01 A18 Electronic Control System [PDF]
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Ypres - Belgium EN
Content : Introduction ................................................................................................................................... 5 • Different sections .............................................................................................................................5 • The electronic control system ..........................................................................................................5 • The Electronic Wiring System..........................................................................................................5
Pictographs, wire abbreviations and safety devices ..................................................................... 7 • Pictographs used .............................................................................................................................7 • Wire abbreviations ...........................................................................................................................8 • Safety Devices.................................................................................................................................9
General ....................................................................................................................................... 11 Connection conditions.........................................................................................................................12
• • • •
Power supply cable specifications .................................................................................................12 Supply cable protections................................................................................................................14 Shielded wire connections .............................................................................................................15 Data cables....................................................................................................................................15
Control system and machine drive .....................................................................................................16
• • • • • • • • • • •
Principle .........................................................................................................................................16 Security..........................................................................................................................................16 Power supply - motor switches ......................................................................................................17 Control system of the main motor control box ...............................................................................17 Main motor.....................................................................................................................................17 Brake .............................................................................................................................................18 Cooling system ..............................................................................................................................18 Pickfinding .....................................................................................................................................19 Weaving (driving the machine) ......................................................................................................19 Let-off ............................................................................................................................................20 Take-up motion..............................................................................................................................21
Overview of the weaving machine ......................................................................................................22
• • • •
Division of the weaving machine ...................................................................................................22 Overview of the weaving machine 1 ..............................................................................................22 Overview of the weaving machine 2 ..............................................................................................23 Overview of the weaving machine 3 ..............................................................................................23
Board naming........................................................................................................................................24
The Control Box (CB) ................................................................................................................. 25 The sides of the control box................................................................................................................26
• • • • • • •
Overview of the control box ...........................................................................................................26 Button side.....................................................................................................................................26 Cable entry side.............................................................................................................................27 Front ..............................................................................................................................................28 Power Panel side...........................................................................................................................30 Identification sticker .......................................................................................................................31 Maintenance ..................................................................................................................................31
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The rack .................................................................................................................................................32
• • • • •
Boards ...........................................................................................................................................33 CBFSB-1 (Common Board Fast Serial Bus)..................................................................................33 CBMP-3 (Common Board Main Processor)...................................................................................35 CBSD-1 (Common Board Sensors and Devices) ..........................................................................39 ABSD-2 (Airjet Board Sensors and Devices).................................................................................42
Bus systems..........................................................................................................................................44
• • • •
Overview........................................................................................................................................44 FSB (Fast Serial Bus) ....................................................................................................................44 Locan bus ......................................................................................................................................44 Pican bus .......................................................................................................................................46
Mains entry ............................................................................................................................................48
• • • •
Diagram .........................................................................................................................................48 QM: Overload protection switch Mains ..........................................................................................49 FL: EMI FiLter ................................................................................................................................50 LR: Line Reactor............................................................................................................................50
High voltage part...................................................................................................................................51 Power panel...........................................................................................................................................55
• • • • • • •
MPS-2 (Main Power Supply) .........................................................................................................56 SRDD (Switch Reluctance Dual Drive)..........................................................................................58 NG_LDEC (New Generation Loom Drive Electronic Converter) ...................................................62 MMCU-1 (Main Motor Control Unit) ...............................................................................................63 EBMM-1 (Elco Board Main Motor).................................................................................................64 OBMM-1 (Output Board Main Motor).............................................................................................65 MMRB-1 (Main Motor Rectifier Board) ..........................................................................................65
Devices on the machine ............................................................................................................. 67 • • • • • • • • • • • • • • • • • •
PDP (Picanol DisPlay) ...................................................................................................................67 Control buttons on the breast plate................................................................................................69 RS: ReSolver .................................................................................................................................70 Proximity switches .........................................................................................................................72 Safety light curtain .........................................................................................................................73 EPR (Electronic Pressure Regulator) ............................................................................................75 ELSY: Electric Leno SYstem .........................................................................................................76 IRO Control Box.............................................................................................................................76 NG_FDCB: Filling Detector Control Box........................................................................................77 E-Leno ...........................................................................................................................................78 Can Dobby S3XXX ........................................................................................................................79 Jacquard ........................................................................................................................................79 Cam motion with leveling system (1681, 1781) .............................................................................81 Cam motion with leveling system (S1692).....................................................................................83 Parking brake.................................................................................................................................84 Electrical cutters ............................................................................................................................86 Thermal cutter................................................................................................................................87 PKE................................................................................................................................................88
Service........................................................................................................................................ 91 • General ..........................................................................................................................................91 .
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Replacing boards and/or assemblies .................................................................................................92
• • • • • • • • • • • •
General ..........................................................................................................................................92 RMA (Return Merchandise Authorization) .....................................................................................92 Replacing the assem. NG_LDEC ..................................................................................................93 Replacing the EBMM .....................................................................................................................94 Replacing the OBMM.....................................................................................................................95 Replacing the MMRB.....................................................................................................................98 Removing and mounting boards from the rack............................................................................101 Replacing the assem. SRDD .......................................................................................................103 Replacing the CBFSB..................................................................................................................105 Replacing the CBMP ...................................................................................................................107 Replacing the PDP ......................................................................................................................109 Replacing the protection foil on the assem.PDP_9inch...............................................................111
Software...............................................................................................................................................113
• • • •
Installing Software .......................................................................................................................113 CSF (Customer System File).......................................................................................................115 Machine log .................................................................................................................................116 Screen capture ............................................................................................................................117
Fuses ...................................................................................................................................................118
• Marking ........................................................................................................................................118 • Fuse details .................................................................................................................................118 Tools ....................................................................................................................................................119
• • • • • • • • • •
Masterstick (BE316654) ..............................................................................................................119 USB-stick (N1038701) .................................................................................................................119 F-contact tools .............................................................................................................................120 Burndy (TRIM TRIO) contact tools ..............................................................................................121 D-sub contact tools ......................................................................................................................122 Molex Mini-Fit Jr contact tools .....................................................................................................123 Molex Mini-Fit Sr contact tools.....................................................................................................124 Torx screwdriver ..........................................................................................................................125 Wire strip tool...............................................................................................................................125 Crimp tool for wire end-sleeves (0,08 mm² - 16 mm²) .................................................................126
Electrical Wiring ........................................................................................................................ 127 • • • • • • •
General ........................................................................................................................................127 TPVN ...........................................................................................................................................127 Cable identification ......................................................................................................................128 Diagrams .....................................................................................................................................129 Color coding wires .......................................................................................................................129 Cable number ..............................................................................................................................130 Shielded wire connections ...........................................................................................................131
Abbreviations ............................................................................................................................ 133
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Introduction Different sections 2 Sections
The electronic part of the manual is divided into 2 sections: • The Electronic Control System (This section) • The Electronic Wiring System
The electronic control system Description
The electronic control system is the general section. This section describes the electronic control and is not specific, but general to all OMNiplus Summum machines.
The Electronic Wiring System Description
The electronic wiring system is the specific section. This section is only valid for machines with the TVPN-number mentioned in this section. See: TPVN [127]. All diagrams and cables listed in this section are generated only for the machines with this TPVNnumber.
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Pictographs, wire abbreviations and safety devices Contents
•
Pictographs used ........................................................................................................................ 7
•
Wire abbreviations ...................................................................................................................... 8
•
Safety Devices............................................................................................................................ 9
Pictographs used The following table shows the safety pictographs used in this manual: Pictograph Name Description Note Provides additional information concerning important topics in the text. Warning Disregarding this warning may result in the loss of electronic data or in mechanical damage. Danger Disregarding this warning may lead to material damage but also and in particular to physical injury to persons. CE version Only applies to the CE version. Liability
Provides information about the legal liability.
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Wire abbreviations Introduction
The abbreviations for the colors of cable wires are determined here. Other abbreviations are explained in the “Abbreviations” section in the Picanol manual.
Colored wires
The following table gives an overview of the abbreviations Abbreviation In full WH WHite BN BrowN GN GreeN YE YEllow GY GreY PK PinK BU BlUe RD ReD BK BlacK VT VioleT GY/PK GreY/PinK RD/BU ReD/BlUe WH/GN WHite/GreeN BN/GN BrowN/GreeN WH/YE WHite/YEllow YE/BN YEllow/BrowN WH/GY WHite/GreY GY/BN GreY/BrowN WH/PK WHite/PinK PK/BN PinK/BrowN WH/BU WHite/BlUe BN/BU BrowN/BlUe WH/RD WHite/ReD BN/RD BrowN/ReD WH/BK WHite/BlacK BN/BK BrowN/Black GY/GN GreY/GreeN YE/GY YEllow/GreY PK/GN PinK/GreeN YE/PK YEllow/PinK GN/BU GreeN/BlUe YE/BU YEllow/BlUe GN/RD GreeN/ReD YE/RD YEllow/ReD GN/BK GreeN/BlacK YE/BK YEllow/BlacK GY/BU GreY/BlUe
Description white brown green yellow grey pink blue red black violet grey with pink rings red with blue rings white with green rings brown with green rings white with yellow rings yellow with brown rings white with grey rings grey with brown rings white with pink rings pink with brown rings white with blue rings brown with blue rings white with red rings brown with red rings white with black rings brown with black rings grey with green rings yellow with grey rings pink with green rings yellow with pink rings green with blue rings yellow with blue rings green with red rings yellow with red rings green with black rings yellow with black rings grey with blue rings
The following table gives an overview of the abbreviations. Abbreviation In full GNYE GreeNYEllow
Description green/yellow earth wire
Earth wire
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Safety Devices Emergency stop
The control box remains live when the emergency stop button is pressed.
• • Safety light grid
This is a red button on a yellow background. If any emergency stop is locked, the control buttons will not work => unlock = 1/8 turn clockwise.
The safety light grid does not function when the machine is operating at full speed.
• •
Is located over the pressure roll. The safety light grid prevents movement of the sley during start-up, slow motion and pick finding. The machine motion can be started again following the normal procedure.
STAND-BY
• • •
The machine must be placed in this condition for all repair activities and lubrication work. Condition for setting the machine. All machine movements are blocked, but the electronic components will remain live.
POWER ON
• • •
Power circuits are turned on. All motors, except for the prewinder motor, remain switched off. The main motor will only start after: - The start button has been pressed. - Any automatic movement and also machine start-up is indicated by clear flashing warning lights. - In case of emergency, all machine actions can be interrupted by means of an emergency stop.
Warning lights
If the warning lights are flashing, do not touch the weaving machine.
Main switch
• •
Is located on the right hand side of the main control box. Must be padlocked in the -0- position when major work is performed.
Work to be performed
•
The control boxes may only be opened and connected by qualified and authorized members of staff. This means that they must have a basic knowledge of the fundamental rules of electricity and the relevant legislation, and that they must have experience with electric wiring, electric components and with the symbols on electric diagrams. If, for work to be performed, it is required that the earth connections are disconnected, then these must be reconnected in the original way before the control system is switched on again. When a control box is open, EMC (electromagnetic compatibility) is not guaranteed. While work is going on with a control box open and the main switch on, no appliances producing strong electromagnetic fields – such as mobile phones or walkie-talkies – may be brought near the control box.
• • •
Earth connection
• • • • •
Stepping motors
• • •
The weaving mill must have an effective earth connection. This must have been checked and verified by the responsible services. After the control box has been placed, the earth wire must first be connected to the machine. For more information on the earthing, see the “Installation” section. The earth wire of the bobbin stand must be connected to the prewinder stand, see the “Installation” section. The machine must be connected to the mains earth connection in the prescribed manner. The earth connections interconnecting machine components may not be interrupted. If during work on the machine they are disconnected, they must be reconnected in the original way before the control system is switched on again. The machine is equipped with several stepping motors: the filling cutters, the waste cutters, the selvedge motions… These motors may never be opened, as some loss of torque may result from opening and re-closing them. In the event of a fault or failure, these motors should be sent to Picanol.
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General Contents
Connection conditions................................................................................................................... 12
•
Power supply cable specifications ............................................................................................ 12
•
Supply cable protections........................................................................................................... 14
•
Shielded wire connections ........................................................................................................ 15
•
Data cables............................................................................................................................... 15
Control system and machine drive ............................................................................................... 16
•
Principle .................................................................................................................................... 16
•
Security..................................................................................................................................... 16
•
Power supply - motor switches ................................................................................................. 17
•
Control system of the main motor control box .......................................................................... 17
•
Main motor ................................................................................................................................ 17
•
Brake ........................................................................................................................................ 18
•
Cooling system ......................................................................................................................... 18
•
Pickfinding ................................................................................................................................ 19
•
Weaving (driving the machine) ................................................................................................. 19
•
Let-off........................................................................................................................................ 20
•
Take-up motion......................................................................................................................... 21
Overview of the weaving machine ................................................................................................ 22
•
Division of the weaving machine .............................................................................................. 22
•
Overview of the weaving machine 1 ......................................................................................... 22
•
Overview of the weaving machine 2 ......................................................................................... 23
•
Overview of the weaving machine 3 ......................................................................................... 23
Board naming.................................................................................................................................. 24
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Connection conditions Power supply cable specifications • • • • •
Contents
Load demands
Load demands [12] Rated power [12] General conditions [12] Electrical requirements of the weaving room Cable section [13]
[13]
Power consumption is the energy consumption during normal machine operation. The power consumption depends on: • the machine configuration, • the machine speed; • the type of fabric and the machine settings. The required load must be calculated separately for each machine.
Rated power
The rated power depends on external factors during a cold start or in specific working environments. The mains must always be able to supply enough power in similar extreme situations. The rated power is also taken into account when calculating the mains cable conductor size.
Rated supply voltage
The table below shows the rated supply voltage (Vnom): Vnom (3 phase/PE/no Neutral) Transformer used? 200V to 346V YES 380V to 460V NO 480V to 600V YES
General conditions
•
Stability of the power supply - Supply voltage fluctuations must be between -10% and +10% of the nominal operating voltage (EN50160). - e.g.: at Unom = 460V, the supply voltage must never drop below 414V or be higher than 506V.
•
Power consumption at cold start At a cold start (e.g. after a weekend stop) power consumption is twice as high as compared to the consumption at typical operating temperature conditions. It takes about 3 hours for the power consumption to drop to normal. The electrical wiring and the transformer (if present) must be able to support this high power consumption at a cold start.
•
Conditions at machine start-up At machine start-up, the power consumption is approximately 80KVA (for 0,2sec). During this short time lap, the voltage at the machine should not drop below 85% of the nominal operating voltage.
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Electrical requirements of the weaving room
The weaving machines need a nominal voltage between 380V and 460V. If the weaving room does not dispose of a power supply between these values, a transformer must be used. The machine is foreseen to be used on electrical installations according IEC 60364 and power supplies according EN 50160 Distribution system: • 3AC 380V - 460V ±10% +PE • 3AC 200V - 346V ±10% +PE; autotransformer used; WYE 3AC 440V secondary • 3AC 480V - 600V ±10% +PE; autotransformer used; WYE 3AC 440V secondary WYE grounded in star point preferred; delta ungrounded can be used, however more susceptible to effects of ground faults. System of live conductor: • Three-phase 3 wire Neutral is not used inside the control box. There is a terminal for connecting the neutral conductor. Mono-phase 230VAC is not available in the control box. For further information, please contact your Picanol service engineer. System earthing: • TB (TN-C; TN-C_S; TN-S); • TT; • IT If an IT-type is used, insulation monitoring should be installed by the customer. Picanol does not supply such a monitoring system.
Cable section
The tables below show the minimum value of the cable section for a specific supply voltage and the maximum cable length from the power source to the machine. These tables take the above mentioned requirements into account. These tables apply if: • every machine has a separate supply cable to the power source. • the supply voltage equals the nominal level. If the supply voltage drops below the nominal voltage, the cross section of the connection cable must be increased to compensate for that loss in voltage. For the calculation of the cable cross section, the following resistances are taken into account (copper wires): Cable section in mm² Resistance per meter in 50 0,000387 35 0,000524 25 0,000727 16 0,00115 10 0,00183 6 0,00308 4 0,00461
•
Cable length power source - machine (meter)
cable section (mm²) 10 20 30 40 50 60 70 80 90 100
The table below is used for stable supply voltages (which meet the European standard EN50160), or corresponding standard that apply to your country.
Supply voltage (V) 200 220 260 280 346 380 400 415 440 460 480 500 6 4-6** 4-6** 4-6** 4-6** 4 4 4 4 4 4 4 10 10 6 6 4-6** 4 4 4 4 4 4 4 16 16 10 10 6 4 4 4 4 4 4 4 25 16 16 10 6 6 6 4 4 4 4 4 25 25 16 16 10 6 6 6 6 6 4 4 35* 25 16 16 10 10 10 6 6 6 6 6 35* 25 25 16 10 10 10 10 10 6 6 6 35* 35* 25 25 16 10 10 10 10 10 6 6 50* 35* 25 25 16 16 10 10 10 10 10 10 50* 50* 25 25 16 16 16 10 10 10 10 10 * 25 mm² single wire is the maximum cable section that can be connected on QM. ** The cable is 6 mm² for reason of overload protection.
550 4 4 4 4 4 4 4 6 6 6
575 4 4 4 4 4 4 4 6 6 6
600 4 4 4 4 4 4 4 4 6 6
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•
Cable length power source - machine (meter)
cable section (mm²) 10 20 30 40 50 60 70 80 90 100
The table below is used for power voltages where voltage fluctuations may be expected (the fluctuations may not exceed 10%).
Supply voltage (V) 200 220 260 280 346 380 400 415 440 460 480 500 10 10 6 6 4-6** 4 4 4 4 4 4 4 25 25 16 16 10 6 6 6 6 4 4 4 35* 25 25 16 10 10 10 10 10 6 6 6 50* 35* 25 25 16 16 10 10 10 10 10 10 70* 50* 35* 25 25 16 16 16 16 10 10 10 70* 70* 50* 35* 25 25 16 16 16 16 16 10 95* 70* 50* 50* 25 25 25 25 16 16 16 16 95* 70* 50* 50* 35* 25 25 25 25 16 16 16 95* 95* 70* 50* 35* 25 25 25 25 25 16 16 120* 95* 70* 70* 35* 35* 25 25 25 25 25 16 * 25 mm² single wire is the maximum cable section that can be connected on QM. ** The cable is 6 mm² for reason of overload protection.
550 4 4 4 6 10 10 10 16 16 16
575 4 4 4 6 10 10 10 10 16 16
600 4 4 4 6 6 10 10 10 10 16
When using one cable to connect the main distribution point with multiple machines and another distribution point is available close to the machines, the copper of the cables can be used in a more efficient way as the cable is rated with a higher voltage. As a result, the difference between nominal power and peak power at start-up of one of those machines becomes smaller. In most cases, there is no influence on the nominal voltage during start-up of a machine. The nominal voltage can drop 15% during startup.
Supply cable protections Overload protection
The overload protection upstream of the power cable of the weaving machine protects: • the power supply cable, • the main switch in the control box. The thermal protection can be done with fuses of the type aM or D (according to the standard IEC 60269-1). The table below shows the fuses to use: Supply voltage Value of the type aM or D fuse 200V to 346V 32A 380V to 460V 25A 480V to 600V 25A
Icu value of the control box
The maximum allowed short circuit current (Icu) supplied to the main switch, is limited, according to the standard IEC 60947-2. The power distribution must be able to cope with that. The maximum allowed short circuit current (Icu) can be found in the table below. Supply voltage Icu (kA) 200V to 346V 10 380V to 460V 4 480V to 600V 3
Leak current protection
The machine control has no leak current protection. If the local laws demand a leak current protection, it must be provided in the power distribution of the weaving mill. The leak current protection should have the following properties: • time delayed leak current protection • should not be lower than 300mA. • one leak current protection per machine.
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Shielded wire connections Yellow cable ties
Yellow cable ties are used where a shielded wire must make contact with the ground plane of the machine. The shield, made of braided copper strands, is used to reduce interference with other devices. After removing a yellow cable tie, the shielded wire must always be reconnected to the ground plane of the machine.
Shielding connections
For more information concerning the shielding connections see: Tools
[119].
Data cables Interferences
In case data cables are installed, Picanol recommends not to lay the data cables next to the power line cables to the weaving machines to avoid interferences.
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Control system and machine drive Contents
• • • • • • • • • • •
Principle [16] Security [16] Power supply - motor switches [17] Control system of the main motor control box Main motor [17] Brake [18] Cooling system [18] Pickfinding [19] Weaving (driving the machine) [19] Let-off [20] Take-up motion [21]
[17]
Principle Block diagram
The following illustration shows the principle:
SRDD C A
D
G
E
H
CBMP F RS NG_LDEC
B
J
I
K A. Input signal from the PX_ref C. LOCAN communication E. Drive motor 2 G. ELO I. MMCU K. Brake main motor
B. Signal to the VPF D. Drive motor 1 F. Drive main brake H. ETU J. Main motor [17] RS. ReSolver
. .
Security The safety system combines software and hardware protection. The hardware protection consists of: • the second contact (PB-*-2) (where * = SMF, SMR, PFF or PFR) of the buttons controlling machine movements. • the activation of the STAND-BY position • the relay control unit on the CBMP board. • the emergency stops.
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Power supply - motor switches .
NG_LDEC motor switch KMM
Function Switches 2 contacts (1-2 and 5-6), while 1 contact (3-4) is connected through. • The INRUSH print is located across 1 contact (1-2). This print makes sure the ELCOs' loading current on the NG_LDEC is restricted and that the ELCOs remain charged in case of an open KMM. • The motor switch switches on after POWER-ON.
Control system of the main motor control box • •
The control system is located on the MMCU board. The MMCU board is part of the NG_LDEC board. The NG_LDEC board is controlled and monitored via the LOCAN bus.
Stator coils
• • •
Contains 8 stator coils (4 double coils). 2 by 2 coils in opposite positions are placed in parallel. R = 0.22 (per double stator coil in cold condition).
Main motor test
See chapter: the Drive’-section.
Rotor shaft
The rotor shaft can move both radially and axially.
Main motor
Radially The radial movement is controlled by the 4 double stator coils.
A D
MM
B
C Radial movement
Function
first second
machine drive brake movement
The stator coils are controlled in such a way that... the rotor rotates. they have a braking effect on the rotor and stop the machine.
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Axial The axial movement is produced by valve V-PF and a pneumatic piston (inputs PF-IN and PF-OUT). PF-OUT PX-WP
PX-PFP PF-IN
93)
3)287
V-PF energized V-PF non-energized V-PF
The rotor shaft... shifts 32 mm to the right is not extended
3),1
The gear wheel on the rotor shaft... Controlled by... is disengaged from the sley drive gear PX-PFP is engaged in the sley drive gear
PX-WP
Brake Machine running
The running machine is braked by controlling the main motor stator coils in a way resulting in a braking effect on the rotor shaft.
Machine stopped
When the machine is stopped, it is held motionless by a brake. Brake Shed system When the brake is actuated, the machine is... holding brake outside cam motion held parking brake - outside cam motion released - dobby - jacquard
On power OFF, the machine is... released held
Cooling system Oil
One circulating lubrication system oil circuit cools the stator of the motor.
Heatsink
The following components are fitted against the heatsink: • the power control system control modules composed of 2 OBMM prints; • the MMRB print (3-phase rectifier); • the dump resistor.
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Pickfinding Function
The pickfinding procedure lets the motor drive the shed mechanism independently from the sley mechanism. The sley mechanism is blocked by a peg during pickfinding.
Process
The illustration below shows the pickfinding process: PX-PFP
A
PF--OUT
PX-WP
B
C
93)
D
93) 3)287 3)287
1. 2. 3. 4. 5. n=0
3),1
E
Weaving --> Pickfinding The machine moves slowly to a pickfinding position Valve VPF is switched on Air is directed to PF-OUT • The piston moves to the right. • The sley gear is disconnected from the main motor gear. • The peg serving to hold the sley gear is engaged. • The position is verified by means of PX_PFP and PX_WP:
A. Peg B. Engaged C. Sley gear D. Disengaged E. Main motor gear .
Weaving (driving the machine) Process
The illustration below shows the weaving process: PX-WP
PX-PFP
PF--IN
B 93)
A 3),1
C D E
1. 2. 3. 4.
Pickfinding --> Weaving Valve VPF is switched off Air is directed to PF-IN • The piston moves to the left. • The sley gear engages the main motor gear. • The peg holding the sley gear is disengaged.
A. Peg B. Disengaged C. Sley gear D. Engaged E. Main motor gear .
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Let-off General
There are two Let-off versions: • without speed change gear box; • with speed change gear box. A speed change gear box offers more pick density and let-off speed options to ensure an optimal working of the let-off. The electrical connection is the same for both versions. The configuration is part of the machine identification.
Without speed change gear box
The following illustration shows the Let-off without change gear box:
BR
With speed change gear box
RS
M
The following illustration shows the Let-off with change gear box “A”: BR
M
RS
A
The let-off motor(s) ELO_LHS and ELO_RHS
Principle of the motor drive
• • •
The stator coils are controlled by means of a chopper voltage from the SRDD drive. The power supply to the SRDD board for power stages is the 290V DC. The current in the different motor phases is monitored by means of current sensors. If 1 measurement is incorrect, the control modules for the motor concerned are switched off by means of the Drive Enable signal.
Maximally 2 let-off motors can be present, depending on the machine configuration. These are: • ELO_RHS
• ELO_LHS The motor (A, B, C and D) The motor contains 4 double stator coils. => R = 2.3 (per double stator coil) The resolver (RS) A resolver is mounted on the rotor shaft. The signals of the resolver are used to continuously calculate the motor speed. This data is used to control the motor. The brake (BR) The motor brake is of the normally closed type: - The brake must be powered to open. - The brake keeps the warp beam in place while power is OFF or in extended downtime situations. • Power supply = 26V DC choppered • R = ±26
•
Temperature control (DTTH) A normally closed bimetal is provided as thermal protection. This opens when the temperature rises above 100°C.
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Warp tension protection
The warp tension sensors 2 types: • TSF • TSW Machine type single beam double beam fancy let-off on the machine
• • •
TSF standard 1 sensor 2 sensors 2 sensors
TSW optional 1 sensor 2 sensors not possible
The warp tension sensor converts the warp tension into an analogue current (4-20 mA). The warp tension sensors must be calibrated before accurate measurements are possible. See section “The warp” part “TSF” or “TSW”. Power supply for the warp tension sensors = +26V DCS
Warp tension limit values • Warp tension and warp tension limit values are set using the machine terminal. • If the warp tension limit values are exceeded, the machine stops. Monitoring the sensors The DTWTCAL signal is used to detect the connection of the warp tension sensor.
Take-up motion General
The SRDD board microprocessor controls the ETU motor on the basis of: • the set pick density; • the machine speed. The ETU motor drives the sand roller through a gear train.
The take-up motor ETU
Principle of the motor drive • The stator coils are controlled by means of a chopper voltage from the SRDD board control modules. • The power supply to the SRDD board for power stages is the 290V DC. • The current in the different motor phases is monitored by means of current sensors. If 1 measurement is incorrect, the control modules for the motor concerned are switched off by means of the Drive Disable signal. The motor (A, B, C and D) The motor contains 4 double stator coils. => R = 2.3 (per double stator coil) The ReSolver (RS) A resolver is mounted on the rotor shaft. The resolver signals are used to: • continuously calculate the motor speed; • determine the motor’s angle position. This data is used to control the motor. The brake (BR) • The motor brake is of the normally closed type. - The brake must be powered to open. - The brake keeps the cloth roll in place while power is OFF or in extended downtime situations. • Power supply = 26V DC choppered. • R = ±26 Temperature control (DTTH) A normally closed bimetal is provided as thermal protection. This opens when the temperature rises above 100°C.
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Overview of the weaving machine Contents
This section contains the following subjects:
• • • •
Division of the weaving machine.............................................................................................. 22 Overview of the weaving machine 1 ........................................................................................ 22 Overview of the weaving machine 2 ........................................................................................ 23 Overview of the weaving machine 3 ........................................................................................ 23
Division of the weaving machine Illustration
The illustration belows shows how the machine is divided into different sections: A
B
C
D
E A. Left-hand side C. Right-hand side E. Weaver’s side
B. Middle D. Warp beam side .
Overview of the weaving machine 1 Illustration
The illustration below shows the overview of the weaving machine part 1: A
B
HS_RX
WL_LHS ES_LHS
WL_RHS
ES_RHS
HS_TX
C PB
DTTHLU
DTLUFL A. Bobbin creel C. PDP (Picanol DisPlay) [67] ES_LHS, ES_RHS: Emergency Stops HS_RX: HandSafety_Receiver DTTHLU: DeTection THermal LUbrication
B. PRW: Prewinders WL_LHS, WL_RHS: Warning Lights HS_TX: HandSafety_Transmitter PB: Push Buttons DTLUFL: DeTection LUbrication FiLter .
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Overview of the weaving machine 2 Illustration
The illustration below shows the overview of the weaving machine part 2: ETU
ES_RRHS
E-Leno_LHS
CB
SL_CB
DTWT1
E-Leno_RHS
FDCB DTLUPRESS
ELO_RHS ETU: Electronic Take Up
ES_RRHS: Emergency Stop_Rear Right Hand Side (Only CE). DTWT1: DeTection WarpTension1 CB: Control Box,see: The Control Box (CB) [25] SL_CB: Signal Light_Control Box ELO_RHS: Electronic Let_Off Right-Hand Side. E-LENO_LHS, E-LENO_RHS: See: E-Leno [78] FDCB: see: “NG_FDCB: Filling Detector Control Box” op pagina – 77 DTLUPRESS: Detection LUbrication PRESSure
Overview of the weaving machine 3 Illustration
The illustration below shows the overview of the weaving machine part 3: ES_RHS
WL_RHS
ES_RRHS
WYD_RHS
HS_TX
ETU ELO_RHS
FDCB HSOTX: HandSafety_Transmitter ES_RHS: Emergency Stop_Right Hand Side ETU: Electronic Take Up ELO_RHS: Electronic Let Off_Right Hand Side
WL_RHS: Warning Lights_Left Hand Side ES_RRHS: Emergency Stop_Rear Right Hand Side (Only CE). FDCB: Filling Detector Control Box WYD_RHS: Waste Yarn Detection_Right Hand Side
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Board naming Name format
The illustration belows shows how the board name is formatted: A B C D E
F
A. Function number B. Board name C. Board version number D. Board revision number E. BE-reference F. Board serial number Read the serial number as RSxxxxxxxx eg. RS1619982743 Board name and BE-reference
The board name shows the name of the board and the function number. The board name is also a reference to the BE-number of this board. Use the BE-number to order a new board. Every board has a collection of functions. Extending the functions on a board, will increase the function number at the end of the board name and change the BE-number. The function number is preceded by the minus sign.
Location name
In case a board can be positioned in different locations, the location will be specified by the combination of the board name and a capital letter between brackets. F.e. ABSD(A), ABSD(B), ABSD(C), CBSD(A) and CBSD(B).
Assemblies
When the board name is preceded by ‘assem.’ always completely replace the assembly. Never remove the board from the heatsink. F.e. ‘assem. SRDD_L’.
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The Control Box (CB) Contents
The sides of the control box.......................................................................................................... 26
•
Overview of the control box ...................................................................................................... 26
•
Button side................................................................................................................................ 26
•
Cable entry side........................................................................................................................ 27
•
Front ......................................................................................................................................... 28
•
Power Panel side...................................................................................................................... 30
•
Identification sticker .................................................................................................................. 31
•
Maintenance ............................................................................................................................. 31
The rack ........................................................................................................................................... 32
•
Boards ...................................................................................................................................... 33
•
CBFSB-1 (Common Board Fast Serial Bus)............................................................................. 33
•
CBMP-3 (Common Board Main Processor).............................................................................. 35
•
CBSD-1 (Common Board Sensors and Devices) ..................................................................... 39
•
ABSD-2 (Airjet Board Sensors and Devices)............................................................................ 42
Bus systems.................................................................................................................................... 44
•
Overview................................................................................................................................... 44
•
FSB (Fast Serial Bus) ............................................................................................................... 44
•
Locan bus ................................................................................................................................. 44
•
Pican bus .................................................................................................................................. 46
Mains entry...................................................................................................................................... 48
•
Diagram .................................................................................................................................... 48
•
QM: Overload protection switch Mains ..................................................................................... 49
•
FL: EMI FiLter ........................................................................................................................... 50
•
LR: Line Reactor....................................................................................................................... 50
High voltage part ............................................................................................................................ 51 Power panel..................................................................................................................................... 55
•
MPS-2 (Main Power Supply) .................................................................................................... 56
•
SRDD (Switch Reluctance Dual Drive) ..................................................................................... 58
•
NG_LDEC (New Generation Loom Drive Electronic Converter) .............................................. 62
•
MMCU-1 (Main Motor Control Unit) .......................................................................................... 63
•
EBMM-1 (Elco Board Main Motor) ............................................................................................ 64
•
OBMM-1 (Output Board Main Motor)........................................................................................ 65
•
MMRB-1 (Main Motor Rectifier Board) ..................................................................................... 65
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The sides of the control box Overview of the control box Different sides
The illustration below shows the different sides of the control box: .
A
B
C
D
E
A. SL: Signal Light
D. Cable entry side
B. Button side
E. Power Panel side
C. Front
[26]
[27] [30]
[28]
Button side Parts
.
.
B A
C
H
E D
F
I
G
A. PBFA: Push Buttons FAncy beam (if applicable). F. Unwinding of the ground beam (single or double). B. Winding up the fancy beam (if applicable).
G. PBPTHR: Push Button Pull THRough.
C. Unwinding of the fancy beam (if applicable).
H. ES_CB: Emergency Stop Control Box.
D. PBLO: Push Buttons Let-Off.
I. PBPWRON: Switch Push Button PoWeR ON.
E. Winding up the ground beam (single or double).
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Cable entry side Parts .
C A
B D
E
G F
A. Connections for the main power supply
E. Entries for batching motion 2 cable glands M20x1.5
B. Cable bundle
F. Identification sticker
C. Diagnostic - Picascope plug
G. Entry for ethernet, Bicom and Loomgate. n
[31]
Cable diameter: 4-6 mm
D. Ground connection between Control Box and machine
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Front Parts .
A
C
D
B
A. QM: Overload protection switch Mains
[49]
C. Connections for the Main Transformer. Used with cable sheath PMSI0734
B. To open the front side of the control box.
D. Connections for the main power supply. Cable diameter: 10-28 mm
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.
A
B
C
D
A. The rack
[32]
B. QM: Overload protection switch Mains
[49]
C. LR: Line Reactor
[50]
D. High voltage part
[51]
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Power Panel side Parts
.
A
B
A. Warning Sticker; wait 3 minutes after switching B. Door-key to open and close the panel. off the power to open the control box. .
.
A
B
C
D
F
H
E G
A. Power panel
[55]
B. MPS-2 (Main Power Supply) C. The rack
E. NG_LDEC (New Generation Loom Drive Electronic Converter) [62] [56]
F. Components hotwire cutter.
[32]
D. SRDD (Switch Reluctance Dual Drive)
G. Fan_CB [58]
H. CTTH
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Identification sticker Explanation .
A B C D E F A. Voltage and frequency
D. Rated ultimate short circuit braking capacity (Short circuit current QM main switch).
B. Maximum possible current installation in regime E. This number stands for the frequency. • 5 = 50Hz • 6 = 60Hz C. Maximum possible current main motor in regime. F. Voltage
Maintenance Dust
To avoid fire or malfunction, Picanol recommends removing all dust from the inside of The Control Box (CB) [25], and from the cooling plates of the MPS-2 (Main Power Supply) [56], SRDD (Switch Reluctance Dual Drive) [58] and NG_LDEC (New Generation Loom Drive Electronic Converter) [62].
Screw connections
Picanol recommends to regularly check and, if necessary, tighten the screw connection on the High voltage part [51]. (KMM, QMLVL, QMASP,...)
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The rack Illustration
The illustration below shows the rack: .
A
B
P1
C P3
A. Rack position
[32]
C. Fast Serial Bus Power distribution
B. CBFSB-1 (Common Board Fast Serial Bus) [33] P1, P3. G-connectors, see: G-connectors
[34]
[32].
. .
Rack position
The rack position is marked with a name related to the name of the board that must be mounted in that specific position, see: Rack label [32]. Some boards can be mounted in multiple positions, depending on the execution of the machine. When a board can be put in multiple positions, the position is marked with a letter between brackets. F.e. ABSD(A), ABSD(B), ABSD(C), ABSD(D) and ABSD(E). The position where the board is put determines the function of the board. This way the board can have multiple functions depending on the position in the board rack.
Rack label
The following illustration shows the rack label: A
B A. Slot names
B. Slots .
G-connectors
The G-connectors connect the boards in the rack with the devices on the machine. To avoid misinterpretation of the connections on the G-connectors, the name of the connection depends on the side of the connector. The table below explains the names of the G-connectors connections: Side Name Example Illustration A. PCB side (Printed XP XP_CBMP_P1 Circuit Board) A XW XW_CBMP_P1 B. Wiring side B .
A B
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Boards Boards
The following boards are used:
• • • •
CBFSB-1 (Common Board Fast Serial Bus)............................................................................ 33 CBMP-3 (Common Board Main Processor)............................................................................. 35 CBSD-1 (Common Board Sensors and Devices) .................................................................... 39 ABSD-2 (Airjet Board Sensors and Devices)........................................................................... 42
CBFSB-1 (Common Board Fast Serial Bus) Function
The different boards connected to the board rack communicate through the Fast Serial bus. The CBFSB distributes the Fast Serial Bus and the supply voltages for the board rack. The CBFSB also contains the following features: • Identification for the slot position in the rack. • Unique machine serial number. • Distribution and protection of the different supply voltages.
Illustration
The following illustration shows the CBFSB: 9
8
7
6
5
4
3
2
1
M
A
B
D4
A. Slave slots (1-9) C. Fast Serial Bus Power distribution [34] D5. LED, ON when the 26V is present.
C
D5
B. MID D4. LED, ON when the 5V is present. M. Master slot .
Block diagram
The following illustration shows the block diagram of the CBFSB board: A
B C D A. Bus connector C. Fast Serial Bus Power distribution E. Rack position identification
[34]
E B. Fast Serial Bus D. Machine identification controller .
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Fast Serial Bus Power distribution
The following illustration shows the power distribution on the CBFSB board: P11 P13 D1
P12 A B C
D2
F1
D
F2
E
P14 D6
F
A. Fast Serial Bus power distribution C. Machine Identification controller E. Detection Locan 26V P11. 5VDC coming from the MPS P13. 290VDC/48VAC coming from the MPS D1. ON (yellow) when 290V from MPS is present. F2. Fuse 6, 26V to the IRO control box See Fuse Value list Electrical Wiring, E-plan.
B. Regulator D. Detection Pican 26V F. IRO control box P12. 26VDC/290VDC to SRDD and IRO control box P14. 26VDC coming from the MPS F1. Fuse 6, 26V to the SRDD .
LED indications
The voltages on the CBFSB board can visually be checked by means of a lit LED: LED ON OFF D1 (Yellow) 290V from MPS is present 290V from MPS is missing D2 (red) F1 failure F1 is ok D4 (Yellow) 5V from MPS is present 5V from MPS is missing D5 (Yellow) 26V from MPS is present 26V from MPS is missing D6 (red) F2 failure F2 is ok
Machine Identification controller
The Machine identification controller has two functions: • Giving the machine a unique identification number. • Verifying the 26V going to the Prewinder control box and the SRDD devices (SRDD_26V).
Voltage check
Measure the DC voltages between the ‘DGD’-point and the corresponding voltage point:
48VAC 26V
DGD
Fusing
The CBFSB board contains the following fuses: Fuse F1 F2 See Fuse value list Electrical Wiring, E-plan.
5V
Remark 26V to the SRDD 26V to the IRO control box
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CBMP-3 (Common Board Main Processor) Function
The CBMP is the heart of the Bluebox platform and has three major blocks: • The Main processor [35]; • The FPGA [35] (Field Programmable Gate Array); • The Safety microcontroller [36].
Illustration A
Push to eject the SD card!
P22
TP209: 1V5 P10 LED1 LED2 LED3
P1 P12
P9
F2 F1 LED5 P7 TP503: DGD LED4
P8
P2
P6
P27 F4
P13
F3 P29
LED7 P5 LED6 P4
P3
A: SD card LED1: 26V (yellow) LED3: status main processor (orange) LED5: ST_FPGA LED7: status EXTERNAL connection P6: display connection P8: LOCAN P12: PICAN (PT1024)
P35
P34 LED2: reset_ok (green) LED4: status DISPLAY connection LED6: status safety processor P5: signal cable between MPS and CBMP P7: LOCAN (CAN) P9: Parallel/Bicom [37] P13: EXTERNAL (eg. Loomgate)
Main processor
The main processor loads its program from the sd card. The RUN-led (LED3) will blink slowly while loading and will blink fast once the application is fully loaded.
FPGA
The FPGA is an integrated circuit which contains programmable logic designed to be configured by software. The ST_FPGA-Led (LED5) will blink slowly while loading the software and will blink fast in normal operation.
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Safety microcontroller
The safety microcontroller is a second processor that independently controls the safety features. The ST_SFT-led (LED6) will blink fast when the safety micro-controller is running.
Block diagram
The illustration below shows the block diagram of the CBMP: A B
L C
D
E K J
I
A. SD card C. Input/Output E. Machine identification controller G. Input/Output I. Ethernet switch K. PDP (Picanol DisPlay) [67]
H
F G B. Main processor D. Power management F. Resolver H. Safety processor J. production network L. Parallel / bicom .
Fusing
The CBMP board contains the following fuses: Fuse Remark F1 26V PICAN_LHS F2 26V PICAN_RHS F3 DGN_26V (diagnostic plug) F4 26VF (Fused 26V for different functions on CBMP) See Fuse Value list Electrical Wiring, E-plan.
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Parallel/Bicom
There are 3 ways to connect a loom monitoring system to the machine: • Parallel loom monitoring: Parallel loom monitoring loads the basic information (stops, picks woven...) from the machine. The weaving machine is equipped with a connector that includes 5 contacts which become high or low depending on the machine status (running, stopped...). The monitoring system supplier connects to this interface by using a data unit to record production and stops. A separate terminal is needed in case of additional communication between the operator and the monitoring system. This terminal must be provided by the monitoring system supplier. Bidirectional communication between the machine and the server is not possible through the PDP.
Connector
CBMP_P9
Pin
Short name
Description
6
PI_LD
Selvedge stop
7
PI_PP
Signal that toggles every pick
8
PI_WD
Warp stop
9
PI_STRT
Running / stopped
10
PI_FD
Filling stop
11
SUP_PI
Supply voltage
12
PI_RES
Bobbin brake stop
• Bicom: Serial and Ethernet: Via bicom it is possible to have communication between the machine and the monitoring system. The monitoring system can send commands to the machine and vice versa. In case of bicom, the user can send declarations from the machine to the monitoring system via the PDP. - Serial bicom: The data is exchanged via a RS422 interface. The monitoring system supplier must install additional boards in the controlbox to capture the data from the machine and send it to the monitoring system - Ethernet bicom: The machine is connected to a LAN network (ethernet cable). Each machine connected to this network has its own IP address. By means of these IP addresses, the monitoring system can request or send data to each machine. Bicom requires the monitoring system supplier to implement a communication protocol. This protocol requires expert skills to implement and can be bought from Picanol. If the protocol is purchased by the customer, the monitoring system supplier can only implement this at this customer. If the protocol is bought by the monitoring system supplier, it can be used at different customers.
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LOCAN
The LOCAN-connector must be correctly connected and disconnected: Disconnecting Connecting
A
Open both clips “A” to disconnect the cable. Also see Locan bus
A
Push the connector until the clips “A” are completely closed.
[44].
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CBSD-1 (Common Board Sensors and Devices) Illustration
P1
P9
LED1 F1 LED2 P2 LED3 P7 F2 P8
P3
P6
F3 LED1: 26V (yellow) do not remove! LED3: run (orange) Function
F4
F5
F6
LED2: reset_ok (green) .
The function of the CBSD depends on the position in the rack. Inserting the CBSD in another position in the rack, will result in another machine functionality. The CBSD handles the input and output of several sensors and devices.
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Possible devices per board position
LED indications
CBSD(A) • SLCBWH • SLCBRD • SLCBOG • SLCBGN • SLCBBU • DWC_VUP • DWC_VDOWN • LED_REED_LHS • LED_FBR_LHS • FAN • PBLOF • PBLOR • PBPTHR • WYD1 • WYD2 • DTLUFL • DTLUSHD • PX_LVL • DTKAUX • DTQMASP1 • DTKMM • DTQMLVL • DTKMASP • BMSTA • WD_SUP • WD1 • WD2 • LEDWD1 • LEDWD2 • DTTHMASP1 • DTTHTM • 48VACP_IN • 48VACP_OUT • KLVLON • KMASP1 • STRSTP • KLVLOFF • KAUX • KMM • FBRCT1 • WCT_RHS • AIRPRESS_SUP • AIRCON • DWC_PRESS • AIO_DGNS • DTWT1 • DTWT2
CBSD(B) CBSD(C) • SLMCWH • LED_REED_RHS • SLMCRD • LED_FBR_RHS • SLMCOG • SLMCGM • SLMCBU • DWCFA_VUP • DWCFA_VDOWN • LED_BCKSHD_LHS • LED_BCKSHD_RHS • CTTH_RUN • PBFAF • PBFAR • DTCTTH • PXFASFTY • 48VACP_IN • DWCFA_PRESS • DTWT_FA
The signals on the CBSD can visually be checked by means of the LEDs: LED ON LED1 26V is present LED2 reset_ok signal is present LED3 LED is blinking fast; FPGA is running.
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Fusing
The CBSD board contains the following fuses: Fuse Remark F1 26VU (26V for the upper CBSD part) F2 26VL (26V for the lower CBSD part) F3, F4 DTTH00: Protection bimetal transformer00) F5, F6 DTTH01: Protection bimetal transformer01) See Fuse Value list Electrical Wiring, E-plan.
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ABSD-2 (Airjet Board Sensors and Devices) Function
The ABSD board has the following devices: • current drives; • small stepper motor drivers; • large stepper motor drivers. The function of the ABSD board depends on its position in the rack. Inserting the ABSD board in another position in the board rack will result in another machine functionality.
Illustration P15
P16
P1
LED1 F1 LED2 P2
LED3
F2
P10 P3
LED1: 26V (yellow) LED3: run (orange) LED indications
LED2: reset_ok (green)
The signals on the ABSD can visually be checked by means of the LEDs: LED ON LED1 26V is present LED2 reset_ok signal is present LED3 LED is blinking fast ==> running.
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Functions per board position
Board position ABSD(A)
ABSD(B)
ABSD(C)
ABSD(D)
ABSD(E)
Possible devices • CH1-2 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT, VCLMP_MNM) • VRN[1-17] (max T220) • ELSY_LHS, ELSY_RHS • FICT, VSN, VSNEX/VSU, V_PRA_SU, CRDL_VCLMP • FD1, FD2, FDSU • CH3-4 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT, VCLMP_MNM) • VRN[18-25] (max T340) • MTI/ATI_LHS, MTI/ATI_RHS • CH5-6 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT, VCLMP_MNM) • ATI_MID1_MCT, ATI_MID2_MCT • CH7-8 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT, VCLMP_MNM) • VPMMN • VRN[26-29] (max T400) • ELSY_MID1, ELSY_MID2, ELSY_MID3 • ATI_MID1, ATI_MID2 • TI_MID1, TI_MID2, TI_MID3 • FBRCT2, FBRCT3 • VMNTF_CH[1-4] • ELCA_TF_CH[1-4]
Block diagram
A
B
C
D E F A. 32 valve drivers C. rack position E. 10 small stepper motor drivers
B. Power management D. 5 inputs F. 3 large stepper motor drivers .
Fusing
The ABSD board contains the following fuses: Fuse Remark F1 26VU (26V for the upper ABSD part) F2 26VL (26V for the lower ABSD part) See Fuse Value list Electrical Wiring, E-plan.
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Bus systems Overview Diagram
ABSD
NG_LDEC
FSB (Fast Serial Bus) See section
CBFSB-1 (Common Board Fast Serial Bus)
[33]
Locan bus Function
The Locan bus is a bus system that connects the CBMP with the following devices: • SRDD (Switch Reluctance Dual Drive) [58]; • NG_LDEC (New Generation Loom Drive Electronic Converter) [62]. The Locan bus consists of the following functionalities: • CAN communication (500kbps); • Position signal; • Drive and brake enable signals. The Locan cable is a twisted pair flat cable that start at the CBMP and ends at the NG_LDEC.
1st Position = brown wire
.
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Illustration Front
[28]
Power Panel side
[30]
A
B
C A. Connection on the CBMP C. Connection on the NG_LDEC
B. Connection on the SRDD .
The connector “A” should be closed properly. See: LOCAN
[38].
Block diagram NG_LDEC
SRDD
A B
CBMP
C NG_LDEC (New Generation Loom Drive Electronic SRDD (Switch Reluctance Dual Drive) [58] Converter) [62] CBMP-3 (Common Board Main Processor) [35] A. CAN communication B. Position signal C. Drive and brake enable signals .
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Pican bus Function
The Pican bus is a bus system that connects the CBMP board with the following devices: • Prewinder Control box (LHS_PICAN) • Pican_FDCB (RHS_PICAN) • E-leno’s (RHS_PICAN) • Jacquarette • Can dobby (RHS_PICAN) • Jacquard (RHS_PICAN) The Pican bus consists of the following functionalities: • CAN communication (500kbps): bidirectional communication between the CBMP and the other Pican devices; • Position signal (PT1024): Used to transfer the machine position (coming from the resolver) to the Pican devices; • 26V supply voltage, protected by the fuses F1 (RHS_PICAN) and F2 (LHS_PICAN) on the CBMP; • Event line: not used. The Pican communication and the PT1024 position signal are always terminated on both sides with a 120 ohm resistor.
Block diagram
.
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Measuring the Pican bus
1. Switch off the machine. Do not remove any board or Pican device. 2. Measure the resistance between the points on the XW_CBMP_P1 connector mentioned in the table below: Points Value What? 30Z (green) and 32Z (yellow) 60 Ohm CAN communication termination 30B (white) and 32B (brown) 60 Ohm PT1024 position signal termination 30D (black) and 32B (brown) 70k Ohm or higher Drivers 30D (black) and 30B (white) 70k Ohm or higher 30D (black) and 30Z (green) 70k Ohm or higher 30D (black) and 32Z (yellow) 70k Ohm or higher
A
B
C
A. XW_CBMP_P1 C. PICAN_LHS
B. PICAN_RHS .
Also see: • Can Dobby S3XXX [79] • Jacquard [79] • E-Leno [78] • IRO Control Box [76]
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Mains entry Diagram
L2
L3
The illustration below shows the mains diagram when the machine is not executed with a transfo: L1
Mains diagram
1
3
5
2
4
6
R
S 3~
T
R’
S’
T’
QM
FL
X_L21 X_L22 X_L23
A
X_L13
X_L12
X_L11
LR
B A. Connections to: • [53] • QMASP1: Overload protection switch motor aspirator [53] B. Connections to: • MPS-2 (Main Power Supply) [56] • NG_LDEC (New Generation Loom Drive Electronic Converter) • Mains supply See E-plan.
[62]
.
When executed
The illustration below shows the transfo:
DTTHTM
DTTHTM: DeTection THermal Transformer Mains
.
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QM: Overload protection switch Mains Overload
The QM also has an overload protection. See: Overload protection
Positions
The table below shows the different positions of the main switch: Main switch position... Machine status 0 - OFF dead with the exception of the parts and conductors from the mains terminals to the main switch input terminals.
I - ON
Safety
[14].
live.
During a lubrication action or an intervention on the machine and/or the weaving mill equipment, the main switch must be padlocked in the -OFF- position. Proceed as follows to padlock the main switch: 1. Slide out the padlock part “A”. A
2. Padlock the main switch.
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FL: EMI FiLter Function
The FL has the following functions: • to protect the main power supply against interferences, • to prevent the control of causing interferences on the mains.
Illustration
The following illustration shows the FL:
LR: Line Reactor Function
The LR improves the power factor.
Illustration
The illustration below shows the LR:
.
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High voltage part
FAN_CB
XW279A
L3*
L2*
L1*
INRUSH
Illustration
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Contactors
KMM: Contactor main motor (is closed when you activate power-on). KMASP: Contactor motor aspirator. KAUX: Contactor auxiliary (which is used for the batching motion supply and the MLU (Motor Lubrication). KMLVLON: Contactor motor leveling ON. KMLVLOFF: Contactor motor leveling OFF. KWDDL: Contactor Warp Detection DropperLess Filters
ZMASP: Filter motor aspirator. ZMLVL: Filter motor leveling.
Terminals
X1, X2, X3, X4, X7, X8: Earth terminal. L11, L12, L13: Terminal. L21, L22, L23: Terminal. L31, L32, L33: Terminal. Terminal connections:
XKF: Terminal for the batching motion and the supply for the fan FAN_CB..
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Overload protection switch
QMLVL: Overload protection switch motor leveling (used in case of CAM S1692). Current at 50Hz Current at 60Hz Mains voltage Breaker setting Breaker range Breaker setting Breaker range 360V 2.0A 1.4A 1,6A to 2,5A 380V 2.4A 1.5A 1,0A to 1,6A 400V 2.8A 1.6A 420V 3.2A 2,5A to 4,0A 1.8A 440V 3.6A 2.2A 1,6A to 2,5A 460V 4.2A 4,0A to 6,3A 2.5A QMLVL: Overload protection switch motor leveling (used in case of CAM 1681, 1781): Mains voltage Current at 50Hz Current at 60Hz 380V 4A 4A 400V 4,5A 415V 2A 4,5A 440V 2,2A 460V 2,4A 2,5A QMASP1: Overload protection switch motor aspirator Mains voltage Current at 50Hz 380V 400V 415V 1,4A 440V 460V QWDDL: Overload protection DropperLess Mains voltage Current at 50Hz 380V 400V 415V 0,4A 440V 460V Fuses
Current at 60Hz 1,5A 1,3A
Current at 60Hz
0,4A
FAUX1, FAUX2, FAUX3: fuses for the batching motion. FCTTH1, FCTTH2: fuses for the thermal cutter. FTWDDL: Fuse Transfo Warp Detection DropperLess Fuse values, see electrical wiring.
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Inrush
INRUSH: board for pre-loading the NG_LDEC.
Fuse values, see electrical wiring. Transfo
TWDDL: Transfo Warp Detection DropperLess
.
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Power panel Latching the Power panel
Always latch the power panel while working on the rear side of the control box, using the fixation tool “A”.
A
Proceed as follows to latch the power panel: 1. Switch off the power and wait for 3 minutes. Wait for 3 minutes to discharge all drives. 2. Open the rear side of the control box
B 3. Remove the fixation tool “A” from the panel:
A
4. Place the fixation tool “A” in the holes above the wheel “B” to latch the power panel: A
A
B
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MPS-2 (Main Power Supply) Requirements
The MPS board requires a three-phase voltage between 380VAC and 460VAC. The required frequency of the supply voltage should be 50Hz or 60Hz.
Function
The MPS board generates the following supply voltages: • 290VDC • 26VDC • 12VDC (only used for the display) • 5VDC • 48VAC/55Hz The 26VDC towards the FSB board is only available after a validation by the CBMP board. The CBMP first checks if all installed boards are in a correct slot and then activates a switch on the MPS to make the 26VDC towards the CBFSB available.
Signals
The following signals can be found on the MPS: • AC_UV: undervoltage is active when the supply voltage is below 310Vac. • /AC_OK: Three-fase supply voltage (mains) is available. • /DC_OK: All DC supply voltages are available.
Illustration
The following illustration shows the MPS board “A”: A
.
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Connections
The following illustration shows the MPS-board and its connections and fuses: F3 F2 F1 P1
P2
P3
P4 P5 P6
P1: Mains input 3x400VAC + GND P2: 290VDC output P3: 5VDC / 48VAC output P4: 26V_ENABLE, /AC_OK, /DC_OK, AC_UV P5: 12VDC P6: 26VDC Diagram
The following illustrations shows the communication between the MPS and the CBMP:
Signal /AC_OK 0V /DC_OK 0V AC_UV 0V
Fuses
The MPS board contains the following fuses: Fuse F1 F2 F3 See Fuse Value list Electrical Wiring, E-plan.
5V 5V 5V
Remark Mains protection
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SRDD (Switch Reluctance Dual Drive) Function
The SRDD has the following functions: • The board drives two SR-motors, for example ELO and ETU • The output stage for the machine brake. SRDD_L: with low voltage brake system (26VDC). This board can drive a pneumatic valve which drives a pneumatic parking brake, or an electrical holding brake.
Locan bus
See: Locan bus
[44].
M1
M2
M1. Motor 1
M2. Motor 2
Replacing
To replace the SRDD, see: Replacing the assem. SRDD
[103].
Board position
It is possible to mount 2 SRDD assemblies. This results in a maximum of 4 SR-motors that can be driven.
B
A
A. SRDD(A)
B. SRDD(B) .
.
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Illustration P3 P7
P11
P4
P1
P10 P15
P12
P17
P14 = dump P1. M1 resolver and identification P4. M1 phases motor P10. LOCAN P12. Brake signal from NG_LDEC P15. M2 phases motor P22. 26VDC / 290VDC coming from the CBFSB
P22 P23 P3. Machine brake P7. M1 brake P11. M2 brake P14. Dump resistor P17. M2 resolver and identification P23. 26VDC / 290VDC to the SRDD
In case of ETU ratio 34/43 or 39/25, a dump resistor is mounted on the SRDD board. .
P14 = Dump resistor
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SR motor
Every SRDD board can drive 2 SR motors. These SR motors contain the following parts: • four-phase switched reluctance motor; • resolver; • holding brake; • bimetal.
A
BR
BIM
RS
A. SR Motor BR. Brake
BIM. BIMetal RS. Resolver .
Motor identification
The SRDD identifies the SR motor by means of a jumper on the resolver connector: Motor Jumper connection Illustration ELO_RHS 5-12 ETU 6-13 ELO_LHS 7-14 ELOFA 8-15 A. Jumper .
A
.
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LED’s M1
M2
290V
M1. Status LED’s motor 1 (L0-L3) 290V. LED, on when 290V is present. LED indications
M2. Status LED’s motor 2 (L0-L3)
The LED’s (L0 to L2) on the SRDD board indicate an error code. The number of blinks in a sequence show a typical error code. After the sequence of flashes (D) there is a short pause followed by two flashes of all 4 LED’s (C). The sequence will repeat itself again. The following illustration shows an example of an error code: A
L3 L2
B
L1 L0
C
C D A. Soft DEN_M1 or Soft DEN_M2 (DEN: Drive ENable) B. These LED’s show the typical error code. C. All LEDs flash two times D. Sequence of flashes.
D
C
D
In this example the sequence counts 3 flashes, so the error code is 3. .
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NG_LDEC (New Generation Loom Drive Electronic Converter) Function
The NG_LDEC controls, checks and protects the control of the main motor and it controls the machine brake. The NG_LDEC disengages the main motor or prevents it from starting if one of the following conditions is exceeded: • Overcurrent motor phases: 250A; • Differential: ±2A; • Overvoltage DC: 796V; • Undervoltage DC: 370V; • Temperature of the modules: 80°C; • Low voltage check; • Saturation protection. If an error occurs, an error message will appear on screen and LEDs will light up on the NG_LDEC. Also see: LED indications [64].
Replacing
To replace the assem. NG_LDEC, see: Replacing the assem. NG_LDEC
[93].
Illustration
Block diagram E A B C
C
D G
D G
E
E
G
D
F
G
H
A. Main motor C. Dump resistance E. MMRB-1 (Main Motor Rectifier Board) [65] G. OBMM-1 (Output Board Main Motor) [65]
F B. Connection box D. EBMM-1 (Elco Board Main Motor) [64] F. MMCU-1 (Main Motor Control Unit) [63] H. Machine brake .
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MMCU-1 (Main Motor Control Unit) Function
The MMCU board controls: • the main motor (SUMO); • the machine brake.
Illustration
A
B
LED-0 LED-1 LED-2 LED-3 DEN1_FB BREN_FB
C
A. 5V Indication C. LOCAN
D
B. Processor MMCU board. D. Brake signal going to the SRDD board. .
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LED indications
The LED’s (LED-0 to LED-3) on the MMCU board indicate an error code. The number of blinks in a sequence show a typical error code. After the sequence of flashes there is a short pause followed by two flashes of all 4 LED’s. The sequence will repeat itself again. The following illustration shows an example of an error code: .
All LED’s flash two times.
.
==> 10 flashes ==> error code 10
All LED’s flash two times.
.
. .
EBMM-1 (Elco Board Main Motor) Function
The EBMM has the following functions: • Buffering the DC voltage; • Discharging energy after power off. There are 2 EBMM boards in the NG_LDEC. These 2 boards always have to be exchanged together.
Replacing
To replace the EBMM, see: Replacing the EBMM
[94].
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OBMM-1 (Output Board Main Motor) Function
The OBMM has the following functions: • controlling the power stages for 2 motor coils; • measuring the power at the motor phases; • monitoring the temperature of the modules; • protecting against saturation of the modules; • generating voltage for the drivers. There are 2 OBMM boards in the NG_LDEC. One board controls motor phases A and C (OBMMac), the other OBMM board drives the motor phases B and D (OBMMbd).
Replacing
To replace the OBMM, see: Replacing the OBMM
[95].
MMRB-1 (Main Motor Rectifier Board) Function
The MMRB has the following functions: • Rectifying the 3 phase AC power into DC power. • Measuring the voltage and current towards the motor control system (OBMM boards). • Controls the dump system.
Replacing
To replace the MMRB, see: Replacing the MMRB
[98].
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Devices on the machine Contents
•
PDP (Picanol DisPlay) .............................................................................................................. 67
•
Control buttons on the breast plate........................................................................................... 69
•
RS: ReSolver ............................................................................................................................ 70
•
Proximity switches .................................................................................................................... 72
•
Safety light curtain .................................................................................................................... 73
•
EPR (Electronic Pressure Regulator) ....................................................................................... 75
•
ELSY: Electric Leno SYstem .................................................................................................... 76
•
IRO Control Box........................................................................................................................ 76
•
NG_FDCB: Filling Detector Control Box ................................................................................... 77
•
E-Leno ...................................................................................................................................... 78
•
Can Dobby S3XXX ................................................................................................................... 79
•
Jacquard ................................................................................................................................... 79
•
Cam motion with leveling system (1681, 1781) ........................................................................ 81
•
Cam motion with leveling system (S1692)................................................................................ 83
•
Parking brake............................................................................................................................ 84
•
Electrical cutters ....................................................................................................................... 86
•
Thermal cutter........................................................................................................................... 87
•
PKE........................................................................................................................................... 88
PDP (Picanol DisPlay) Function
The PDP is the user interface with the machine (CBMP). The communication with the CBMP board is done via an Ethernet connection.
Versions
There are 2 versions of the PDP: assem. PDP_9INCH
assem. PDP_12INCH
” 12
9”
Replacing
To replace the PDP, see: Replacing the PDP
[109].
Localization
The following illustration shows the localization of the PDP: B
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assem. PDP_9inch
The following illustration shows the LED’s and connectors of the PDP_9inch assembly: P7
A
P21 P17 LED2 PDP2_9inch B C LED6 LED7 P6
P8
P23
P24
A. assem.PDP_USB C. RESET button P6. Communication with the CBMP board P8. 12V supply from the MPS board LED1. 12V assem. PDP_12inch
LED1
B. SD-card P7. TFT (Thin-Film Transistor screen) P21. Touch screen LED2. USB supply
The following illustration shows the LED’s and connectors of the PDP_12inch assembly:
D P17 P20
P19 P21
LED2 E PDP_12inch
P4
F LED6
LED4 LED5
LED7 P6
P8
P23 D. assem.PDP_USB F. RESET button P4. Touch screen P8. 12V supply from the MPS board LED1. 12V LED4. Activity
P24
LED1
E. SD-card P6. Communication with the CBMP board P19. TFT (Thin-Film Transistor screen) LED2. USB supply LED5. Communication link
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Control buttons on the breast plate Compatibility
Location
The OMNIplus Summum control buttons are NOT interchangeable with the OMNIplus 800 control buttons! The illustration below shows the control buttons on the breast plate: Machine width Control buttons T190-T280 A B T340-T400
G
H I
G. Push Buttons Left Hand Side
H. Push Buttons Middle
I. Push Buttons Right Hand Side .
Control buttons
The following illustration shows the control buttons: PB-STRT PB-PFR
PB-SMR
PB-PFF
PB-SMF
PB-STOP PB_STRT: Push Button_STaRT PB_PFR: Push Button_PickFinding Reverse PB_PFF: Push Button_PickFinding Forward PB_SMR: Push Button_Slow Motion Reverse PB_SMF: Push Button_Slow Motion Forward PB_STOP: Push Button_STOP Block diagram
The following illustration shows the control buttons block diagram:
A
B
C
A. Push Buttons Left Hand Side
B. Push Buttons Middle
C. Push Buttons Right Hand Side .
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RS: ReSolver Function
The (brushless) resolver provides two voltages that represent the absolute position of the input shaft. The resolver is a rotary transformer where the magnitude through the resolver windings varies sinusoidal as the rotor shaft rotates.
Primary/secondary windings
The resolver has two types of windings: • Primary winding = the reference winding, located in the rotor; • Secondary windings = the sinus and the cosine windings, mechanically displaced 90 degrees from each other. In the resolver, energy is supplied to the reference winding through a rotary transformer. The inducted voltages in the sinus and cosine windings are equal to the value of the reference winding voltage multiplied by the sinus or cosine of the angle of the input shaft from a fixed zero point.
Diagram
The illustration below shows the diagram of the resolver: A
VC= VRCOS(Α)
B VR C
D
VS= VRSIN(Α) a
A. Cosine winding (secondary windings) C. Rotary transformer VC. Cosine voltage VS. Sinus voltage
B. Sinus winding (secondary windings) D. Reference winding (primary winding) VR. Reference voltage α. Angle of the input shaft from a fixed zero point. .
Illustration
The following illustration shows an intersection of the resolver and the rotor and stator:
A A. Rotor
B
B. Stator .
When the resolver needs to be replaced, replace the rotor together with the stator. The numbers on the new rotor “A” and the new stator “B” need to be the same. A
B
.
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Shielded resolver cable
The shielded resolver cable contains 2 separate screens to maximise shielding. A
A. Outer shielding
B
C
B. Aluminium foil
C. Drain wire .
Measuring the resolver
Additional information
Proceed as follows to measure the resolver: 1. Switch off the machine. 2. Measure the resistance between the following points: H1_27_116_116(*) 02F White RS_REF_H 27 Ohm 04F Brown RS_REF_L 02D Green RS_COS_H CBMP_P3 116 Ohm 04D Yellow RS_COS_L 02B Grey RS_SIN_H 116 Ohm 04B Pink RS_SIN_L (*): You can have 2 types of resolvers, H1_27_116_116 or T1_45_58_58
T1_45_58_58(*) 45 Ohm 58 Ohm 58 Ohm
For more information about mounting and setting the resolver, see chapter ‘Mechanical Settings > Drive’.
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Proximity switches Main proximity switches
The following illustration shows the main proximity switches on the machine: PX_REF
PX_PFP
PX_WP
PX_WP. ProXimity switch_Weave Position PX_REF. ProXimity switch_REFerence
PX_PFP. ProXimity switch_PickFinding Position
Additional information
For more information about the proximity switches, see chapter: ‘Mechanical Settings > Drive’.
Other proximity switches
The table below describes the other proximity switches: PX Description PX-FA-SFTY Only in case of fancy beam. This PX detects if the back rest roller is within its functional working area. PX_LVL_WP Only in case of outside cam motion with leveling. This PX detects if the machine is ready for weaving (leveling OFF).
Function
Proximity switches act as variable resistors. The output resistance depends on the presence of metal. The table below shows the proximity switches output according its condition: The proximity sensor state Output resistance Uncovered low resistance In front of metal high resistance B
A A. Proximity switch
B. Metal plate .
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Diagram
The illustration below shows a diagram of a proximity sensor (PX): LDO: Low-Dropout regulator .
LDO
Safety light curtain Localisation
The following illustration shows where the safety light curtain is located: Emitter
Operation
Receiver
By interrupting the detection field, the following movements are prevented: • starting; • slow motion; • pick finding The safety light curtain does NOT work: - when a machine is operating at full speed; - during service operation mode. Upon starting or shutting down the machine, every automatic slow-motion or pick finding movement will be stopped when interrupting the safety light curtain. Only applicable on CE machines.
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Emitter
The following illustration shows the emitter and its components: Illustration Indicator On A. Top-beam-state Turns on when the beam is receiving light indicator B. Stable-state indicator Turns on when incidence level is 170% or more of the output ON threshold. A C. On/Off-state indicator Green: Turns on when safety output is on. Red: Turns on when safety B output is off. D. Lockout indicator Turns on when the light C curtain enters a lockout on the receiver. D E. Power indicator Turns on when the power of the emitter is on. E F F. Test indicator G. Bottom-beam-state indicator
Blinking Blinks when cap error or connection error occurs. Blinks when the safety output is turned off due to disturbance light or vibration. Red: Blinks when the light curtain enters a lockout due to a safety output error. Blinks when the light curtain enters a lockout on the emitter. Blinks when the light curtain enters a lockout due to power voltage/ noise. — Blinks when external test is being performed. Turns on when the bottom — beam is receiving light.
.
G
Receiver
The following illustration shows the receiver and its components: Illustration Indicator On A. Top-bottom-state Turns on when the top beam is receiving light. indicator B. Stable-state indicator Turns on when incidence level is 170% or more of the output on threshold. A C. On/off-state indicator Green: Turns on when safety output is on. Red: Turns on when safety B output is off. D. Lockout indicator Turns on when the light C curtain enters a lockout on the emitter. D E. Communication Turns on when communication between E indicator emitter and receiver is established. F G
F. Configuration indicator
G. Internal indicator H
H. Bottom-beam-stateindicator
Blinking Blinks when cap or connection error occurs. Blinks when the safety output is turned off due to disturbance light or vibration. Red: Blinks when the light curtain enters a lockout due to a safety output error. Blinks when the light curtain enters a lockout on the receiver. Blinks when the light curtain enters lockout due to a communication error between receiver and emitter. — Blinks when the light curtain enters lockout due to a model type error between receiver and emitter. — Blinks when the light curtain enters a lockout due to an internal error. Turns on when the bottom — beam is receiving light.
.
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EPR (Electronic Pressure Regulator) Illustration
The following illustration shows the EPR-devices:
A
B
C
A. EPR_MN_[CH1-CH4] C. EPR_RN_LHS+RHS Block diagram
B. EPR_RN_MID .
The following illustration shows the block diagram of an EPR device:
A
A. Pressure tank 1 .
Synchronisation
After Power On, all EPR devices synchronise. The following illustration shows an EPR in a random position and a synchronised EPR: Random position Synchronisation position
Additional information
For more information about the EPR devices, see chapter: ‘Mechanical Settings > Insertion’.
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ELSY: Electric Leno SYstem Illustration
The following illustration shows the ELSY devices: ELSY_LHS
ELSY_MID
ELSY_RHS
.
ELSY • ELSY_LHS • ELSY_MID1 • ELSY_MID2 • ELSY_MID3 • ELSY_RHS Additional information
Board position ABSD(A) ABSD(E) ABSD(E) ABSD(E) ABSD(A)
For more information about the ELSY devices, see chapter: ‘Mechanical Settings > Selvedge’.
IRO Control Box Illustration
The following illustration shows the IRO control box:
FB2 A
FB1 A. Pulse termination and CAN termination FB2. Fuse T5A See Fuse Value list Electrical Wiring, E-plan.
FB1. Fuse T3,15A .
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NG_FDCB: Filling Detector Control Box Illustration
The following illustration shows the FDCB:
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E-Leno Illustration
The following illustration shows the E-Leno devices:
E-Leno_RHS
E-Leno_LHS
Termination
The following illustration shows the termination connector on the E-Leno:
Measuring points
The following illustration shows the different measuring points on the E-leno device:
.
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Can Dobby S3XXX Illustration
The following illustration shows the S3XXX dobby, the connections and the pulse and CAN termination:
CH CL
PH PL
SH
A. Pulse termination and CAN termination CL. CAN Low PL. Pulse bus Low
A CH. CAN High PH. Pulse bus High SH. SHielding .
Measure the PICAN bus
Proceed as follows to measure the PICAN bus on the CAN C4 board: Points Value What? CH - CL 60 Ohm CAN termination PH - PL 60 Ohm PT1024 termination Ground - CH 70K Ohm or higher Drivers Ground - CL 70K Ohm or higher Ground - PH 70K Ohm or higher Ground - PL 70K Ohm or higher
Jacquard Connections
The controller of the jacquard must be connected on the right hand side of the machine: B
A
The first cable is for the PICAN communication and the second cable is for the emergency stop and 48VAC.
• •
Machine without e-leno: The PICAN cable from the jacquard has to be connected on the PICAN_OUT of the NG_FDCB “A”. Machine with e-leno: The PICAN cable from the jacquard has to be connected on the retour cable for the LHS_E-leno W004A ES_J.
Connect the emergency stop cable from the jacquard on cable W004A “B”.
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Diagram
The following illustration shows the jacquard connection diagram: A w004a es_j
B
C W067 Pican_LHS W059 Pican_RHS
D
G W162B E-LENO RHS TO LHS E
W162A FDCB TO E-LENO RHS
F W162C
A. The Control Box (CB)
[25]
C. Control box jacquard. See manual supplier. E. E-leno left-hand side G. NG_FDCB Emergency stop cable
B. CBMP-3 (Common Board Main Processor) [35] D. Prewinder control box F. E-leno right-hand side
Before connecting the Emergency stop cable, the temporary plug (BE153972) on cable W004A ES_J must be removed.
This plug is only needed for running-in the machine without jacquard.
Termination Staubli JC7 controller
The following illustration shows the termination of the Staubli JC7 controller:
.
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Termination Bonas S600 and S800
The following illustration shows the termination of the Bonas S600 and S800:
Cam motion with leveling system (1681, 1781) Leveling system
The leveling of the cam motion is done with piston driven by oil pressure.
Diagram
The following illustration shows the diagrams for the leveling system of the cam motion:
PX_LVL_WP: PX LeVeLing Weaving Position MLVL: Motor LeVeLing
KMLVL_ON: Contactor Motor LeVeLing ON QMLVL: Overload Protection Switch Motor LeVeLing
KMLVL_OFF: Contactor Motor LeVeLing OFF .
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Location
The following illustration shows the leveling system on the cam motion:
W035
W036B
W036B
.
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Cam motion with leveling system (S1692) Leveling system
The leveling of the cam motion is done by a motor driven screw.
Diagram
The following illustration shows the diagrams for the leveling system of the cam motion:
PX_LVL_LP: PX LeVeLing Leveling Position PX_LVL_WP:PX LeVeLing Weaving Position KMLVL_OFF: Contactor Motor LeVeLing OFF
KMLVL_ON: Contactor Motor LeVeLing ON QMLVL: Overload Protection Switch Motor LeVeLing MLVL: Motor LeVeLing
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Parking brake Location
The following illustrations show the parking brake and the other devices for the working of the parking brake:
VPBR
PBR_DTPRESS
PBR
VPBR. Valve Parking BRake PBR. Parking BRake
PBR_DTPRESS. Parking BRake DeTection PRESSure .
The parking brake is controlled by the NG_LDEC, but the driver for the parking brake valve (26 VDC) is located on the SRDD_L(A). Voltage Valve is... parking brake is... 0 VDC closed closed 26 VDC open open
.
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Diagram
The following illustration shows the diagram of the parking brake system:
VPBR PBR_PN_DTPRESS Also see Brake
[18].
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Electrical cutters Location
The following illustration shows the location of the electrical cutters:
FICT Overview
WCT_LHS
FBRCT 1-3
WCT_RHS
The following illustration shows an overview of the possible electrical cutters on the machine, and their board connection: TYPE OF CUTTER
BOARD CONNECTION .
FICT: FIlling CuTter FBRCT1-3: FaBRic CuTter 1-3
WCT_LHS: Waste CuTter Left Hand Side WCT_RHS: Waste CuTter Right Hand Side
.
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Thermal cutter Device
The thermal cutter device (CTTH) is located on the floor of the control box:
Overview
The following illustration shows an overview of the thermal cutter devices and its board connection:
• •
Run signal: The machine gives 26V when the machine is running and 0V when the machine is stopped. Status signal: the thermal cutter device can stop the machine by opening the switch when something is wrong with the device. The switch is closed when there is no problem.
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PKE PKE with bobbin change sensor
The following illustration shows PKE with knot sensor:
BE316884
The following illustration shows the diagram:
The following illustration shows the parts: C
A D B .
A. Prewinder connection B. Full PKE sensor C. Bobbin change sensor D. Connection box . .
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Full PKE with knot sensor
The following illustration shows the diagram:
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Service General Contents
•
General ..................................................................................................................................... 91
Replacing boards and/or assemblies ........................................................................................... 92
•
General ..................................................................................................................................... 92
•
RMA (Return Merchandise Authorization) ................................................................................ 92
•
Replacing the assem. NG_LDEC ............................................................................................. 93
•
Replacing the EBMM ................................................................................................................ 94
•
Replacing the OBMM................................................................................................................ 95
•
Replacing the MMRB................................................................................................................ 98
•
Removing and mounting boards from the rack....................................................................... 101
•
Replacing the assem. SRDD .................................................................................................. 103
•
Replacing the CBFSB............................................................................................................. 105
•
Replacing the CBMP .............................................................................................................. 107
•
Replacing the PDP ................................................................................................................. 109
•
Replacing the protection foil on the assem.PDP_9inch.......................................................... 111
Software......................................................................................................................................... 113
•
Installing Software .................................................................................................................. 113
•
CSF (Customer System File) .................................................................................................. 115
•
Machine log ............................................................................................................................ 116
•
Screen capture ....................................................................................................................... 117
Fuses ............................................................................................................................................. 118
•
Marking ................................................................................................................................... 118
•
Fuse details ............................................................................................................................ 118
Tools .............................................................................................................................................. 119
•
Masterstick (BE316654) ......................................................................................................... 119
•
USB-stick (N1038701) ............................................................................................................ 119
•
F-contact tools ........................................................................................................................ 120
•
Burndy (TRIM TRIO) contact tools ......................................................................................... 121
•
D-sub contact tools ................................................................................................................. 122
•
Molex Mini-Fit Jr contact tools ................................................................................................ 123
•
Molex Mini-Fit Sr contact tools................................................................................................ 124
•
Torx screwdriver ..................................................................................................................... 125
•
Wire strip tool.......................................................................................................................... 125
•
Crimp tool for wire end-sleeves (0,08 mm² - 16 mm²) ............................................................ 126
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Replacing boards and/or assemblies General Replacement process
When a board or assembly is defective, proceed as follows: 1. Send a request for a ‘RMA’-number to your local CSR-office. 2. Your local CSR-office will send you an RMA-number. 3. Dismount the defective board or assembly according to the respective procedure described in this chapter. 4. Fill in the RMA-form. See RMA (Return Merchandise Authorization) [92]. 5. E-mail the filled-in RMA-form to [email protected]. Always fill in the e-mail subject as follows: RMA . 6. Send the defective board or assembly to your local CSR-office. Always mention the RMA number when sending the defective boards or assemblies! 7. After you received the new board or assembly, replace it according to the respective procedure described in this chapter.
RMA (Return Merchandise Authorization) Form
To return a defective board or assembly the RMA-form must be filled in correctly. The different entries of the form are explained below: Form Illustration (example) 1) Name defective board or assembly: .....................(A) 2) BE number defective board or assembly: ............(B) 3) Serial number defective board or assembly: ........(C) See: Board naming [24]. 4) Problem description: .............................................(D) B 5) Machine serial number and the CSF file: .............(E) 6) Error number and error description or if possible a bitmap of the info screen: ............................................(F) A
C
D. Describe the problem, what happened, when did it happen, how did it happen.
E. Write down the serial number of the machine (see the identification plate on the right-hand side of the machine) and the name of the CSF-file (see CSF (Customer System File) [115]).
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Form F.
Illustration (example)
1. Go to the info screen. 2. Take a screen capture. See: Screen capture [117]. 3. Take a CSF. See: CSF (Customer System File) [115]. 4. Take a LOG. See: Machine log [116].
Replacing the assem. NG_LDEC Removing the assem. NG_LDEC
Proceed as follows to remove the assem. NG_LDEC: 1. Switch off the power supply.
2. Wait at least 3 minutes and open the rear side of the control box. See: Power Panel side control box. 3. Latch the power panel. See: Latching the Power panel [55]. 4. Disconnect the connectors on the NG_LDEC. 5. Remove the assem. NG_LDEC.
[30] of the
For any further operations on the NG_LDEC, place the NG_LDEC in a dust-free environment. Dust between the power modules and the heat sink will damage the modules.
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Fitting the assem. NG_LDEC
1. Fit the new assem. NG_LDEC into its position.
2. Reconnect all connectors on the NG_LDEC. 3. Remove the fixation tool. 4. Close the main control box.
Replacing the EBMM Removing the EBMM
Proceed as follows to remove the EBMM: Always replace both EBMM boards. If one board is defective, the other board will also be damaged. 1. Remove the NG_LDEC, see: Replacing the assem. NG_LDEC [93]. 2. Remove the cover of the NG_LDEC.
3. Loosen the bolts “A” of both EBMM boards and remove the boards.
A
Fitting the EBMM boards
A
Proceed as follows to fit the EBMM boards: Always replace both EBMM boards. If one board is defective, the other board will also be damaged. 1. Fit the EBMM boards and tighten the bolts “A” (1,4 Nm).
A
A
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2. Mount the cover.
3. Fit the assem. NG_LDEC. See: Fitting the assem. NG_LDEC
[94].
Replacing the OBMM Removing the OBMM
Proceed as follows to remove the OBMM: The procedure below applies to both OBMM boards. 1. Remove the NG_LDEC. See: Replacing the assem. NG_LDEC
[93].
2. Remove the cover of the NG_LDEC.
3. Disconnect the flat cable from the OBMM.
4. Loosen the bolts “B” and remove the EBMM board.
B
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5. Remove the bolts “C” from the OBMM board.
C
6. Remove the 8 bolts “D” from the power modules.
D
7. Remove the OBMM board 8. Remove the cooling paste from the heat sink and from the OBMM power module. Fitting the OBMM
Proceed as follows to fit the OBMM board: The procedure below applies to both OBMM boards. 1. Evenly apply cooling paste onto the heat sink. Spread the cooling paste with a spatula.
2. Fit the OBMM board and hand tighten the bolts “C”.
C
3. Tighten the 8 bolts “D” of the power modules. Tighten the bolts in diagonal order. Tighten first to 2 Nm, afterwards to 4 Nm. 1
6
3
8
5
2
7
4
D
.
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4. Tighten the bolts “C” (1,4 Nm).
C
5. Connect the flat cable to the OBMM board.
6. Fit the EBMM board and tighten the bolts “B” (1,4 Nm).
B
7. Remount the cover.
8. Put the LDEC back and restore all connections. See: Fitting the assem. NG_LDEC [94].
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Replacing the MMRB Removing the MMRB
Proceed as follows to remove the MMRB board from the NG_LDEC: 1. Remove the assem. NG_LDEC panel from the control box. See: Replacing the assem. NG_LDEC [93]. 2. Remove the cover.
3. Disconnect both flat cables from the MMRB board “A”. A
A
4. Loosen the bolts “B” of both EBMM boards and remove the boards.
B
B
5. Loosen the bolts “C” of the MMCU board and remove the board.
C
6. Remove the bolts “D” from the MMRB board.
D
.
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7. Remove the bolts “E” of the power modules and remove the MMRB board.
E
8. Remove the cooling paste from the heat sink and from the MMRB power module. Fitting the MMRB
1. Evenly apply cooling paste onto the heat sink. Spread the cooling paste with a spatula.
2. Fit the new MMRB board and finger-tighten the bolts “D”.
D
3. Tighten the 4 bolts “E” of the power modules. Tighten the bolts in diagonal order. First tighten to 2 Nm, afterwards to 4 Nm. 1
4
3
2
E
4. Tighten the bolts “D” of the MMRB (1,4 Nm).
D
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5. Connect both flat cables “A” to the MMRB. A
A
6. Fit the MMCU board and tighten the bolts “C” (0,6 Nm).
C
7. Fit both EBMM boards and tighten the bolts “B” (1,4 Nm).
B
B
8. Remount the cover.
9. Restore all connections and reconnect the LDEC panel. See: Fitting the assem. NG_LDEC [94].
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Removing and mounting boards from the rack Removing
Proceed as follows to remove a board from the rack: 1. Switch off the power supply.
Wait at least 3 minutes before continuing the procedure. 2. Open the Front [28] of the control box. 3. Remove the upper and lower holding plates “A” of the rack:
B
A
B
Be sure to loosen the correct bolts “B”: 4. Remove all cables from the board (if present). 5. Push the board hooks from the desired board a little to the side to unlock them: Push the board hooks in the direction of the arrow as shown in the illustration below:
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6. Tilt the board hooks and remove the board from the rack:
Mounting
Proceed as follows to mount a board in the rack: 1. Insert the board in the corresponding rack position (see: Rack position
[32].)
Make sure the board is properly inserted and completely plugged in. 2. Lock the board hooks.
3. Mount the holding plates “A”:
A
4. Reconnect all cables (if applicable) 5. Close the control box and switch on the main power.
.
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Replacing the assem. SRDD Remarks
Always replace the complete assembly. Never remove the board from the heat sink.
Unpacking
Proceed as follows to unpack the assem. SRDD: Do not cut or damage the plastic foil. 1. Open the box and lift the assem. SRDD by pulling both cardboard handles
2. Flip both long sides upwards.
3. Remove the assem. SRDD from the package.
Packing
To pack the assem. SRDD, carry out the Unpacking
[103]-procedure in reverse.
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Removing
Proceed as follows to remove the assem. SRDD: 1. Switch off the power supply. Wait 3 minutes before continuing the procedure
2. Latch the power panel using the fixation tool “A”. A
A
A
3. Disconnect the connectors on the SRDD. 4. Remove the assem. SRDD: Replace only the assem. SRDD that is damaged.
5. Unpack the new assem. SRDD. See Unpacking [103]. 6. Pack the old assem. SRDD. See Packing [103]. For any further operations on the SRDD, place the SRDD in a dust-free environment. Dust between the power modules and the heat sink will damage the modules. 7. Mount the new assem. SRDD.
.
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Replacing the CBFSB Tools
To replace the CBFSB you will need the following: • Torx Tx20and Tx8 screwdrivers, (See Torx screwdriver [125]); • Upgrade package (UBB1-file), see Upgrade package [113]; • Masterstick or USB-stick, see Masterstick (BE316654) [119] and USB-stick (N1038701) • Spare CBFSB board.
[119];
The CBFSB contains a unique identification number that has to be linked with the options for a given machine serial number. Replacing the CBFSB will require a new upgrade package, when you install this board into a specific machine. Software request form
When replacing the CBFSB board, the “CBFSB board exchange: software request form” must be filled in. After sending this form to the Picanol Service Engineer, you will receive an upgrade package. The following illustration shows the software request form:
A B C D E F
A. Customer name C. Machine serial number E. BE-number new CBFSB
B. Email account customer D. Serial number original CBFSB F. Serial number new CBFSB See: Board naming [24] .
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Replacing
Proceed as follows to replace the CBFSB: 1. Fill in the ‘CBFSB board exchange: software request form’ to get the correct upgrade package (ubb1-file). See Software request form [105]. 2. Turn off the machine, and open the Front [28] of The Control Box (CB) [25]. 3. Write down the location of each board in the rack:
4. Remove all boards from the rack. See Removing and mounting boards from the rack 5. Remove the original CBFSB from the rack and install the new CBFSB:
[101].
6. Remount all boards in the rack. Check with your notes (see step 3) for the correct location of the boards. 7. Turn on the power and wait until the following message appears on the PDP:
A
B 8. Choose ‘CBFSB’ (‘A’) and press (‘B’). The following message appears:
9. Install the upgrade package. See Upgrade package
[113].
.
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Replacing the CBMP Ways to replace the CBMP
There are 2 ways to replace the CBMP: • Quick CBMP replacement [107] (replace the board, keep the existing SD-card) • Full CBMP replacement [108] (replace the board and load new software, configuration and settings)
Tools
To replace the CBFSB you will need the following: • Torx TX20 screwdriver, see Torx screwdriver [125]; • Upgrade package (UBB1-file), see Upgrade package [113]; • Masterstick or USB-stick, see Masterstick (BE316654) [119] and USB-stick (N1038701) • Spare CBMP board; • Manometer.
Quick CBMP replacement
Proceed as follows to execute a quick replacement of the CBMP: 1. Turn off the machine, and open the Front [28] of The Control Box (CB) [25]. 2. Remove the SD-card of the new CBMP. 3. Remove the original CBMP from the rack, see Removing and mounting boards from the rack 4. Remove the SD-card of the original CBMP. 5. Place the original SD-card in the new CBMP. 6. Place the new CBMP in the rack.
[119];
[101].
2 6
4+5
3
7. Turn on the power and wait until the following message appears on the PDP:
A
B 8. Choose ‘CBFSB’ (‘A’) and press (‘B’).
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Full CBMP replacement
Proceed as follows to execute a full replacement of the CBMP: 1. Copy the following data: • Style file. See chapter ‘Terminal > Service > Explorer > Copy files or folders’; • CSF, see CSF (Customer System File) [115]; • Machine logging, see: Machine log [116] 2. Turn off the machine, and open the Front [28] of The Control Box (CB) [25]. 3. Remove the original CBMP from the rack, see Removing and mounting boards from the rack 4. Place the new CBMP. 5. Turn on the power, and wait until the following message appears on the PDP:
[101].
A
B
6. Choose ‘CBMP (‘A’) and press (‘B’). 7. Insert the USB-stick in the PDP and install the upgrade package. See Installing Software [113]. 8. Set the correct password using the Masterstick (BE316654) [119]. 9. Restore the styles-file or enter all settings manually. 10. Perform the following actions: • Warp beam change procedure (including the zero adjustment of the warp tension sensor); • EPR calibration. See chapter ‘Insertion > Air preparation settings’. • CAM box/dobby: position of the first frame. See chapter “Shed > The outside cam motion” or “Shed > The dobby”. • E-leno configuration. 4
3
7+8+9+10 replace software, configuration and settings
.
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Replacing the PDP Unpacking
Proceed as follows to unpack the PDP from its package: Do not cut or damage the plastic foil. 1. Open the box and lift the PDP by pulling both cardboard handles
2. Flip both long sides upwards
3. Remove the PDP from the package.
Packing
To pack the PDP, carry out the Unpacking
[109]-procedure in reverse
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Removing
Proceed as follows to remove the PDP: 1. Switch off the main power supply (main switch QM): Wait 3 minutes before continuing the procedure.
2. Loosen the bolts “A” and remove the cover on the left-hand side of the machine: A
3. Loosen the bolts “B” and remove the bolts “C”: Lift the PDP and block it by placing a screwdriver in the hole “D” to remove the bolts “C”. B C
D
4. Bring down the PDP and tilt the PDP towards weaver’s side.
5. Disconnect the cables from the PDP:
Disconnect the cable from the cable plug or cable tie on the PDP-side. 6. Remove the assem. PDP: 1
2
2
Mounting
To mount the PDP, carry out the Removing
[110]-procedure in reverse.
.
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Replacing the protection foil on the assem.PDP_9inch Preparation
Proceed as follows to mount the protection foil on a PDP2. 1. Place the foil in the correct orientation with the big flap on the left-hand side.
2. Bend the corners by hand.
Do not bend the big and small flap at the bottom of the foil. 3. Remove the protection foil on the back side. Mounting
1. Mount the bottom side by bending the foil and slip the flaps under the housing.
USB
2. Mount the upper side by bending the foil in the other direction.
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Result
The following illustration shows a correctly mounted protection foil.
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Software Installing Software When
The upgrade package is needed when you want to: • upgrade the software to a more recent version; • replace the CBMP board; • replace the CBFSB board; • modify the machine configuration.
Upgrade package
The upgrade package is a file with the extension .ubb1.
Tools
A USB-stick or Masterstick is required. See USB-stick (N1038701) (BE316654) [119].
Overview
The following illustration shows the overview of the software installation:
Installation
Proceed as follows to install the software: 1. Download the upgrade package from the Picanol SFTP server via https://sftp.picanolgroup.com.
[119] or Masterstick
Enter your user name and password to login to the SFTP server. Picanol automatically gives you a user account when sending you an upgrade package. The .ubb1-file is approximately 100Mb. Downloading the .ubb1-file can take more than 10 minutes in case of slow Internet connection. 2. Copy the ubb1-upgrade package in the “software”-folder on the USB-stick.
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3. Insert the USB-stick in the PDP and select the upgrade package:
Confirm the installation of the ‘.ubb1’-file by clicking the
Press the information button was designed for.
-button.
to see more information about which machines the software
A full installation of the upgrade package can take about 15 minutes. 4. Press the “OK” button to start the software installation. Log file
When the software is installed, a log file will automatically be generated. The UBB_log file: • is located in the log directory of your USB stick • has the following syntax: ubb_log___.zip
.
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CSF (Customer System File) What
The CSF is a snapshot from the current configuration.
CSF has the following syntax: csf___.zip Generating
Proceed as follows to save a data overview in a .zip-file: 1. Place an USB stick in the PDP. 2. Generate the .zip-file: Access Screen
USB>
3. Remember the generated file name:
4. Remove the USB-stick from the PDP. The CSF is located in the ‘CSF’-directory of the USB-stick.
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Machine log What
A machine log is a file that records events that occur over an amount of time.
Machine log has the following syntax: log_machine___.zip Generating
Proceed as follows to save a data overview in a .zip-file: 1. Place an USB stick in the PDP. 2. Generate the .zip-file: Access Screen
3. Remove the USB-stick from the PDP. The machine log is located in the ‘Log’-directory of the USB-stick.
.
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Screen capture Introduction
The PDP can be used to create screen captures. The terminal puts the screen captures on the USB memory stick.
Screen without pop-up
Follow these steps to create a screen capture of a screen without pop-up: 1. Plug in the USB Memory Stick on the terminal. 2. Press the empty area “A” in the top bar of the PDP.
A If the screen capture function has not been enabled yet, a pop-up appears in which the function can be enabled. Enable the function and press the empty area “A” again. The PDP makes a screen capture. A pop-up appears on the screen if the screen capture is ready. Screen with pop-up
Follow these steps to create a screen capture of a screen with a pop-up: 1. Plug in the USB Memory Stick on the terminal. 2. Go to the following screen and press “Screen capture”: Access Screen
3. Press “Screen capture ON (delay)” and enter a delay. E.g. 15 s. 4. Go to the screen which you want to create a screen capture of (but without the pop-up). 5. Press the empty area “A” in the top bar and go to the screen with the pop-up within the set delay.
A A counter is counting down. The terminal makes a screen capture on 0. A pop-up appears on the screen if the screen capture is ready. Only on certain screens
On certain screens a screen capture can also be created as follows: 1. Plug in the USB Memory Stick on the terminal. 2. Press Access
. E.g.: Screen
If the screen capture function has not been enabled yet, a pop-up appears in which the function can be enabled. Enable the function and press
again.
The terminal makes a screen capture. A pop-up appears on the screen if the screen capture is ready.
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Fuses Marking Example
The following table describes the fuse marking:
T 3,15A H 250V A A. Fuse characteristic [118] C. Fuse breaking capacity [118]
B
C
D
B. Maximum current D. Maximum voltage .
Fuse characteristic
The following table describes the fuse characteristics: Fuse characteristic Description FF Very fast acting F Fast acting M Medium acting T Slow acting TT Very slow acting
Fuse breaking capacity
The following table describes the fuse breaking capacity: Fuse breaking capacity Description L Low breaking capacity H High breaking capacity
Fuse details Electrical wiring
For more information about the fuses, see chapter: ‘Electrical wiring’.
.
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Tools Masterstick (BE316654) Function
The masterstick is a special USB-stick delivered by Picanol with the following functions: • Granting full access to the machine settings by opening the lock on the PDP; • Allowing to change the password on the PDP The standard password is always “1111”. The password can only be changed using the masterstick. For daily access to the PDP, use the password system to unlock the PDP instead of the masterstick. Formatting the masterstick will cause a loss of all the functions of the masterstick.
Changing the password
Proceed as follows to change the password on the PDP: 1. Insert the masterstick in the PDP 2. Enter a new password in the ‘Access control’ screen.
After entering the new password, the terminal will ask to confirm it. Re-enter the new password to confirm.
USB-stick (N1038701) Function
The usb-stick is a data carrier that makes use of the Universal Serial Bus interface and can be used for data exchange with the PDP. Only use Picanol USB-sticks. Other USB-sticks can cause damage or will not work properly. The USB-stick can be used for the following applications: • creating CSF files, see CSF (Customer System File) [115]; • saving CSF files, see CSF (Customer System File) [115]; • installing an upgrade package, see Software [113]; • making screen captures, see Screen capture [117].
Formatting the USB-stick
Proceed as follows to format the USB-stick: Access Screen
Formatting the USB-stick by any other means than via the PDP will make the USB-stick unrecognizable for the PDP.
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F-contact tools F-contact extractor
The table below shows the extraction tool and the F-contact connector: Extraction tool Connector N1023004
Proceed as follows to extract a wire:
Push the extraction tool into the connector as shown on the illustration above. When the extraction tool hits the end of the connector, lift the extraction tool a little and pull out the wire from the connector. F-contact crimp tool
N1023020
FC3
FC2
.
F-contact number • N1013143 (0,14mm² - 0,56mm²) • N1013144 (0,50mm² - 1,50mm²)
Position F-contact crimp tool FC2 FC3
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Burndy (TRIM TRIO) contact tools Burndy (TRIM TRIO) extraction tool
The table below shows 2 possible extraction tools and the Burndy (TRIM TRIO) contact connector: Extraction tool Connector N1023005
or
N1023022 Burndy (TRIM TRIO) contact crimp tool
N1023021
.
• • • • •
N1013517 N1013518 N1013527 N1013528 N1013631
Used Burndy (TRIM TRIO) contact numbers female (0,50mm² - 1,50mm²) male (0,50mm² - 1,50mm²) female (0,32mm² - 0,50mm²) male (0,32mm² - 0,50mm²) male (0,12mm² - 0,25mm²)
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D-sub contact tools D-sub extraction tool
The table below shows the extraction tool and the D-sub contact connector: Extraction tool Connector N1023023
Proceed as follows to extract a wire:
D-sub contact crimp tool
N1023019
.
D-sub contact number • N1013571 (female) • N1013587 (male)
Position D-sub crimp tool 0,20mm² - 0,56mm²
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Molex Mini-Fit Jr contact tools Molex Mini-Fit Jr extraction tool
The illustration below shows the Molex Mini-Fit Jr extraction tool. N1023026
Proceed as follows to extract a wire:
Molex Mini-Fit Jr crimp tool
N1023025
.
• • •
N1013614 N1013682 N1013698
female female male
Used Molex Mini-Fit Jr contact numbers (0,20mm² - 0,80mm²) (1,30mm²) (0,20mm² - 0,80mm²)
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Molex Mini-Fit Sr contact tools Molex Mini-Fit Sr extraction tool
Proceed as follows to extract a wire:
Molex Mini-Fit Sr crimp tool
Not available.
N1023013
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Torx screwdriver Torx screwdriver
Use a Torx tool to replace parts in the control box. A
B A. BA800736, magnetic screwdriver B. Torx bit: • BA800734: Tx8 x 1/4” • BA800735: Tx20 x 1/4”
Wire strip tool Wire strip tool N1023024
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Crimp tool for wire end-sleeves (0,08 mm² - 16 mm²) Crimp tool for wire end-sleeves
N1023015
A
.
Number • N1013535 • N1013646 • B44058 • B44518 • B44059 • B44060 • N1013649 • N1013575 • N1013576 • N1013632
Wire section 0,50 mm² 0,50 mm² 0,75 mm² - 1,00 mm² 0,75 mm² - 1,00 mm² 1,50 mm² 2,50 mm² 2,50 mm² 4,00 mm² 6,00 mm² 10,00 mm²
Used end-sleeves info white end-sleeve end-sleeve, non insulated red end-sleeve end-sleeve, non insulated black end-sleeve grey end-sleeve end-sleeve, non insulated orange end-sleeve green end-sleeve brown end-sleeve
Turn the button “A” on:
• •
10°, for wire section 0,08 mm² until 10 mm². 16°, only for wire section of 16 mm².
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Electrical Wiring General Contents
•
General ................................................................................................................................... 127
•
TPVN ...................................................................................................................................... 127
•
Cable identification ................................................................................................................. 128
•
Diagrams ................................................................................................................................ 129
•
Color coding wires .................................................................................................................. 129
•
Cable number ......................................................................................................................... 130
•
Shielded wire connections ...................................................................................................... 131
TPVN Location
The title page of the ‘Electrical Wiring’-section shows the TPVN number. The wiring section is specific for all machines with this TPVN number. The illustration belows shows an example of a TPVN number:
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On machine side
The TPVN number can be found on the right-hand side of the machine:
In case of machines equipped with Quick Style Change, be sure to use the number on the machine side and not on the Quick Style Change side.
Cable identification Cable label
Every cable has a label with information about the cable. The illustration below shows a cable label and the information on it: A B C A. Cable number C. BE number
B. Cable description .
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Diagrams Description
The following table describes the diagrams in the wiring section:
A
B
C D
A. Cable number and cable description C. Connector cable side
B. Cable wires D. Connector print side .
Color coding wires See: Wire abbreviations
[8].
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Cable number Standard numbering
A standard cable number consists of the letter “W” followed by a three digit number. E.g. W015.
Different sections
When a cable has different sections, the cable number ends with a letter. E.g. W104A and W104B. The “A”-cable is always connected in the control box.
A
B
W104a
A. Control box C. Device Split cables
W104B
C
B. Board .
When a cable is split up in two or more ends, the cable number ends with a digit. E.g. W129A is split up in W129B1 and W129B2. A W129B1 B
C
W129a W129B2
A. Control Box C. Device
D
B. Board D. Device .
2000 and higher
Cable numbers starting from W2000 are reserved for single wires or wire units.
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Shielded wire connections Rack
The following illustration shows the shielded wire connections on the rack: X_SH15
Power panel
The following illustration shows the shielded wire connections on the power panel: X_SH20
X_SH24
X_SH25
X_SH27
Cable bundle
The following illustration shows the shielded wire connections in the cable bundle:
X_SH02
X_SH01
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Resolver housing
The following illustration shows the shielded wire connection on the resolver housing:
X_SH74
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Abbreviations A
ABSD
Airjet Board Sensors and Devices
BlueBox air insertion board
BK BN BN/BK BN/BU BN/GN BN/RD BR BU
BlacK BrowN BrowN/BlacK BrowN/BlUe BrowN/GreeN BrowN/ReD BRake BlUe
Black Brown Brown with black rings Brown with blue rings Brown with green rings Brown with red rings Brake Blue
CBMP
Common Board Main Processor
BlueBox main processor board
DEN DTTH DTWTCAL
Drive ENable DeTection THermal DeTection Warp Tension CALibration
Drive enable signal Thermal detection Calibration signal for the warp tension
ELO_RHS EPR EPR_MN EPR_RN ES_CB ES_LHS ES_RHS ES_RRHS ETU
Electronic Let_Off Right-Hand Side Electronic Pressure Regulator Electronic Pressure Regulator_Main Nozzle Electronic Pressure Regulator_Relay Nozzles Emergency Stop Control Box Emergency Stop Left-Hand Side Emergency Stop Right-Hand Side Emergency Stop Rear Right-Hand Side Electronic Take Up
Electronic let off right-hand side Electronic pressure regulator Main nozzle pressure regulator Electronic pressure regulator for the relay nozzles Emergency stop located on the control box Emergency stop on the left-hand side Emergency stop on the right-hand side Emergency stop on the rear right-hand side Electronic take up system
FDCB FPGA
Filling Detection Control Box Field Programmable Gate Array
PICAN control box for the filling detectors Integrated circuit with programmable logic
GN GN/BK GN/BU GN/RD GY GY/BN GY/BU GY/GN GY/PK
GreeN GreeN/BlacK GreeN/BlUe GreeN/ReD GreY GreY/BrowN GreY/BlUe GreY/GreeN GreY/PinK
Green Green with black rings Green with blue rings Green with red rings Grey Grey with brown rings Grey with bleu rings Grey with green rings Grey with pink rings
HS_RX HS_TX
Hand Safety Receiver Hand Safety Transmitter
Receiver from the optical safety device Sender from the optical safety device
MID MMCU MMRB MPS
Machine IDentification number Main Motor Control Unit Main Motor Rectifier Board Main Power Supply
Identification number of the machine Main motor control board Rectifier board for the main motor Main power supply board
OBMM
Output Board Main Motor
Power board main motor
PB PBFA PBLO PBPTHR PBPWRON PDP PK PK/BN PK/GN PRW
Push Buttons Push Buttons Fancy Push Buttons Let-Off Push Button Pull THRough Push Button PoWeR ON Picanol DisPlay PinK PinK/BrowN PinK/GreeN PReWinder
Push buttons Push buttons for the fancy Push buttons for the let-off Push button pull through Power on button Picanol display Pink Pink with brown rings Pink with green rings Prewinder
B
C
D
E
F
G
H
M
O
P
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PX PX-FA-SFTY PX_LVL_OFF
ProXimity sensor ProXimity sensor FAncy SaFeTY ProXimity sensor LeVeLing OFF
Proximity sensor Proximity sensor fancy safety Proximity sensor levelling off
RD RD/BU RMA
ReD ReD/BlUe Request Merchandise Authorisation
RS
ReSolver
Red Red with blue rings Form with information about a defective board or assembly Resolver
SRDD
Switch Reluctance Dual Drive
BlueBox auxiliary motor control board
VT
VioleT
Violet
WH WH/BK WH/BU WH/GN WH/GY WH/PK WH/RD WH/YE WL WL-LHS WL-RHS
WHite WHite/BlacK WHite/BlUe WHite/GreeN WHite/GreY WHite/PinK WHite/ReD WHite/YelloW Warning Lights Warning Lights - Left-Hand Side Warning Lights - Right-Hand Side
White White with black rings White with blue rings White with green rings White with grey rings White with pink rings White with red rings White with yellow rings Warning lights Warning lights on the left-hand side Warning lights on the right-hand side
YE YE/BK YE/BN YE/BU YE/GY YE/PK YE/RD YWGR
YEllow YEllow/BlacK YEllow/BrowN YEllow/BlUe YEllow/GreY YEllow/PinK YEllow/ReD Yellow Green earth wire
Yellow Yellow with black rings Yellow with brown rings Yellow with blue rings Yellow with grey rings Yellow with pink rings Yellow with red rings Yellow-green tinted earth wire
R
S
V
W
Y
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