B754 2 AIrjet Loom Manual
Document Sample
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.
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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.
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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.
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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.
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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
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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
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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.
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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
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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
