Main switch OFF and secured

2.4.3 Cabinet doors and covers2.4.3.1 Function2.4.3.2 Weaving machine in operation2.4.3.3 Weaving machine stopped2.4.3.4 Checks, repairs, settings

3 Customer informations3.1 CCP PCB customer information3.1.1 Introduction3.1.2 Important information3.1.3 Procedure3.1.3.1 Replacing the CCP PCB3.1.3.2 Replacing the OPP PCB

3.1.4 Backup copy3.1.4.1 Create backup copy3.1.4.2 Load backup copy

Button 19: