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B754 2 AIrjet Loom Manual

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B754 2  AIrjet Loom Manual Powered By Docstoc
					ZAX-e Air Jet Loom




             Maintenance Manual
             Speed Controller C




  TSUDAKOMA Corp.
                             (SI)
                          B754-2
FOREWORD
     Thank you for purchasing TSUDAKOMA textile machinery.
     Your machine’s optimum performance depends upon proper handling and maintenance.
     For high quality product and long machine life, be sure the machine is operated properly. To
     achieve optimum performance, take the time to carefully read this manual.


Remarks
  1. Before operating the machine, carefully read the safety instructions and remarks in the
     Operation Manual, Maintenance Manual “Mechanical Section, ” and in this Maintenance Manual.
  2. For ease of understanding, we use the following messages for safety. Strictly follow the
     instructions.

          DANGER!:         If you do not follow this instruction, you may be killed.

          WARNING!: If you do not follow this instruction, you may be seriously injured.

          CAUTION!: If you do not follow this instruction, you may be injured.

          WARNING!: If you do not follow this instruction, fire may break out.
  3. Remarks
     [ R e m a r k s ] describes instructions to be referred to for proper and full use and keeping
     machine’s quality. Please follow them.
  4. Do NOT modify the machine without TSUDAKOMA’s approval.
  5. Follow the adjustment instructions in this manual, otherwise we can not insure the damage due to
     improper operation.
  6. Record any maintenance (periodical inspection, part replacement) done by fixers.
  7. Due to improvements or special designs, your machine may differ from the description in this
     manual.
  8. Please keep all the manuals at hand.

For Further Inquires:
     Please feel free to ask us for detailed information about our products and this manual, by
     contacting the following:
  1. TSUDAKOMA Local Agent:




  2. TSUDAKOMA Corp.
     Sales Department:            PHONE (81) 76- 242- 1111
                                  FAX (81) 76- 242- 4172
     (For ordering parts, please specify the part’s number, name, quantity, and your machine
     number and month of manufacturing. Your machine number and delivery date are engraved on the
     name plate of your machine.)
                                                         CONTENTS


1. SPEED CONTROLLER C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
     1.1     Remarks on Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2    OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
     2.1     Keypad Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
     2.2     Setting for Loom RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
     3.1     Periodical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
     3.2     Parts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
     3.3     Replacing the Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
     3.4     Replacing the Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC COMPONENT MALFUNCTION NOTICE . . . . . . . . . . . . . . . . . . . . . . 8
1. SPEED CONTROLLER C
        The speed controller C controls loom rpm steplessly with a speed control inverter.
        It can easily change the loom rpm when changing fabrics for higher operation efficiency. Slow
        inching operation is available to inch the loom.




             KEYPAD PANEL




                                      Speed control inverter



1.1 Remarks on Handling
  (1) Safety Instructions

        DANGER!
    •   Do not touch the inside the speed controller C within 5 minutes after turning OFF the main switch
        of the loom.
        The condenser inside the speed controller C is charged and you may get an electrical shock.
    •   Be sure to turn ON the main switch of the loom after attaching the cover. Do not remove the cover
        while the power is ON.
    •   Do not change wiring, connect or disconnect the connector while the power is ON.
    •   Do not check the voltage inside the inverter with a tester while the power is ON.
        Otherwise, you may get an electrical shock.
    •   Only qualified maintenance personnel can perform a maintenance check or replace the parts.
        Otherwise, you may get an electrical shock or be injured.
    •   Keep any foreign matter including lint, dust or scrap metal away from the speed controller C, and
        its cooling fan.
        Otherwise, a fire or an accident may break out.




                                                      1
B754-2 February, 2004
    ( 2 ) Other Instructions
    1) The data of the inverter has been set prior to delivery. Do not change the settings other than the
       inverter frequency.
    2) Do not connect Output Terminal U, V, and W to the power source.
    3) Do not conduct an insulation test for the inverter.
    4) Do not put a phase advancing condenser in the output of the inverter.

2    OPERATION
2.1 Keypad Panel
                                                       LED Indicator
                                                       The set frequency, output frequency, and alarm
                                                       cord are displayed.

                                                       Indicator Display
                                                       The unit of data and display magnification are indicated.



                                                       LCD Indicator
                                                       Operation status is displayed.

                                                       Indicator Display
                                                       Operating condition is indicated.
                                                       FWD: The loom rotates forward.
                                                       REV: The loom rotates in reverse.
                                                       STOP: The loom stops.

                                                       RUN LED
                                                       Operation status is displayed.

                                                       Control Key
                                                       Key operation is unavailable.

          Operation Key
          For frequency setting
2.2 Setting for Loom RPM
    1) Lock the stop button of the loom while the loom is stopped. Five seconds later, the frequency at the
       time of operation is displayed.
    2) When increasing the rpm (frequency), press and hold                  .
        When decreasing the rpm (frequency), press and hold                 .
        Though the frequency can be set in the range below, use the inverter at 35Hz or higher to prevent
        the motor from being damaged:
              For power source voltage 200V or 220V:                  0 ~ 60Hz
              For power source voltage 380V or higher:                0 ~ 50Hz
    3) After changing the rpm (frequency), press                  while the changed frequency is blinking. If it
        is pressed after the data finishes blinking or if it is not pressed at all, the changed frequency is
        not registered in the inverter. When you reset the power switch, the frequency returns to the
        value before changing the data. If you forgot to press the button, change the frequency one more
        time and press            while the value is blinking.
        If the wrong button is pressed by mistake, press            to return to the previous display.
        Press           when selecting the digit to be changed.
                                                        2
B754-2 February, 2004
    Standard set frequency and Loom rpm
        For the power source voltage 200V or 220V (Highest setting frequency: 60H z *2)

                 LOOM RPM            SET FREQUENCY             SET FREQUENCY         SET FREQUENCY
                  at 60H Z *1         35Hz           40 Hz        45Hz     50Hz       55Hz       60Hz
                         500           292            333          375      417        458        500
                         550           321            367          413      458        504        550
                         600           350            400          450      500        550        600
                         650           379            433          488      542        596        650
                         700           408            467          525      583        642        700
                         750           438            500          563      625        688        750
                         800           467            533          600      667        733        800
                         850           496            567          638      708        779        850
                         900           525            600          675      750        825        900
                         950           554            633          713      792        871        950
                        1000           583            667          750      833        917       1000




             For the power source voltage 380V or higher (Highest setting frequency: 50H z *2)


                 LOOM RPM                            SET FREQUENCY
                  at 50H Z *1         35Hz           40 Hz        45Hz     50Hz
                         500           350            400         450       500
                         550           385            440         495       550
                         600           420            480         540       600
                         650           455            520         585       650
                         700           490            560         630       700
                         750           525            600         675       750
                         800           560            640         720       800
                         850           595            680         765       850
                         900           630            720         810       900
                         950           665            760         855       950
                        1000           700            800         900      1000




                           Set frequency
    Loom rpm =                                           x Loom rpm at the highest set frequency*1
                        Highest set frequency*   2



    Errors may generate depending on loads. The figures above are for reference.




                                                              3
B754-2 February, 2004
3. MAINTENANCE AND INSPECTION


        DANGER!
    •   When conducting an inspection, wait 5 minutes or more after turning OFF the main switch of the
        loom.
        Otherwise, you may get an electrical shock.
    •   Only qualified maintenance personnel can perform a maintenance check or replace the parts.
        Otherwise, you may get an electrical shock or be injured.


3.1 Periodical Inspection
        In order to avoid accidents and assure longer and more reliable operations, perform the following
        periodical inspection.

                        Item                          Inspection                   Countermeasure
        External terminals, Fixing        Check that the screws are tight. Tighten them.
        bolts, Connectors, etc.
                                          Check that connectors are not    Plug the connectors in again.
                                          loose.

        Radiation fin                     Check that dust has not          Clean it.
                                          accumulated.

        Printed board                     Check that conductive dust or     Clean it.
                                          oil has not adhered to the board. Replace the printed board if it
                                                                            can not be cleaned.

        Internal elements                 Check that dust has not adhered Remove dust.
        (Condensers, Transistors,         to the elements.
        etc.)
                                          Check the condenser for any      Replace the control printed
                                          discoloration or odor.           board.



3.2 Parts Maintenance
        Conduct preventive maintenance according to the durability of each part.


                         PART NAME               STANDARD DURABILITY               COUNTERMEASURE

                Main circuit condenser                     5 years            Replace it.

                Electrolytic condenser of the                                 Replace the control printed
                                                           7 years
                control printed board                                         board.

                Cooling fan                                3 years            Replace the cooling fan.



        Note:     The above-mentioned durability is just for reference to conduct a preventive
                  maintenance. It does not provide any guarantee against the parts durability.


                                                       4
B754-2 February, 2004
3.3 Replacing the Inverter

        DANGER!
    •   When replacing the inverter, wait 5 minutes or more after turning OFF the main switch of the
        loom.
        Otherwise, you may get an electrical shock.
    •   Only qualified maintenance personnel can perform wirings.
    •   Tighten the terminals securely.
        Otherwise, a fire may occur.
    •   Connect the ground wire securely.
        Otherwise, you may get an electrical shock or a fire may break out.
    ( 1) Shut off the main switch of the loom and wait 5 minutes or more.
    ( 2) Loosen the 2 mounting screws of the cover of the inverter.
          Then pull the top of the cover to remove it as shown below.
    ( 3) Remove the cables connected to the terminal blocks 1 and 2 inside the inverter.
    ( 4) Install the inverter in the reverse order of the above.
          For connecting the cables, refer to the following table to avoid mistakes.

             MOUNTING SCREW
                                                          TERMINAL BLOCK 2




                                                                                TERMINAL BLOCK 1


                 POWER SOURCE CABLES                                    SIGNAL CABLES
        TERMINAL BLOCK 1          CABLE                     TERMINAL BLOCK 2          CABLE
              L1/ R                R1                             PLC                   24V
              L2/ S                 S1                            FWD                   LOF
              L3/ T                 T1                            REV                   LOR
                G                   E                               X1                  SL1
                U                  U0                               X3                 LOM
                V                   V0                              X4                  ACK
               W                   W0                               X5                  NE0
                                                                  30B                  INVT
                                                                   30C                   0V
                                                                    Y1                 CRIB
                                                                    Y2                   NE
                                                                  CME                    0V
                                                      5
B754-2 February, 2004
3.4 Replacing the Cooling Fan
        DANGER!
    •   When replacing the cooling fan, wait 5 minutes or more after turning OFF the main switch of the
        loom.
        Otherwise, you may get an electrical shock.
    •   Only qualified maintenance personnel can perform a maintenance check or replace the parts.
        Otherwise, you may get an electrical shock or be injured.

    ( 1) Shut off the main switch of the loom and wait 5 minutes or more.
    ( 2) Loosen the 2 mounting screws of the cover of the inverter.
          Then pull the top of the cover to remove it as shown below.
    ( 3) Unplug the connectors for the cooling fan on the control board.
    ( 4) Remove the cover of the wiring inlet.
    ( 5) Loosen the 8 screws for fixing the cooling fan to remove it.
    ( 6) Install the cooling fan in the reverse order of the above.
          To insert the connectors of the cooling fan, both CN4 and CN5 are available.




        MOUNTING SCREW

                                                          SCREW                                  SCREW

                                                      CONNECTOR


                                                                                                COVER




                                                      6
B754-2 February, 2004
4. TROUBLESHOOTING
          In the event of an abnormality in the inverter, the protective function will activate immediately
          to stop the loom, displays Trouble Code ‘378’ on the iT-board, and displays the alarm name on the
          keypad panel.
          For alarm contents and countermeasures, see the following table.
  Keypad panel display
                            Alarm Name              Description                         Countermeasure
 LED           LCD
 OC1 OC DURING ACC                         Overcurrent flows through the 1) Check the wiring for damage.
                                           motor or output circuit has a 2) Remove the phase-advancing
 OC2 OC DURING DEC         Overcurrent                                      condenser on the loom motor, if any.
                                           short circuit or a grounding
 OC3 OC AT SET SPD                         fault.                        3) Replace the motor.
 OU1 OV DURING ACC                                                       1) If an irregular rotation due to the
                                           Regenerative current from the    unbalanced structure generates, use a
 OU2 OV DURING DEC         Overvoltage                                      dummy frame to be balanced.
                                           motor increases.
 OU 3 OV AT SET SPD                                                      2) Replace the motor.
                                                                            1) Check the mill voltage.
                                                                            2) If the problem occurs when the loom
                                           Power supply voltage
  LU   UNDERVOLTAGE        Undervoltage                                        starts, check that the wire of the
                                           decreases.
                                                                               power supply has the correct
                                                                               thickness.
                           Input open-                                      Check the mill voltage.
  L i n PHASE LOSS                         A phase failure occurs.
                           phase
                   Overheating of The temperature of the cooling 1) Clean the ventilation slots if there is
 OH1 FIN OVERHEAT                                                   any lint.
                   heat sink      fin rises.
                                                                 2) If the cooling fan does not rotate
                   Inverter
                                  The temperature inside the        after cleaning, replace the cooling
 OH3 HIGH AMB TEMP internal
                                  inverter rises.                   fan.
                   overheating
                           Inverter                                         1) Check if the loom is overloaded.
 OLU INVERTER OL                           The inverter detects overload.
                           overload                                         2) Replace the motor.
 E r1 MEMORY ERROR M e m o r y e r r o r Inverter memory error occurs. 1) Turn off the inverter’s power switch
                                                                          and turn it on again.
                    Keypad panel Communication error between
                                                                       2) Reconnect the connector between the
 E r2 KEYPD COM ERR communication the keypad panel and the
                    error                                                 keypad panel and the control board.
                                         control board occurs.
                                                                       3) If the problem recurs, replace the
 E r3 CPU ERROR     CPU error            CPU error occurs.                inverter.


          If the cooling fan in the control box (excluding the inverter’s) has an abnormality, the loom is
          immediately stopped by electric trouble. The trouble code below is displayed on the iT-board:

 Trouble
                     Description              Inspection                          Countermeasure
   Code

                                                                1) Check that no lint or yarn debris is in the
                                                                   cooling fan.
                                          1) If the cooling fan 2) Check the “24V” and the “0V” wiring and the
            External unit trouble.           does not rotate:      connectors of the cooling fan for
            The cooling fan in the                                 disconnection.
  3400                                                          3) Replace the cooling fan.
            control box has an
            abnormality.                                      1)     Check the “EX” wiring and the connectors of
                                          2) When the cooling        the cooling fan for disconnection.
                                             fan rotates:     2)     Re-connect Connector Cn15 of the main board.
                                                              3)     Replace the cooling fan.
                                                           7
B754-2 February, 2004
                         ELECTRIC COMPONENT MALFUNCTION NOTICE
                                                                                        TSUDAKOMA Corp.
   Dear Users,
   Please complete this form, attach it to the defective component, and send it to Tsudakoma or give it to
   our technical service staff. Please check the applicable items and give as complete a description as
   possible.
                  Company & Plant
User
                  Person in charge
                  Part name
                  Code
Replaced part
                  Serial #
                  Replaced date
                  Model                        ZAX, ZAX-e, ZW403, ZW405, ZW408, Other [                            ]
                  Nominal width                140, 150, 170, 180, 190, 210, 230, 250, 280, 340, 360, 390
Loom           Lot #
specifications Manufactured date
                  Machine serial No.
                  Loom rpm                     [        ] rpm
                  Trouble code
                  Description
                  (Please specify in detail)

                  Frequency                    The problem can not be solved.     Several times/day       Sometimes       Other

Problem                                        When the power is supplied, When the loom is started (immediately, after a few
                                               seconds), During operation, When the loom is stopped, During stoppage,
                  Conditions when the          During forward inching, During reversing, Other [           ]
                  problem occurred.            Is there any problem on the external equipment?                         Yes No
                                               Can the problem be solved by using the reset button or
                                                                                                                       Yes No
                                               turning the power on and off?

Tower           ON                             Red, Blue, Orange, Green, White, Transparent
indication lamp B l i n k s                    Red, Blue, Orange, Green, White, Transparent
                  The printed board was Spare part in your stock, Printed board from a normal loom,
                  replaced with:        Replacement part from Tsudakoma
                  Were there any other               Yes
                                                                 [Part name:                            ][Code:                       ]
                  replaced parts?                    No
Printed board
                                               Was the problem solved?                                     Yes No
replacement Condition after
              replacement                      If the problem was not solved, has        Increased              No change
                                               the problem frequency changed?                            Decreased
                  Did you try to mount the           Yes.        The same problem occurred. No problem occurred.
                  defective part on a normal
                  loom?                              No.         Another problem occurred. [                                      ]

                  Fabric                       Filament, spun, denim, Jacquard, [                              ]
                                               Set value         [       ]N
Loom setting Tension
and the                                        Present value During operation: [                   ]N, During stop: [       ]N
present value Winding diameter                 [             ] cm
                  Set value for pick
                  density
                                               [               ] ppi, ppc

                                                                8
B754-2 February, 2004
ZAX-e Maintenance Manual

   Speed Controller C



       B754-1 August, 2003

      B754-2 February, 2004




         TSUDAKOMA Corp.

 18-18, Nomachi 5-chome, Kanazawa,

         921-8650, JAPAN

     Phone: 81-76-242-1111

      Fax: 81-76-242-4172

				
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