installation guide - itema...summary of main chapters e-30.01.2008 information 1 safety 2 buildings...

Installation guide

Operating Instructions

Summary of main chapters

E-30.01.2008

Information 1

Safety 2

Buildings / Air conditioning / Workplace 3

Transport / Commissioning 4

Power supply / Installation 5

Lubricants 6

Warp preparation 7

Weft preparation 8

Weaving accessories 9

Disposal 10

Installation guide

E-30.01.2008

Index

1 Information

1.1 Information concept . . . . . . . . . . . . . . . . . . 1.1-17

1.2 Using the Operating Instructions . . . . . . . . . . . 1.2-19

1.2.1 About this manual . . . . . . . . . . . . . . . 1.2-19

1.2.2 Symbols used . . . . . . . . . . . . . . . . . 1.2-19

1.2.3 Descriptive elements . . . . . . . . . . . . . . 1.2-20

1.2.4 Guidance elements . . . . . . . . . . . . . . . 1.2-21

1.3 Third-party documentation . . . . . . . . . . . . . . 1.3-23

1.3.1 Suppliers . . . . . . . . . . . . . . . . . . . . 1.3-23

1.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . 1.4-27

1.4.1 Patents . . . . . . . . . . . . . . . . . . . . . 1.4-27

1.4.2 Copyright . . . . . . . . . . . . . . . . . . . 1.4-27

1.5 Validity of the operating instructions . . . . . . . . . 1.5-29

1.5.1 Type key . . . . . . . . . . . . . . . . . . . . 1.5-29

2 Safety

2.1 General information . . . . . . . . . . . . . . . . . . 2.1-33

2.1.1 EU declaration of conformity and trademark . . 2.1-33

2.1.2 Authorised application . . . . . . . . . . . . . 2.1-33

2.1.3 Liability. . . . . . . . . . . . . . . . . . . . . 2.1-33

2.1.4 Alterations to the machine . . . . . . . . . . . 2.1-34

2.1.5 Damage to the machine . . . . . . . . . . . . 2.1-34

2.1.6 Obligations of the user . . . . . . . . . . . . . 2.1-34

E-30.01.2008

Index

2.1.6.1 Operating instructions . . . . . . . . . . . . . . 2.1-35

2.1.6.2 Personnel . . . . . . . . . . . . . . . . . . . . 2.1-35

2.1.6.3 Competencies and responsibilities . . . . . . . . 2.1-35

2.1.6.4 Access to weaveroom, visitors . . . . . . . . . . 2.1-35

2.1.7 Additional directives and standards . . . . . . 2.1-36

2.2 General safety instructions . . . . . . . . . . . . . . 2.2-37

2.2.1 Safety-conscious working . . . . . . . . . . . 2.2-37

2.2.1.1 Protective equipment . . . . . . . . . . . . . . 2.2-37

2.2.1.2 Working with harmful materials . . . . . . . . . . 2.2-37

2.2.1.3 Hair and clothing . . . . . . . . . . . . . . . . 2.2-38

2.2.1.4 Before starting the machine . . . . . . . . . . . 2.2-38

2.2.1.5 Button operation/starting the machine. . . . . . . 2.2-38

2.2.1.6 While the weaving machine is running . . . . . . 2.2-38

2.2.1.7 Scissors and tools . . . . . . . . . . . . . . . . 2.2-38

2.2.2 Working on the machine . . . . . . . . . . . . 2.2-39

2.2.3 Working on the electrical equipment . . . . . . 2.2-39

2.2.3.1 Before working on the electrical equipment . . . . 2.2-40

2.2.4 Working with the stroboscope . . . . . . . . . 2.2-41

2.2.5 Working with compressed air . . . . . . . . . 2.2-41

2.2.6 Working on the pneumatic system . . . . . . . 2.2-41

2.2.7 Noise hazards . . . . . . . . . . . . . . . . . 2.2-42

2.3 Hazard symbols and warning notices . . . . . . . . 2.3-43

2.3.1 Danger notices . . . . . . . . . . . . . . . . . 2.3-43

2.3.2 Warning notices . . . . . . . . . . . . . . . . 2.3-45

E-30.01.2008

Index

2.3.3 Caution notices . . . . . . . . . . . . . . . . 2.3-47

2.4 Safety equipment. . . . . . . . . . . . . . . . . . . . 2.4-49

2.4.1 Stickers, signs and notices. . . . . . . . . . . 2.4-49

2.4.2 Safety equipment. . . . . . . . . . . . . . . . 2.4-49

2.4.2.1 EMERGENCY STOP switch . . . . . . . . . . . 2.4-49

2.4.2.2 Safety switch . . . . . . . . . . . . . . . . . . 2.4-50

2.4.2.3 Main switch ON . . . . . . . . . . . . . . . . . 2.4-50

2.4.2.4 Main switch “OFF” / “OFF” and secured. . . . . . 2.4-51

2.4.2.5 Holding brake . . . . . . . . . . . . . . . . . . 2.4-52

2.4.3 Light curtain . . . . . . . . . . . . . . . . . . 2.4-53

2.4.4 Cabinet doors and covers . . . . . . . . . . . 2.4-54

2.4.4.1 Function . . . . . . . . . . . . . . . . . . . . 2.4-54

2.4.4.2 Weaving machine in operation . . . . . . . . . . 2.4-54

2.4.4.3 Weaving machine stopped . . . . . . . . . . . . 2.4-54

2.4.4.4 Checks, repairs, settings . . . . . . . . . . . . . 2.4-55

2.5 Fire regulations. . . . . . . . . . . . . . . . . . . . . 2.5-57

3 Buildings / Air conditioning / Workplace

3.1 Design of load-bearing structures . . . . . . . . . . 3.1-61

3.1.1 Notes for the user . . . . . . . . . . . . . . . 3.1-61

3.1.2 Floor slab design. . . . . . . . . . . . . . . . 3.1-61

3.1.2.1 Subsoil . . . . . . . . . . . . . . . . . . . . . 3.1-61

3.1.2.2 Drainage . . . . . . . . . . . . . . . . . . . . 3.1-61

3.1.2.3 Bearing course . . . . . . . . . . . . . . . . . 3.1-62

3.1.2.4 Separation course . . . . . . . . . . . . . . . . 3.1-62

E-30.01.2008

Index

3.1.2.5 Concrete slab . . . . . . . . . . . . . . . . . . 3.1-63

3.1.2.6 Floor covering and underlay . . . . . . . . . . . 3.1-63

3.1.2.7 Joints . . . . . . . . . . . . . . . . . . . . . . 3.1-63

3.1.3 Design of ceiling tiles . . . . . . . . . . . . . 3.1-64

3.1.3.1 Load-bearing capacity . . . . . . . . . . . . . . 3.1-64

3.1.3.2 Natural frequency of load-bearing structure . . . . 3.1-64

3.1.3.3 Design considerations . . . . . . . . . . . . . . 3.1-65

3.1.4 Floor covering and underlay . . . . . . . . . . 3.1-65

3.1.4.1 Requirements . . . . . . . . . . . . . . . . . . 3.1-65

3.1.4.2 Floor evenness . . . . . . . . . . . . . . . . . 3.1-66

3.1.4.3 Suitable floor coverings . . . . . . . . . . . . . 3.1-66

3.1.5 Vibration reduction . . . . . . . . . . . . . . . 3.1-66

3.1.5.1 Vibration-reducing bearings . . . . . . . . . . . 3.1-67

3.1.5.2 Floating floors . . . . . . . . . . . . . . . . . . 3.1-67

3.1.6 Building construction and quality control . . . 3.1-68

3.1.6.1 Building construction. . . . . . . . . . . . . . . 3.1-68

3.1.6.2 Quality control . . . . . . . . . . . . . . . . . . 3.1-68

3.1.6.3 Emission reduction . . . . . . . . . . . . . . . 3.1-68

3.1.7 Preparing the floor . . . . . . . . . . . . . . . 3.1-68

3.2 Noise emission . . . . . . . . . . . . . . . . . . . . . 3.2-73

3.2.1 Explanation of amounts . . . . . . . . . . . . 3.2-73

3.2.2 Noise level measurements . . . . . . . . . . . 3.2-74

3.3 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . 3.3-77

3.3.1 Planning the lighting . . . . . . . . . . . . . . 3.3-77

E-30.01.2008

Index

3.3.2 Installation . . . . . . . . . . . . . . . . . . . 3.3-78

3.3.3 Operation, optimization . . . . . . . . . . . . 3.3-78

3.3.4 Recommended values . . . . . . . . . . . . . 3.3-79

3.4 Air conditioning . . . . . . . . . . . . . . . . . . . . 3.4-81

3.4.1 Building and planning . . . . . . . . . . . . . 3.4-81

3.4.1.1 Building planning . . . . . . . . . . . . . . . . 3.4-81

3.4.1.2 Planning the ventilation system. . . . . . . . . . 3.4-81

3.4.1.3 Planning of the components . . . . . . . . . . . 3.4-82

3.4.2 Operational phase . . . . . . . . . . . . . . . 3.4-82

3.4.3 Requirements of the air conditioning plant . . . 3.4-83

3.4.3.1 Air volumes . . . . . . . . . . . . . . . . . . . 3.4-83

3.4.4 Recommended values . . . . . . . . . . . . . 3.4-84

3.5 Vacuum cleaning . . . . . . . . . . . . . . . . . . . . 3.5-85

3.5.1 Planning the system . . . . . . . . . . . . . . 3.5-85

3.5.2 Operational phase . . . . . . . . . . . . . . . 3.5-86

4 Transport / Commissioning

4.1 Incoterms . . . . . . . . . . . . . . . . . . . . . . . . 4.1-89

4.1.1 Definition. . . . . . . . . . . . . . . . . . . . 4.1-89

4.1.2 ICC - International Chamber of Commerce . . . 4.1-89

4.1.3 Standard ICC arbitration clause . . . . . . . . 4.1-89

4.1.4 Incoterms in practice . . . . . . . . . . . . . . 4.1-90

4.1.5 Incoterms 2000 . . . . . . . . . . . . . . . . . 4.1-90

4.2 Checklist . . . . . . . . . . . . . . . . . . . . . . . . 4.2-93

E-30.01.2008

Index

4.3 Work carried out by service engineer. . . . . . . . . 4.3-95

4.3.1 Sequence of operations for commissioning . . 4.3-96

4.3.1.1 Transport and installation . . . . . . . . . . . . 4.3-96

4.3.1.2 Mechanical adjustment . . . . . . . . . . . . . 4.3-97

4.3.1.3 Pneumatic and weaving-related adjustments . . . 4.3-98

4.3.1.4 Final adjustments and checks . . . . . . . . . . 4.3-99

4.4 Space requirements . . . . . . . . . . . . . . . . . . 4.4-101

4.4.1 Layout drawing. . . . . . . . . . . . . . . . . 4.4-101

4.4.1.1 Positioning for the extending cleaning devices (example) . . . . . . . . . . . . . . . . . . . . 4.4-102

4.4.2 Dimensions . . . . . . . . . . . . . . . . . . 4.4-103

4.4.2.1 Weaving machine with cam/dobby . . . . . . . . 4.4-103

4.4.2.2 Weaving machines with Jacquard device . . . . . 4.4-107

4.4.2.3 Connecting the crossbars for machines with Jacquard device . . . . . . . . . . . . . . . . . 4.4-113

4.5 Unloading/transportation . . . . . . . . . . . . . . . 4.5-115

4.5.1 Using a forklift truck to unload the weaving machine . . . . . . . . . . . . . . . . 4.5-116

4.5.2 Using a crane to unload the weaving machine . 4.5-120

4.5.3 Moving the weaving machine. . . . . . . . . . 4.5-121

4.5.4 Unloading the control cabinet . . . . . . . . . 4.5-124

4.6 Setting up the weaving machine . . . . . . . . . . . 4.6-127

4.6.1 Positioning the weaving machine . . . . . . . 4.6-127

4.6.1.1 Variant with warp beam ø<1000 mm . . . . . . . 4.6-127

4.6.1.2 Variant with warp beam ø>1000 mm . . . . . . . 4.6-128

E-30.01.2008

Index

4.6.2 Leveling the weaving machine . . . . . . . . . 4.6-129

4.7 Warranty claim . . . . . . . . . . . . . . . . . . . . . 4.7-133

5 Power supply / Installation

5.1 Electricity . . . . . . . . . . . . . . . . . . . . . . . . 5.1-137

5.1.1 Electrical supply . . . . . . . . . . . . . . . . 5.1-137

5.1.1.1 Basic requirements . . . . . . . . . . . . . . . 5.1-137

5.1.1.2 General connected loadings . . . . . . . . . . . 5.1-137

5.1.1.3 Types of power supply systems . . . . . . . . . 5.1-138

5.1.1.4 Frequency . . . . . . . . . . . . . . . . . . . 5.1-139

5.1.1.5 Voltage . . . . . . . . . . . . . . . . . . . . . 5.1-139

5.1.2 Fluctuations in voltage . . . . . . . . . . . . . 5.1-140

5.1.2.1 Voltage . . . . . . . . . . . . . . . . . . . . . 5.1-140

5.1.2.2 Frequency . . . . . . . . . . . . . . . . . . . 5.1-140

5.1.2.3 Harmonic oscillation . . . . . . . . . . . . . . . 5.1-140

5.1.2.4 Voltage asymmetry . . . . . . . . . . . . . . . 5.1-140

5.1.2.5 Voltage interruptions. . . . . . . . . . . . . . . 5.1-140

5.1.2.6 Voltage dips. . . . . . . . . . . . . . . . . . . 5.1-140

5.1.3 Safety rules . . . . . . . . . . . . . . . . . . 5.1-141

5.2 Electrical characteristics . . . . . . . . . . . . . . . 5.2-143

5.2.1 Power requirement . . . . . . . . . . . . . . . 5.2-144

5.2.2 Power input . . . . . . . . . . . . . . . . . . 5.2-144

5.2.2.1 Basic machine. . . . . . . . . . . . . . . . . . 5.2-145

5.2.2.2 Options . . . . . . . . . . . . . . . . . . . . . 5.2-145

5.2.3 Power factor . . . . . . . . . . . . . . . . . . 5.2-146

E-30.01.2008

Index

5.3 Connection to the mains supply . . . . . . . . . . . 5.3-147

5.3.1 Back-up fuse . . . . . . . . . . . . . . . . . . 5.3-147

5.3.1.1 Mains filter . . . . . . . . . . . . . . . . . . . 5.3-147

5.3.1.2 RCD Protection Devices . . . . . . . . . . . . . 5.3-147

5.3.1.3 Protective devices . . . . . . . . . . . . . . . . 5.3-148

5.3.1.4 Starter current . . . . . . . . . . . . . . . . . . 5.3-148

5.3.2 Electrical connection . . . . . . . . . . . . . . 5.3-150

5.3.3 Sockets . . . . . . . . . . . . . . . . . . . . 5.3-153

5.4 Compressed air. . . . . . . . . . . . . . . . . . . . . 5.4-155

5.4.1 Planning for the compressed air plant . . . . . 5.4-155

5.4.2 Operation, optimization . . . . . . . . . . . . 5.4-157

5.4.3 Quality requirements . . . . . . . . . . . . . . 5.4-158

5.4.3.1 Classification . . . . . . . . . . . . . . . . . . 5.4-158

5.4.3.2 Pressure level . . . . . . . . . . . . . . . . . . 5.4-158

5.4.3.3 Residual oil content . . . . . . . . . . . . . . . 5.4-158

5.4.3.4 Residual moisture . . . . . . . . . . . . . . . . 5.4-158

5.4.3.5 Temperature . . . . . . . . . . . . . . . . . . 5.4-158

5.4.3.6 Solids content . . . . . . . . . . . . . . . . . . 5.4-159

5.4.4 Compressed air preparation . . . . . . . . . . 5.4-159

5.4.4.1 Comparison of oil-free and non oil-free compressors . . . . . . . . . . . . . . . . . . 5.4-159

5.4.4.2 Supplementary information regarding compressed air preparation. . . . . . . . . . . . . . . . . . 5.4-160

5.4.5 Planning the number of compressors . . . . . 5.4-161

5.4.5.1 One large compressor . . . . . . . . . . . . . . 5.4-161

E-30.01.2008

Index

5.4.5.2 Several small compressors. . . . . . . . . . . . 5.4-162

5.4.6 Installation notes . . . . . . . . . . . . . . . . 5.4-163

5.4.6.1 What's important in the compressor room? . . . . 5.4-163

5.4.7 Recommendations for compressed air pipework5.4-164

5.4.7.1 Material quality . . . . . . . . . . . . . . . . . 5.4-164

5.4.7.2 Installation recommendations . . . . . . . . . . 5.4-165

5.4.7.3 Connecting the individual weaving machines . . . 5.4-165

5.4.8 Configuring a compressed air plant . . . . . . 5.4-166

5.5 Pneumatic properties . . . . . . . . . . . . . . . . . 5.5-169

5.5.1 Measurement unit for air . . . . . . . . . . . . 5.5-169

5.5.2 Characteristics of compressed air . . . . . . . 5.5-170

5.5.3 Compressed air consumption . . . . . . . . . 5.5-170

5.5.4 Machine compressed air plant . . . . . . . . . 5.5-172

5.5.5 Pneumatic connection . . . . . . . . . . . . . 5.5-173

5.5.6 Composition of a compressed air plant . . . . 5.5-174

5.5.6.1 Air filter in intake. . . . . . . . . . . . . . . . . 5.5-175

5.5.6.2 Compressor . . . . . . . . . . . . . . . . . . . 5.5-175

5.5.6.3 Dryer . . . . . . . . . . . . . . . . . . . . . . 5.5-175

5.5.6.4 Compressed air tank. . . . . . . . . . . . . . . 5.5-175

6 Lubricants

6.1 Regulations . . . . . . . . . . . . . . . . . . . . . . . 6.1-179

6.1.1 General. . . . . . . . . . . . . . . . . . . . . 6.1-179

6.1.1.1 Validity . . . . . . . . . . . . . . . . . . . . . 6.1-179

6.1.1.2 Safety rules, legal requirements . . . . . . . . . 6.1-179

E-30.01.2008

Index

6.1.1.3 Attention . . . . . . . . . . . . . . . . . . . . 6.1-179

6.1.1.4 Designations . . . . . . . . . . . . . . . . . . 6.1-180

6.1.1.5 Recommendation . . . . . . . . . . . . . . . . 6.1-180

6.1.1.6 Responsibility . . . . . . . . . . . . . . . . . . 6.1-180

6.1.2 Sourcing . . . . . . . . . . . . . . . . . . . . 6.1-181

6.1.2.1 Choice of supplier . . . . . . . . . . . . . . . . 6.1-181

6.1.2.2 Changing supplier, brand and type . . . . . . . . 6.1-181

6.1.3 Storage. . . . . . . . . . . . . . . . . . . . . 6.1-181

6.1.3.1 Locality . . . . . . . . . . . . . . . . . . . . . 6.1-181

6.1.3.2 Length of storage . . . . . . . . . . . . . . . . 6.1-181

6.1.4 Toxicity. . . . . . . . . . . . . . . . . . . . . 6.1-181

6.1.4.1 Legal requirements . . . . . . . . . . . . . . . 6.1-181

6.1.4.2 Disposal . . . . . . . . . . . . . . . . . . . . 6.1-182

6.1.5 Checks . . . . . . . . . . . . . . . . . . . . . 6.1-182

6.1.6 Sultex AG as lubricant supplier . . . . . . . . 6.1-182

6.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . 6.2-183

6.2.1 Oil specifications . . . . . . . . . . . . . . . . 6.2-183

6.2.2 Grease specifications . . . . . . . . . . . . . 6.2-184

6.2.3 Use and filling amount . . . . . . . . . . . . . 6.2-185

7 Warp preparation

7.1 Processing of fiber yarns . . . . . . . . . . . . . . . 7.1-189

7.1.1 Warping . . . . . . . . . . . . . . . . . . . . 7.1-189

7.1.2 Sizing . . . . . . . . . . . . . . . . . . . . . 7.1-190

E-30.01.2008

Index

8 Weft preparation

8.1 Package make-up . . . . . . . . . . . . . . . . . . . 8.1-195

8.1.1 Requirements . . . . . . . . . . . . . . . . . 8.1-195

8.1.2 Causes of problems . . . . . . . . . . . . . . 8.1-195

8.1.3 Recommendations . . . . . . . . . . . . . . . 8.1-196

9 Weaving accessories

9.1 Warp beam . . . . . . . . . . . . . . . . . . . . . . . 9.1-199

9.1.1 Full warp beam . . . . . . . . . . . . . . . . . 9.1-199

9.1.2 Half warp beam. . . . . . . . . . . . . . . . . 9.1-200

9.1.3 Warp beam mode of transport . . . . . . . . . 9.1-201

9.2 Cloth beams . . . . . . . . . . . . . . . . . . . . . . 9.2-203

9.3 Reed . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3-205

9.3.1 "Normal" type . . . . . . . . . . . . . . . . . 9.3-205

9.3.2 "Double cone" type. . . . . . . . . . . . . . . 9.3-206

9.3.3 Variants . . . . . . . . . . . . . . . . . . . . 9.3-207

9.3.3.1 Adjustable reed . . . . . . . . . . . . . . . . . 9.3-207

9.3.3.2 Adjustable reed with auxiliary selvedge . . . . . . 9.3-207

9.3.3.3 Reed – overall width, including auxiliary selvedge . 9.3-208

9.4 Heddle frames . . . . . . . . . . . . . . . . . . . . . 9.4-209

9.4.1 Heddle frame dimensions . . . . . . . . . . . 9.4-209

9.4.1.1 Weaving machine width 170 to 230 . . . . . . . . 9.4-209

9.4.1.2 Weaving machine width 260 to 380 . . . . . . . . 9.4-210

9.4.1.3 Weaving machine width 400 . . . . . . . . . . . 9.4-211

E-30.01.2008

Index

9.4.2 Frame connections . . . . . . . . . . . . . . . 9.4-212

9.4.2.1 Harness drive linkage . . . . . . . . . . . . . . 9.4-212

9.4.2.2 Terminals on dobby . . . . . . . . . . . . . . . 9.4-212

9.5 Heddles . . . . . . . . . . . . . . . . . . . . . . . . . 9.5-215

10 Disposal

10.1 Deinstallation . . . . . . . . . . . . . . . . . . . . . 10.1-219

10.1.1 Procedure . . . . . . . . . . . . . . . . . . 10.1-219

10.1.2 Regulations . . . . . . . . . . . . . . . . . 10.1-219

E-30.01.2008

Main chapter

1 Information

E-30.01.2008

E-30.01.2008

1.1 Information concept


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

Fig. 1.1-1

The operating instructions consist of the Installation Guide, User Manual, Adjustment Manual and the Terminal Manual.The installation guide contains detailed information about how to set up a weaving machine prior to commissioning.The user manual describes the control and display elements and the control cabinet.The adjustments and maintenance work that become necessary during operation are described in the adjustment manual, which will help suitably qualified personnel keep the weaving machine running smoothly.The terminal manual contains information on operation of the terminal, such as the list of all error messages and suitable ac-tion for remedying these.The electronic spare parts catalog, "Elspace", contains a de-tailed listing of all spare parts.The "Circuit diagram" is always located in the box with the red corners so that the appropriate documentation for each machine type is always close at hand for the mill electrician.The "Machine Software" configuration CD-ROM contains the

E-30.01.2008 1.1-17


Terminal Help texts, all error messages (these can be printed), the terminal simulator, circuit diagram, machine software, etc.The "External suppliers documentation" provided by our vendors contains information regarding additional bought-in equipment

1.1-18 E-30.01.2008

1.2 Using the Operating Instructions


We advise you to read the following before using the Operating Instructions.In addition, read the chapter entitled "Safety" carefully.

1.2.1 About this manual

The operating instructions are structured in the form of a book. Page numbering starts again at the beginning of each main chapter.The following signposts will direct you to the chapter you require.• Main chapter front sheet

– shows the individual main chapters• General contents page

– shows the chapter heading and the sections it contains• Main chapter contents

– shows the sections and the subsections they containThe header at the top of each page contains the name of the cur-rent section.The footer at the bottom of the page contains the section number, followed by a dash and the page number within the sec-tion.

1.2.2 Symbols used

The symbols used in the operating instructions are explained here.For an explanation of the safety symbols, refer to the chapter en-titled "Safety".Cross-references within the operating instrucions or to other documents or vendor manuals are indicated thus:


E-30.01.2008 1.2-19


1.2.3 Descriptive elements

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

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

Options are:

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

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

warp gaiter

Weaver

Weaveroom foreman

Mill electrician

Service technician

1.2-20 E-30.01.2008


1.2.4 Guidance elements

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

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

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

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

E-30.01.2008 1.2-21


1.2-22 E-30.01.2008

1.3 Third-party documentation


The following list contains the most important documentation re-lating to ancillary equipment.The amount of additional documentation (operating instructions, spare parts catalogues, diagrams, etc.) provided with each ma-chine varies depending on the specific version of the weaving machine.Technical advice regarding these items of equipment or addi-tional copies of the documentation can be obtained directly from the manufacturer.

1.3.1 Suppliers

Operating instructions, user guides, spare parts catalogues Address

Dobbys

FirstVia Spazzi, 52I-24028 Ponte Nossa (BG)ItalyTel. +39 (0)35 705 51 1Fax.+39 (0)35 702 51 1

Stäubli AGSeestrasse 238CH-8810 HorgenSwitzerlandTel. +41 (0)43,244 22 22Fax. +41 (0)43 245 22 45

Weft feeder

IRO Sweden ABKarlsnäsvägen 7S-52322 UlricehamnSwedenTel. +46 321 29 700Fax +46 321 29 800Mail [email protected]

L.G.L. Electronics S.p.A.Via Foscolo, 156I-24024 GandinoBergamo - ItalyTel. +39 035 733 408Fax +39 035 733 146Mail [email protected]://www.lgl.it

E-30.01.2008 1.3-23


Weft detector

Eltex of Sweden ABBäckgatan, 6Box 608S-343 24 ElmhultSwedenTel. +46 476 488 00Fax +46 476 134 00

Heald frames

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

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


Warp stop motion

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


Controls

EutronGiorgio TestaCommercial Manager ItalyTrevioloTel. +39 (0)35 697 02 3Fax. +39 (0)35 697 09 [email protected]

Batch winder

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


1.3-24 E-30.01.2008


Motors

Lafert S.p.A.Via J.F. Kennedy, 43I - 30027 San Donà di Piave/VeneziaItalyTel. +39 (0)421,229 61 1Fax +39 (0)421,222 90 8

Lubricating units / maintenance unitsSchnitzler GmbHHöffgeshofweg 26D-47807 KrefeldGermany

Transport equipment / warp beam lift-er truck

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


E-30.01.2008 1.3-25


1.3-26 E-30.01.2008

1.4 Copyright

1.4 Copyright

1.4.1 Patents

Sulzer Textil weaving machines are protected by the following patents:

1.4.2 Copyright

Reproduction in any form of technical documentation for Sulzer Textil weaving machines, including individual text passages, il-

US patent numbers

4276911 5199466 5520224 5862837 6112776

4498501 5244164 5538048 5884674 6155309

4520851 5247968 5558133 5890519 6164342

4534386 5259422 5564473 5899242 6179011

4534387 5341852 5568826 5904186 6186184

4550752 5348053 5575314 5937913 6188149

4643233 5348057 5613525 5941288 6189576

4655259 5355912 5615714 5947162 6213161

4722370 5386855 5628346 5947163 6223778

4844132 5423355 5630449 5950684 6230760

4933654 5431194 5649569 5950685 6244961

4957403 5439034 5657796 6006795 6253797

4974639 5439037 5666998 6009915 6305435

5014756 5441084 5684255 6026864 6308742

5058628 5441085 5711352 6041830 6347647

5090453 5450880 5727114 6058981 6371169

5107903 5465763 5755267 6065503 6382261

5113914 5477892 5813440 6070620 6382262

5135033 5483997 5819812 6092561

5146955 5492153 5826625 6098670

5174341 5503194 5827975 6102084

E-30.01.2008 1.4-27

1.4 Copyright

lustrations or tables, and its translation into other languages is prohibited, except with the permission of Sultex AG.All rights, especially copyrights, are retained by Sultex AG, CH-8630 Rüti.

1.4-28 E-30.01.2008

1.5 Validity of the operating instructions


These operating instructions are for weaving machines in the L5500 range.

1.5.1 Type key

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

Fig. 1.5-1

E-30.01.2008 1.5-29


Type specification L 5500 B 190 N4 EP

Weaving system

Model

Fibre

B CottonW WoolS SyntheticsP PolypropyleneH Hard fibre

Nominal width [cm]

170 / 190 / 210 / 220 / 230 / 260 / 280 / 300 / 320 / 340 / 360 / 380 / 400

Colour selector

2 Single colour4 Two weft6 Four weft8 Eight weft (only with Jacquard machine)

Shed formation

EP Cam motionSP DobbyJ Jacquard machine

1.5-30 E-30.01.2008

Main chapter

2 Safety

E-30.01.2008

E-30.01.2008

2.1 General information


2.1.1 EU declaration of conformity and trademark

The weaving machine manufactured by Sultex AG is a high-tech product and may therefore only be used for the tasks and the product type for which it was designed and constructed accord-ing to the state of the art and in conformity with the following di-rectives:• Machinery Directive 89/392/EEC and subsequent amend-

ments (91/368/EEC - 93/44/EEC - 93/68/EEC - 98/377/EEC)• Harmonised standards EN ISO 11111 (Safety requirements

for textile machinery)• Harmonised standards EN 292 – EN 294 – EN 349 –

EN 60204-1• Low Voltage Directive 73/23/EEC• Directive 89/336/EEC

2.1.2 Authorised application

Your weaving machine is designed to produce fabrics solely within the agreed range.Always observe the operating conditions specified by Sultex AG.

2.1.3 Liability

The installation, operating and adjustment instructions contain the information required for instructing the user in the correct use of the machine.Despite this, some risks are involved when operating the ma-chine. The safety instructions and warning symbols in these op-erating instructions are intended to help you protect yourself against these risks.Sultex AG, CH-8630 Rüti does not accept any liability for mal-functions, damage or accidents caused by ignoring the safety and warning notices in these operating instructions or by failure to observe them. This also applies to any modifications and var-iations carried out and/or any installation of unauthorised acces-sories.

E-30.01.2008 2.1-33


In particular, Sultex rejects any liability for damage arising from the following situations:• Natural disasters• Incorrect operation• Failure to carry out maintenance• Unauthorised work and repairs• Dust and fluff in the control cabinet• Dust and fluff on ventilators and motors• Damage to electronic components caused by condensation or

by contact with conductive external elements

2.1.4 Alterations to the machine

Always inform Sultex AG if you make any alterations to the me-chanical or electrical systems of the weaving machine.Sultex AG will deny any liability for damage resulting from fitting any other than original Sulzer Textil components. The use of any components other than original spare parts will also invalidate the warranty.

2.1.5 Damage to the machine

In the event of damage to the machine, provide a detailed ac-count of how the damage occurred (with photographs and draw-ings).Notify Sultex AG, CH-8630 Rüti, immediately of any damage. The report must contain the following information:• Detailed description of the damage with reference to the

weaving machine type and the relevant settings manuals and spare parts catalogues

• Checks carried out• Settings implemented and their effect• Serial number of the relevant weaving machine(s)

2.1.6 Obligations of the user

In addition to the regulations listed below, the person responsi-ble for the weaving machine must observe the applicable statu-

2.1-34 E-30.01.2008


tory regulations with regard to the health and safety of personnel in the workplace.

2.1.6.1 Operating instructions

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

2.1.6.2 Personnel

Employ only trained personnel on the weaving machine; these personnel must have read and understood these operating in-structions, at least the chapter Safety rules and the information relating to their particular job.Keep personnel continuously informed about safety rules and measures and make sure these are complied with.Ensure that personnel are familiar with the location and function of all the safety equipment on the machine.Make sufficient personnel protective equipment available to per-sonnel. Protective equipment includes:• Hearing protection• Work wear• Safety shoes and gloves• Safety goggles• Hairnet

2.1.6.3 Competencies and responsibilities

Clearly define areas of responsibility and specify who has overall responsibility, especially when several people are working on the machine at the same time.Specify which employees are authorised to open the control cab-inet. The key may be entrusted to these persons only.

2.1.6.4 Access to weaveroom, visitors

Keep unauthorised persons away from the weaveroom.Inform visitors about safety behaviour. If necessary, make per-sonal safety equipment also available to visitors.

E-30.01.2008 2.1-35


2.1.7 Additional directives and standards

Please also observe the regulations and standards currently in force in your country, e.g.:• Legislation, directives and standards• Trade union regulations• Installation and maintenance regulations

2.1-36 E-30.01.2008

2.2 General safety instructions


2.2.1 Safety-conscious working

2.2.1.1 Protective equipment

Always wear personal protective equipment:• Hearing protection• Work wear• Safety gloves and shoes• Safety goggles• Hairnet, etc.Take the necessary additional precautions if you are working with materials, such as asbestos, which are injurious to the health.Always wear enclosed safety goggles during all work involving risk to the eyes.

2.2.1.2 Working with harmful materials

The following materials can cause irritation to the skin and eyes:• Lubricants• Colors• Adhesives and sealing materials• Cleaning agents and solventsComply with the maker's instructions when handling these mate-rials.When working with these materials, wear gloves and enclosed safety goggles.If the materials come into contact with the skin or eyes, rinse off immediately with water. If necessary seek urgent medical ad-vice.When working with cleaning agents and solvents, make sure that the room is adequately ventilated.

E-30.01.2008 2.2-37


2.2.1.3 Hair and clothing

Do not wear:• Loose items of clothing• Long sleeves with buttons• Open-heeled footwear• Overalls that button at the front (exception: concealed press

studs)• Hair loose

2.2.1.4 Before starting the machine

Starting the machine must not endanger persons, the machine or material.All safety equipment must be operational. All protective covers must be intact and in the protection position.

2.2.1.5 Button operation/starting the machine

When pushing buttons never touch the machine with your bare hand.Never operate control buttons before ensuring that there is no danger to persons, machine or material.Never rest your fingers on the control buttons.Never reach into the working area of the machine after pressing a control button.

2.2.1.6 While the weaving machine is running

Never touch moving machine parts.Never lift or remove protective covers.Never remove yarn remnants/fibre fly.Never touch the fabric or move your hands close to rotating com-ponents.

2.2.1.7 Scissors and tools

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

2.2-38 E-30.01.2008


Never carry scissors and tools in open breast pockets.Never place tools on the machine.

2.2.2 Working on the machine

Caution!Before starting maintenance work, mechanical adjustments, re-pairs, etc.:S make sure that the [main switch] is in the OFF position and

secure against switching on with the personal padlock.S Only the person who fits the personal padlock can remove it.

Danger!Moving parts.When the weaving machine stops, certain parts of the main drive (flywheel, belt pulleys) are not stopped immediately. Moving parts can cause crushing injuries.S Wait at least 5 minutes before removing the protective covers.

2.2.3 Working on the electrical equipment

Work on the electrical equipment may only be carried out by skilled personnel (electricians).When working on the electrical equipment, a second person must be present who is responsible for the safety of the first. The second person must know what to do in the event of electrical accidents.

Caution!Like terminals L1, L2 and L3 of the main switch, the supply ca-bles of the main line are permanently live.

E-30.01.2008 2.2-39


Fig. 2.2-1

The main switch area can only be accessed by removing the covering plate screwed on.Take particular care when working with live equipment, e.g. functional checks and trouble shooting.Work only with properly maintained measuring probes and in-struments.

2.2.3.1 Before working on the electrical equipment

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

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

connecting any of the electrical connections in the cabinet, observe the stipulated delay of 5 minutes.

2.2-40 E-30.01.2008


2.2.4 Working with the stroboscope

Wear safety goggles (dark sunglasses).Never look straight at the flash.Protect other people from the flashes (e.g. by putting up screens).

Caution!The stroboscope shows still images of moving objects.S Never reach into the weaving machine while it is running!

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

2.2.5 Working with compressed air

Never use compressed air to clean the skin or items of clothing.Never direct compressed air towards other people.

For Switzerland: maximum admissible blowing pressure = 3.5 bar.

2.2.6 Working on the pneumatic system

If work on the pneumatic system of the machine is required, the air must be completely discharged from the system.

E-30.01.2008 2.2-41


Fig. 2.2-2

> Close inlet valve 1 at the NTC (New Time Controller) ahead of the inlet to the machine.

> Open valve 2 on the lower part of the air filter.The pneumatic system will be completely emptied of air.

2.2.7 Noise hazards

The noise level in a weaveroom under normal industrial condi-tions is in excess of 85 dB(A) and can therefore cause perma-nent damage to your health.Always wear your pesonal hearing protection when the weaving machine is running.

11

2

1

2.2-42 E-30.01.2008

2.3 Hazard symbols and warning notices


For your own safety, you are urgently advised to take note of the hazard symbols and warning notices in these operating instruc-tions. We also draw your attention to the safety rules prevailing in your own country.The hazard symbols are always used in conjunction with a warn-ing notice. The extent of the hazard is indicated by one of the three key words Danger, Warning or Caution. As far as these operating instructions are concerned, these key words can be in-terpreted as follows:

2.3.1 Danger notices

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

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

loads or anywhere near the danger zone.

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

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

Caution Low risk.Denotes a dangerous situation that can result in damage to material or the product if the safety in-structions are not obeyed.

E-30.01.2008 2.3-43


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

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

es.

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

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

cured and transported slowly and carefully.

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

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

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

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

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

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

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

2.3-44 E-30.01.2008


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

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

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

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

ently.

2.3.2 Warning notices

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

removing the cover.

E-30.01.2008 2.3-45


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

ment or by calling for the assistance of several people.

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

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

es.

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

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

with hot parts.

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

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

2.3-46 E-30.01.2008


Warning!Noise!Excessive noise can cause hearing loss and damage your health.S Wear personal hearing protection.

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

pose of according to environmental regulations.

2.3.3 Caution notices

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

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

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

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

ance).

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

E-30.01.2008 2.3-47


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

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

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

switch and wait 5 minutes.

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

nents.

2.3-48 E-30.01.2008

2.4 Safety equipment


2.4.1 Stickers, signs and notices

This denotes: High voltage - danger of death.

2.4.2 Safety equipment

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

2.4.2.1 EMERGENCY STOP switch

Pressing the [EMERGENCY STOP] switch turns off all the weaving machine drives and disconnects the sub-units from the power supply.

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

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

i Never cover, remove or deface any stickers, signs or notic-es, etc. on the weaving machine.Any temporary signs may only be removed by the person who put them there in the first place.The following sign will be found on the weaving machine switch boxes.

E-30.01.2008 2.4-49


> To reset the [EMERGENCY STOP] button, turn it in a clock-wise direction.

To make the machine ready for operation again

> insert a pick at creep speed;

> press pick-finding and creep speed buttons at same time.Weaving machine executes a pick-finding operation and is ready to start.

2.4.2.2 Safety switch

Safety switch (on control cabinet) has same function as the EMERGENCY STOP buttons. When pressed, the power section of the electrical installation is inactive; however, the weaving ma-chine terminal remains switched on to permit mechanical and/or electrical work/settings to be carried out.

> Unlock[safety switch] using the appropriate key.

2.4.2.3 Main switch ON

> [Turn] main switch to "l" position.Weaving machine is live; machine brake is activated.

2.4-50 E-30.01.2008


2.4.2.4 Main switch “OFF” / “OFF” and secured

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

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

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

removing the cover.

> [Turn] main switch to "0" position.The weaving machine is now disconnected from the mains.

> Turn [main switch] to position 0 and lock with your personal padlock.Weaving machine disconnected from mains voltage and se-cured to prevent it being switched on again.

E-30.01.2008 2.4-51


2.4.2.5 Holding brake

The holding brake 1 has the task of keeping the weaving ma-chine in the same position when it is stopped.Holding brake is activated:• immediately after weaving machine is disconnected from the

mains voltage;• 3 seconds after weaving machine stop

Fig. 2.4-1

1 Holding brake - layout without jacquard machine

1

2.4-52 E-30.01.2008


2.4.3 Light curtain

To provide protection against the risk of crushing between mov-able (sley) and static components (machine frame, temples, etc.), weaving machines are equipped with the light curtain safe-ty device *. This prevents hazard areas from being accessed during various operations such as weaving in normal operation, for example, or at creep speed, in phase compensation etc..

(*) only weaving machines with the CE mark.

Fig. 2.4-2

Caution!This safety device only prevents start-up of the weaving ma-chine if the light beam is interrupted. When the weaving machi-ne is running the light curtain is inactive!S Never reach into the weaving machine while it is running!S Keep a safe distance from the weaving machine when it is in

operation.

E-30.01.2008 2.4-53


If the light barrier is interrupted, all weaving machine functions are blocked; the lamp 14 flashes.The weaving machine can be restored to normal mode again by pressing the two pick finding buttons simultaneously.

UM, 3.1.3.4

2.4.4 Cabinet doors and covers

2.4.4.1 Function

Cabinet doors and covers prevent contact with moving parts while the weaving machine is running and prevent contact with live components, even when the machine has stopped.Cabinet doors also act as dust covers for internal components. Some covers are deliberately used to collect controlled amounts of dust.Cabinet doors and covers also help reduce noise levels.

Caution!The following procedure must be followed before any cabinet doors are opened or covers removed:S Stop the weaving machine.S Turn [main switch] to position 0 and lock with your personal

padlock.S Wait at least 5 minutes.

2.4.4.2 Weaving machine in operation

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

2.4.4.3 Weaving machine stopped

Even when a weaving machine is not in use, the cabinet doors must remain closed to prevent soiling of internal components.

2.4-54 E-30.01.2008


2.4.4.4 Checks, repairs, settings

When carrying out checks or repair work, or when in setting mode, it may be necessary to start up the weaving machine with some barriers/cabinet doors open or casings/covers removed. This may only be done by specialist personnel under strict observance of the safety rules!Before recommissioning the machine, all barriers/cabinet doors must be closed and the casings/covers correctly refitted.

E-30.01.2008 2.4-55


2.4-56 E-30.01.2008

2.5 Fire regulations


Caution!S When installing the compressed air supply, position the shut-

off valve outside the machine so that it is safely accessible even if a fire should break out at the machine.

S Take the installation of suitable fire-fighting equipment into ac-count in the layout of the weaveroom.

If a fire breaks out at the machine, take the following precautions immediately:

> Turn [main switch] to "0" position.The weaving machine is now disconnected from the mains;

> Interrupt compressed air supply;

> Try to extinguish the fire as quickly as possible using suita-ble fire-fighting equipment;

> Tell other people to get assistance.

E-30.01.2008 2.5-57


2.5-58 E-30.01.2008

Main chapter

3 Buildings / Air conditioning / Workplace

E-30.01.2008

E-30.01.2008

3.1 Design of load-bearing structures


3.1.1 Notes for the user

These notes should be viewed as recommendations and have been compiled by Sultex AG to the best of its knowledge using experience gained in the field. Sultex AG reserves the right to add to or modify these notes without notice.Sultex AG is under no liability to the users of these notes, who shall not be entitled to present any claims, particularly warranty claims, against Sultex AG.

Sultex AG draws the attention of the users of these notes to the fact that users are obliged to take account of and ob-serve the relevant local and national building regulations.

3.1.2 Floor slab design

The design of floor slabs for weaving machines can only be dis-cussed in very general terms. Differing subsoil conditions require that the composition of each course be adapted as necessary.

3.1.2.1 Subsoil

In the case of subsoil 7, a modulus of deformation Ev2 of at least 30 MN/m2 should be present and be distributed as evenly as possible over the whole area.If this value cannot be attained, subsoil 7 will have to be im-proved by consolidation or replacement.

3.1.2.2 Drainage

Any existing groundwater or penetrating seepage water must be collected and carried off.To prevent mixing of subsoil 7 and bearing course material 5, a

i If requested, Sultex AG will be pleased to present its own proposals and provide consultancy services.

E-30.01.2008 3.1-61


woven filter medium 6 can be installed, especially if the subsoil is coherent or very fine-grained.

3.1.2.3 Bearing course

The modulus of deformation Ev2 must be at least 80 MN/m2 across the bearing course 5. A gravel course made up of a grav-el/sand mix with a grading of 0/32 (which could also be used, for instance, as a concrete admixture) and a depth, depending on geological and hydrological factors, of between approx. 200 and 400 mm, is normal.The course should be evenly compressed when damp using a roller or heavy plate vibrators (vibratory power at least 20 kN).

Fig. 3.1-1

3.1.2.4 Separation course

Plastic foil 4 at least 0.3 mm thick to prevent the penetration of bearing course material into the freshly laid concrete and to re-duce the capillary action from the bearing course 5 into the con-crete slab3.

3.1-62 E-30.01.2008


3.1.2.5 Concrete slab

Concrete: quality C 30/37 in accordance with Eurocode 2 (ENV 1992)Reinforcement and slab thickness:concrete slab3 reinforced diagonally on top and bottom to a thickness of at least 250 mm.

3.1.2.6 Floor covering and underlay

3.1.4 Floor covering and underlay

3.1.2.7 Joints

Fig. 3.1-2

Floor or ceiling tiles subjected to dynamic loads are to be sepa-rated from components such as walls, pillars, foundations, etc. using running joints (expansion joints). This also applies to ad-joining buildings.Depending on machine locations or the layout of floor conduits, the construction joints 8 (compression joints) are to be inserted in the floor slabs at intervals of 10 to 15 m. To ensure even weight distribution, thrust pins 9 are to be fitted to the joints.

E-30.01.2008 3.1-63


To prevent damage resulting from wheels and rollers, a jointing profile 10 can be inserted.

3.1.3 Design of ceiling tiles

3.1.3.1 Load-bearing capacity

A ceiling that is to carry Sulzer Textil weaving machines must, in the case of conventional machines, be able to support an im-posed load of 12 kN/m2.The recommended imposed load takes the static loading, in oth-er words the weight of the machines, and their dynamic loading into account.It should be made of a reinforced concrete slab (C30/37). In the case of dynamic loads, rigid, monolithic load-bearing structures are always preferable (continuous load-bearing slab systems). Cast-in-place concrete is therefore the most suitable choice.

3.1.3.2 Natural frequency of load-bearing structure

Weaving machines generate dynamic forces whose maximum frequencies can be a factor of one to six of the machine speed. If the natural frequency of the load-bearing structure corre-sponds to one of these excitation frequencies, resonance vibra-tions will start to affect the structure. Should this occur, the dynamic loading of the load-bearing structure will increase very rapidly and reach dangerous levels.To minimize these effects, the structure should be designed as rigidly as possible to ensure that the lowest natural frequency ex-hibited by the ceiling in a vertical direction is at least 30 Hz.

i More detailed information about the positioning of weaving machines is required in situations where load-bearing ca-pacity is lower. Specialist advice must be sought in such cases.

i More detailed information about the positioning of weaving machines is required in situations where the natural fre-quency of the structure is insufficient. Specialist advice must be sought in such cases.

3.1-64 E-30.01.2008


3.1.3.3 Design considerations

To ensure the required features are present, the following points should be considered in the design of the load-bearing structure:• Spans should be as short as possible (i.e. small column spac-

ing).• The load-bearing cross-sections must have high moments of

inertia.• Rigid, monolithic load-bearing structures are preferable (con-

tinuous load-bearing slab systems). Cast-in-place concrete is therefore the most suitable choice.

• Horizontal forces should be directed into the subsoil by brac-ing elements.

3.1.4 Floor covering and underlay

3.1.4.1 Requirements

The floor covering 1 should have the following properties:• non-aggressive with respect to metals• resistant to chemicals (oils, petrol, normal acids and alkalis)• highly abrasion resistant• high compression strength• non-slip and preferably warm underfoot• tough, not ceramic

i The bond between the floor covering 1 and underlay 2 and the concrete slab must be sufficiently strong and able to re-sist lateral forces.

E-30.01.2008 3.1-65


3.1.4.2 Floor evenness

The floor should be as even as possible to permit the unhindered operation of warp and cloth transportation vehicles.

Angular tolerance:Gauge limit <30 mm for nominal dimensions of more than 30 m (DIN 18202)

Unevenness tolerance:Limit <4 mm/m and <10 mm at a distance of 4 m (DIN 18202)

3.1.4.3 Suitable floor coverings

There are many products on the market whose suitability should be examined on a case by case basis. Some suitable floor cov-erings for weaving mills are listed below:• Solid concrete

High compression strength and abrasion resistance, resistant to chemicals, cold underfoot.

• Synthetic resin coverings(epoxy, polyester, polyurethane or polyacrylic resins)High compression strength and abrasion resistance, resistant to chemicals (depending on bonding agent), moderately warm underfoot, special requirements placed on underlay in respect of dryness and temperature.

3.1.5 Vibration reduction

The typical changing motion of the weaving machine creates a certain vibration range that is transferred to the structure via the machine's feet. The characteristics of this range depend on var-ious factors (speed, weave, style, etc.)

3.1-66 E-30.01.2008


3.1.5.1 Vibration-reducing bearings

One way of reducing vibration is to attach vibration-reducing bearings between the floor and the weaving machine. Please contact Sultex AG for further details.

3.1.5.2 Floating floors

In the case of new buildings or major conversions, we recom-mend the installation of "floating" floors (i.e. floors that have no direct contact with other building elements such as foundations or walls, but instead have an intermediate layer of insulation ma-terial).Dividing up the entire surface into various areas in the same way will also prove beneficial.Please contact Sultex AG for further details.

Fig. 3.1-3

a = 550 mmb = 400 mmc = 120 mm15 Vibration reducer16 Reinforced concrete17 Reinforced concrete tray

E-30.01.2008 3.1-67


3.1.6 Building construction and quality control

3.1.6.1 Building construction

The minimum requirements in respect of building construction are to be laid down in accordance with Eurocode 2 (ENV 1992).

3.1.6.2 Quality control

The Eurocode 2 (ENV 1992) requirements in respect of quality control in the planning and execution are to be observed.

3.1.6.3 Emission reduction

The dynamic forces generated by weaving machines and direct-ed into the ground can, under certain circumstances, cause vi-bration or other problems in and around weaving mills. In particular, structure-borne sound in the weaveroom building or adjoining rooms, floor and ceiling vibrations and emissions into the neighborhood can result.

3.1.7 Preparing the floor

The weaving machine transfers a static weight onto the floor be-cause of the weight of the machine, together with a dynamic load resulting from the movement of the machine during operation.The illustration shows the static and dynamic loads for each of the four fulcra on the side frame.

i If there is a suspicion of emissions in the weaveroom build-ing or the immediate vicinity, the appropriate specialist ad-vice must be sought without delay.

3.1-68 E-30.01.2008


Fig. 3.1-4

The measurement of these forces in relation to the nominal width of the weaving machine and its speed can be seen in the follow-ing tables.

Tab. 3.1-1

Nominal width [cm]Static loading of the supporting feet [kN]

P1 P2 P3 P4 P total

170 9,3 9,3 9,2 9,2 37

190 9,55 9,55 9,45 9,45 38

210 9,8 9,8 9,7 9,7 39

220 9,95 9,95 9,8 9,8 39,5

230 10,1 10,1 9,9 9,9 40

260 10,35 10,35 10,15 10,15 41

280 10,65 10,65 10,35 10,35 42

300 10,9 10,9 10,6 10,6 43

320 11,2 11,2 10,8 10,8 44

340 11,5 11,5 11 11 45

360 11,7 11,7 11,3 11,3 46

380 12 12 11,5 11,5 47

400 12,3 12,3 11,7 11,7 48

E-30.01.2008 3.1-69


Tab. 3.1-2

Explanations• V = weaving machine speed• The maximum load that each supporting foot transfers to the

ground is the sum of the corresponding static and dynamic loads, i.e. P1+F, P2+F, P3+F and P4+F

• All values are guide values only, and can vary depending on the shedding unit and the various devices used.

• The weight of the warp beam and yarn are not taken into con-sideration in the calculations. These weights must be added on and calculated as an even loading of the rear supporting foot.

• The values for the dynamic load of the frame (F1L) do not de-pend on the warp end, but on the type of weave. The force generated by a frame moving upwards is compensated by a lowering frame.

Nominal width [cm]

Max. horizontal loading due to the momentum of the sleyFC [kN]

Max. vertical loading of each sup-porting foot due to the momentum of the sleyF [kN]

Max. dynamic load on a frameF1L [kN]

with dobby/cam motion

with Jacquard machine

with dobby/cam motion

with Jacquard machine

170 8.4 x V2/106 10.3 x V2/106 7.7 x V2/106 9.7 x V2/106

1,5

190 9.5 x V2/106 11.8 x V2/106 8.7 x V2/106 10.9 x V2/106

210 10.8 x V2/106 13.4 x V2/106 9.8 x V2/106 12.1 x V2/106

220 11.4 x V2/106 14.1 x V2/106 10.2 x V2/106 12.9 x V2/106

230 12.0 x V2/106 14.8 x V2/106 10.8 x V2/106 13.4 x V2/106

260 17.1 x V2/106 26.2 x V2/106 15.2 x V2/106 23.3 x V2/106

3,0

280 18.6 x V2/106 28.5 x V2/106 16.8 x V2/106 25.2 x V2/106

300 20.1 x V2/106 30.9 x V2/106 17.7 x V2/106 27.2 x V2/106

320 21.4 x V2/106 32.9 x V2/106 18.8 x V2/106 28.9 x V2/106

340 23.0 x V2/106 35.3 x V2/106 20.1 x V2/106 30.8 x V2/106

360 24.5 x V2/106 37.6 x V2/106 21.3 x V2/106 32.7 x V2/106

380 25.9 x V2/106 40.0 x V2/106 22.4 x V2/106 34.7 x V2/106

400 27.4 x V2/106 42.2 x V2/106 23.5 x V2/106 36.6 x V2/106

3.1-70 E-30.01.2008


Example:Weaving machine nominal width 190 cm, with dobby at a speed of 900 rpmFC = 9.5 x 9002/106 = 7.695 kNF = 8.7 x 9002/106 = 7.047 kNMaximum load of support foot 1 is thereforeP max = P1 + F = 9.55 + 7.047 = 16.597 kN

E-30.01.2008 3.1-71


3.1-72 E-30.01.2008

3.2 Noise emission

3.2 Noise emission

In normal industrial conditions the rating level in a weaveroom exceeds 85 dB(A).

Warning!Noise.Excessive noise can cause hearing loss and damage your health.S Wear personal hearing protection.

3.2.1 Explanation of amounts

• Sound emissionThe total amount of sound radiated from a sound source in all directions.

• Sound emissionThe total incidence of noise at a particular point. This can em-anate from one or more sources and be affected by reflection from the room surroundings (walls, ceilings and floors) and scattering from articles located in the weaveroom. The sound pressure level at the workplace is an example of sound emis-sion.

• Sound powerThe total amount of acoustic energy per time unit radiated in all directions is defined as sound power (in watts).

• Sound pressureThe alternating pressure varying with locality and time and which is superimposed on the atmospheric pressure is de-fined as sound pressure (in Pascal).

• Equivalent sound pressure level (LAeq)This is the index of sound that can be perceived by the human ear. It varies depending on how far the measuring point is from the source of the noise.

• Sound power level (Lwa)This is a characteristic parameter of the machine in a given operating situation. This value can be used to calculate the noise level in the room in which the machine is installed (if the acoustic properties are known).

• A-evaluation (dB)

E-30.01.2008 3.2-73

3.2 Noise emission

The decibel is the (dimensionless) unit normally used to de-note a noise level.Since the human ear reacts to various frequencies with vary-ing sensitivity, the evaluation curves (A, B, C) have been har-monized so that a different weight is allocated to the varying frequencies of the corresponding noise level.European Directive 98/37/EC prescribes response curve A, which is why the values are shown in dB (A).

• Peak noise level (Lpc)This is the maximum momentary peak noise level.European Directive 98/37/EC requires the value to be in the C category only in cases where it is higher than 135 dB.

• TolerancesA characteristic of weaving machines is that they are config-ured from a basic machine with a wide array of equipment op-tions. Some of these equipment variants have a perceptible effect on noise emission.In addition, there are product and material variants, the effects of which are known only to a certain extent. Thus it is not pos-sible to infer from the noise emission of one operating state a general noise behavior for other operating states.The number of noise measurements carried out by Sultex AG, as well as an investigation into the operating parameters rel-evant for sound emission, enable us to quote calculated mean values of noise emission for various operating states. Our ex-perience shows that all equipment and product variants are in-cluded with a tolerance of ± 4 dB(A).

3.2.2 Noise level measurements

Several machines with different technical characteristics and producing various styles were investigated as part of the noise level measurements.To do this, two typical measurements (as per ISO standards 3746) and a graphic representation are reproduced and used to provide a quick extrapolation of the average noise level on a weaving machine with various characteristics.Graphical representations are approximate, because the sound pressure level is heavily influenced by many different factors, such as the structural properties of the weaveroom, the location of the machines, etc.Please contact Sultex AG if you have any special requirements.

3.2-74 E-30.01.2008

3.2 Noise emission

Tab. 3.2-1

Fig. 3.2-1

Diagram

A B

Model L5500 L5500

Width [cm] 190 190

Shedding unit "Stäubli" dobby Cam motion

Type Dress material Downproof fabric

Number of frames 10 4

Warp endPolyester Micrell dtex 83 – 41.8 ends/cm

Combed cotton Ne 40/1 - 48 ends/cm

Weft yarnPolyester Micrell dtex 83 – 41.8 ends/cm

Combed cotton Ne 40/1 - 413,3 ends/cm

Weave Patterned Plain

Speed [rpm] 725 920

Sound pressure level [dB (A)] Lp = 94, Lp = 93,

Sound power level [dB (A)] Lw = 112.8 Lw = 108.8

E-30.01.2008 3.2-75

3.2 Noise emission

3.2-76 E-30.01.2008

3.3 Lighting

3.3 Lighting

What is being strived for as far as lighting is concerned is not to produce as much light from as little energy as possible, but to achieve maximum levels of productivity, safety and comfort at work.

3.3.1 Planning the lighting

• First of all, conduct a thorough assessment of require-ments. Where possible, distinguish between basic require-ments and lighting required for special purposes.

• Good installations achieve a specific lighting output (pB) of 3 W/m2 and 100 lux.

• Use daylight wherever possible, assuming this does not in-volve high air conditioning costs as the result of direct sun-light.

• Control and regulation: Constant adjustment of the level of artificial lighting with respect to the available daylight helps save large amounts of energy and provides the most comfort-able environment for staff. Manual zone switching allows, for example, lighting close to the windows to be switched off or reduced independently of the rest of the room.

• Presence detectors: In storage areas, energy consumption can be dramatically reduced by the use of presence detectors.

• Reflective surfaces: Light surfaces in the room reduce the number of lighting units required and consequently energy consumption.

• Control gear: It is normally worthwhile installing low-loss or electronic control gear.

• Lamp selection: Consider acquisition and operating costs. Over time, lower annual energy bills will normally make up for higher acquisition costs.– Linear fluorescent lamps use about 80% less energy

than conventional incandescent lamps. In many cases, ex-pensive 3-band lamps are even more cost efficient.

– Halogen metal-vapor lamps and high-pressure sodi-um lamps are an excellent alternative to incandescent and halogen lamps in high halls where high lumens per unit are required (potential energy savings of 15 to 40% compared with mercury-vapor lamps).

E-30.01.2008 3.3-77

3.3 Lighting

– Incandescent and halogen lamps are very poor converters of energy.

– As far as luminous efficiency, color reproduction capability and general operation are concerned, mercury-vapor lamps are now obsolete.

• Light output ratio: Light output ratios above 80% (proportion of lumens per lamp discharged by the luminaire) are consid-ered "very high", whereas those below 50% are considered "low".

3.3.2 Installation

Linear fluorescent lamps should be installed directly above the weaving machine in the direction of the warp. Doing so helps re-duce shadowy areas, particularly when weaving darker fabrics.

3.3.3 Operation, optimization

• Lamps: When replacing lamps, consider converting to low-energy versions, e.g. use fluorescent lamps in place of the usual ones. Replace older fluorescent lamps (38 mm diame-ter) by the newer type (26 mm diameter) - potential saving of 5%.

• Luminaires: Fit reflectors, or more efficient reflectors.• Maintenance: Cleaning the luminaire every three months or

so can increase illuminance by 25 to 50%. If cleaned less fre-quently, it may not be possible to remove the deposits that build up.

• Replace: Replace any lamps that fail prematurely as they fail. In the case of modern lamps with almost identical times to fail-ure, replace the complete group when about 10% of the bulbs have gone (lower maintenance costs).

• Turn off: In infrequently used rooms and during non-produc-tive periods (e.g. weekends).

3.3-78 E-30.01.2008

3.3 Lighting

3.3.4 Recommended values

The lighting level in the workplace should remain constant. The table below shows the desired values at a height of 85 cm above the floor in the specified work areas:

Work area Light intensity [lux]Goods in, Dispatch 250

Stores 120

Spinning preparatory depart-ment

500

Spinning 750

Winding 500

Weaving preparatory depart-ment (area)

250

Warping 500

Sizing 500

Beaming 500

Drawing-in 750

Weaving (light fabrics) 500

Weaving (dark fabrics) 750

Weaving (colored fabrics) 750

Cloth inspection (room) 250

Cloth inspection 1000

Workshop 500

Office 750

E-30.01.2008 3.3-79

3.3 Lighting

3.3-80 E-30.01.2008

3.4 Air conditioning


3.4.1 Building and planning

3.4.1.1 Building planning

The following factors are particularly important: building orienta-tion, insulation, sun protection, the heat retention capability of the structure, the partitioning of zones with differing air condition-ing requirements and the line geometry (short, straight paths).It may be helpful to commission the services of a building sys-tems planner or energy consultant at an early stage. Any addi-tional costs will be more than compensated for by the subsequent savings.

3.4.1.2 Planning the ventilation system

The following aspects need to be considered at the planning stage:• a thorough assessment of requirements: identifying the

most important parameters dictating ventilation requirements, time aspects, controlling demand (adapting to special opera-tional requirements), economic aspects (investment and op-erating costs)

• the dimensioning: in-depth examination of heating and cool-ing requirements. Take internal heat sources (e.g. weaving machines!) into account. Avoid unnecessary contingencies.

• locally generated heat should be dissipated at source to pre-vent it affecting the climate in the room. Any waste heat should be utilized if possible.

• how to use any existing cool outside air.• a ground heat exchanger (preheating of outside air in winter,

cooling in summer) has a very high energy potential. The eco-nomic viability needs to be looked at in more detail, if need be using ground probes as well.

• a measuring concept, to allow an energy audit to be carried out during operation.

E-30.01.2008 3.4-81


3.4.1.3 Planning of the components

• Aim for an efficient airflow through low flow velocities and small pressure drops. At volume rates of flow of 4000 to 10000 m3/hr, the air velocity should not exceed 6 m/sec; at flow rates above 10000 m3/hr, it should not exceed 7 m/sec. In plants with a high degree of energetic efficiency and clean filters, the pressure drop at the maximum volume rate of flow will be no more than 0.09 bar.

• Fans must be efficient across their whole operating range. Above nominal air flows of 15000 m3/hr, highly efficient fans achieve an overall level of efficiency of 70% (incl. motor and drive). Select drives with a high level of efficiency; values will be in the range 30 to 90%. Bypass controls should be avoid-ed. Closed-loop speed control is the best solution. It should, however, be assessed across the entire operating range, es-pecially when under full load.

• Equip ventilating systems with a heat recovery facility.• Keep humidification of the air as low as possible.• Refrigeration: Adjust the cold water temperature according

to requirements and select as high a temperature as possible. Insulate coolant and cold water pipes to prevent heat loss.

3.4.2 Operational phase

• Select a temperature within the specified range that is as en-ergy efficient as possible (low for heating phase, high for cool-ing phase).

• In winter, only use the sun blinds to prevent glare and allow as much sunlight as possible to enter.

• In summer, operate the sun blinds in good time before the room temperature starts to rise. Try to retain as much natural light as possible.

• Regular maintenance should include the following:– Checking and if necessary replacing filters– Checking tension of the flat belt and V-belt– Cleaning components, including air vents– Cleaning sensors, checking setpoint values

• An energy audit may reveal a drop in efficiency somewhere.

3.4-82 E-30.01.2008


3.4.3 Requirements of the air conditioning plant

3.4.3.1 Air volumes

The air conditioning plant need not solely be designed around the number of times the air in the weaveroom is changed, but should also take account of the amount of heat that accumulates in the room and the required relative humidity.The following diagram shows the amounts of air necessary to maintain the required values at specific weaving machine power consumption levels.

Approx. Luftvolumen/Webmaschine

0

1000

2000

3000

4000

5000

6000

7000

8000

0 1 2 3 4 5 6 7 8 9 10

Gesamtaufnahmeleistung der Webmaschine [kW]

Luftv

olum

en c

a. [m

3/h]

75% r.F.70% r.F.65% r.F.60% r.F.55% r.F.

E-30.01.2008 3.4-83


3.4.4 Recommended values

A constant temperature and air humidity must prevail in the weaveroom to ensure ideal operating conditions. Ideal condi-tions will vary depending on the type of fiber and the sizing used on the yarn.

Fibers Rel. humidity [%] Temperature [°C]

Cotton 75 to 80

22 to 24

Silk 65 to 70

Wool 55 to 60

Man-made fibers

60 to 70Synthetic fibers

Pile/cotton

Pile/wool

Linen 80 to 85

3.4-84 E-30.01.2008

3.5 Vacuum cleaning

3.5 Vacuum cleaning

3.5.1 Planning the system

• Assessment of requirements: How the plant is going to be used should be clarified in as much detail as possible (vacu-um requirement parameters, time aspects, controlling de-mand, adapting to special operational requirements, economic aspects, investment and operating costs). Future requirements (upgrade options) should be estimated as real-istically as possible.

• Dimensioning: This should be based on the assessment of requirements. Avoid unnecessary contingencies. Overdimen-sioned systems run at lower than optimum speeds and are consequently unnecessarily expensive to purchase and oper-ate. Even in large weaving mills, it is highly unlikely that more than two people will want to use the vacuum system at the same time. In weaving mills with up to 60 weaving machines, only one vacuum station will normally be required at any given time.

• Type selection: Rotating piston blowers are more efficient than side channel compressors, particularly at underpres-sures of between 200 and 400 mbar, and are therefore more suitable for vacuum systems.

• Underpressure: Should only be high enough to guarantee the removal of wastage. Above this value, the energy con-sumption increases without making the system any more effi-cient.

• Control: The most important factor as far as control is con-cerned is the demand over time. Energy savings of around one third are possible if energy saving systems are used (e.g. employing multi-stage suction capacity). When not in use the vacuum system should be able to switch to standby mode. Some smaller vacuum units switch off automatically after a definable period of inactivity and can be switched on again re-motely when required.

E-30.01.2008 3.5-85

3.5 Vacuum cleaning

3.5.2 Operational phase

• Control: Checking the settings periodically ensures optimum operation of the system from an energy point of view and al-lows adjustments to be made as and when required.

• Maintenance: Regular servicing of the blower and the drive motor ensures the vacuum system remains energy efficient.

• Cleaning: Contaminated filters mean loss of energy. The fil-ters should be emptied from time to time. If large amounts of wastage are anticipated, an automatic filter emptying or cleaning facility should be provided.

3.5-86 E-30.01.2008

Main chapter

4 Transport / Commissioning

E-30.01.2008

E-30.01.2008

4.1 Incoterms

4.1 Incoterms

(International Commercial Terms)

4.1.1 Definition

Incoterms are a set of international regulations governing the transfer of risk and cost billing in the export business. In the In-coterms, the transfer of risk is linked to the price risk (also known as the remuneration risk). This means that the buyer undertakes to pay the agreed price as soon as the risk passes to him, even if the goods are subsequently lost or decrease in value.

The Incoterms are only valid when expressly agreed be-tween seller and buyer.

During contract negotiations, buyer and seller can be certain that their obligations are clearly and simply defined by the inclusion of an Incoterms clause. This can help prevent misunderstand-ings and consequent disputes.

4.1.2 ICC - International Chamber of Commerce

The International Chamber of Commerce (ICC) in Paris is the or-ganization that regulates commercial activities across the world. Its members include tens of thousands of companies and com-mercial organisations in 110 countries. National groups in 59 countries coordinate activities at the national level.The ICC is the body responsible for the Incoterms. Publication no. 460 - ISBN 92-842-0087-3The best known publications of the ICC are:• No. 322 - Uniform Rules for Collections • No. 500 - Uniform Rules and Practices for Documentary Cred-

its (1993 Revision)

4.1.3 Standard ICC arbitration clause

All disputes arising out of or in connection with the present con-tract shall be finally settled under the Rules of Arbitration of the

E-30.01.2008 4.1-89

4.1 Incoterms

International Chamber of Commerce by one or more arbitrators appointed in accordance with the said Rules.

4.1.4 Incoterms in practice

When used as terms of sale, the Incoterms address four main points:

In addition, article 9 of the 1980 UN treaty governing inter-national trade contracts and the Vienna convention also ap-ply.

4.1.5 Incoterms 2000

Delivery Specifies where and at what time the seller is obliged to deliver the goods.

Documents Who has to provide which documents or cor-responding electronic notification.

Risks Who bears the risk for loss or damage to the goods (transfer of risk).

Costs Who pays for what (transfer of costs).

EXW/FCA The buyer decides when and under what con-ditions he will accept the goods and when he passes the bank documents to the seller.

FOB The buyer determines when the goods will be shipped/loaded and therefore has a direct in-fluence on the payment of the goods.

CFR/CPT The risk transfers to the buyer as of FOB.The seller determines which mode of transport to use (which ship or truck) and the conditions under which transportation takes place.

4.1-90 E-30.01.2008

4.1 Incoterms

CIF The risk transfers to the buyer as of FOB.The seller determines the mode of transport and the conditions under which transportation takes place. Also, the seller bears the cost of transport insurance.

E-30.01.2008 4.1-91

4.1 Incoterms

4.1-92 E-30.01.2008

4.2 Checklist

4.2 Checklist

Checklist prior to commissioning yourSulzer Textil weaving machine

Appendix to order acknowledgement No. ........................ dated: ........................

The service engineer will be able to commission your weaving machine if the following prepar-atory work has been completed before he arrives:

Building work in weaveroom complete

Weaveroom floor prepared and fit for traffic

Electrical connections available (check power consumption figures)

Air conditioning plant operational

Compressed air supply available (for air-jet weaving machines in accordance with spe-cial regulations)

Delivery of accessories from other suppliers ensured(weft feeder, jacquard frame, etc.)

Oil, lubricants and cleaning agents purchased

Transport and hoisting equipment acquired(transport frames available on loan from Sultex AG if required)

Style range defined

Weft, warp, leno selvedge and auxiliary selvedge yarns available

Workplace for engineer provided

Training of technical personnel complete/agreed with Sultex AG

Technical personnel, including electricians and ancillary staff, available to assist service engineer

Service engineers requested from other suppliers (e.g. for Jacquard)

We hereby confirm that all the above preparations are complete and request a Sultex AG serv-ice engineer

to attend our premises on: ............................................................................

Place, date: .........................

CUSTOMER

.............................................................(company stamp and signature)

E-30.01.2008 4.2-93

4.2 Checklist

4.2-94 E-30.01.2008

4.3 Work carried out by service engineer


Work carried out by the service engineer when commissioning your Sulzer Textil weaving machine.

Checking incoming goods for missing items or trans-port damage

* Positioning and alignment of the weaving machine

Carrying out an acceptance test and trial run

* Preparing the machine for the relevant style

* Positioning the warp

* Starting weaving

* Optimizing the settings

Recording of machine parameters while stationary if required

Personnel training during commissioning• for weaveroom foreman on Sultex AG course:

– Customer-specific machine configuration– Customer-specific style range– Maintenance– Safety equipment– Spare parts administration

• Weaving• Threading• Positioning the warp• Lubricating

* Resolving problems during commissioning

Handing over the prepared machine

* = Carried out by customer service personnel un-der instruction and supervision of the service technician.

E-30.01.2008 4.3-95


4.3.1 Sequence of operations for commissioning

4.3.1.1 Transport and installation

Tab. 4.3-1

Sequence Operation

1 Transport the weaving machine to the weaveroom

2 Position the weaving machine on the prepared area

3 Unpack weaving machine / remove transport bracing

4 Have weaving machine accessories to hand

5 Remove protective layer of oil from the entire weaving machine

6 Top up oil for shedding mechanism

7 Remove the cloth beam

8 Remove warp beam tube

9 Remove right-hand leno selvedge

10 Remove drop wire holder from the warp stop motion

11 Remove rod/spring for feeding through surplus threads

12 Move the rotating warp stop motion down a little

13 Unload the control cabinet and remove the retainers

14 Leveling the weaving machine

15 Connect power

16 Connect compressed air

17 Switch on motor (note direction of rotation)

18 Check oil levels

19 Turn weaving machine by hand and check that all sub-units can move freely.

20 Carry out synchronism check on the weaving machine (encoder)

21 Bring unoccupied weaving machine into service

4.3-96 E-30.01.2008


4.3.1.2 Mechanical adjustment

Tab. 4.3-2

Se-quenc

eOperation

1 Determine fabric width in the reed

2 Position cloth support

3 Position relay nozzles

4 Position temple holders

5 Position left-hand selvedge cutter

6 Position tandem and main nozzle

7 Adjust tandem and main nozzle

8 Position back rest roller

9 Check setting of back rest roller + 0 (zero point)

10 Check lever increments on the shedding mechanism

11 Adjust harness traction height (2nd and subsequent weaving ma-chines)

12 Remove side and central harness guides

13 Prepare cloth for knotting the threads between fabric nip roller and cloth beam

14 Insert heddle frames and warp beam

15 Connect heddle frames and shedding mechanism

16 Position and fasten reed

17 Position right-hand selvedge cutter

18 Position photocell units

19 Position stretching nozzle

20 Attach photocell cable

21 Position F.A.R. device

22 Position waste bin

23 Position right-hand leno selvedge and adjust phase

24 Position left-hand leno selvedge and adjust phase

E-30.01.2008 4.3-97


4.3.1.3 Pneumatic and weaving-related adjustments

Tab. 4.3-3

Se-quenc

eOperation

1 Knot threads on the cloth in bundles

2 Draw selvedge ends into leno selvedge

3 Fit and position temples

4 Assemble spool holders along with matching pre-measuring devic-es

5 Have drum feeder manual (adjustment instructions) to hand

6 Enter the data for the drum feeder on the weaving machine terminal

7 Adjust drum feeder

8 Put weft package onto package creel

9 Program weft insertion

10 Program EWC – ETD

11 Program color sequence on the weaving machine terminal

12 Program weave on the weaving machine terminal

13 Check blow pressure during thread-in and cutting

14 Check continuous blow pressure and output of the tandem and main nozzles

15 Check pressure on the side selvedge forming units

16 Check pressure on the relay nozzles

17 Weave at creep speed for approx. 3 to 4 cm

18 Draw in torn and surplus threads

19 Move drop wires into position (if necessary)

20 Feed drop wire holder of the warp stop motion into the drop wires

21 Adjust the warp stop motion

4.3-98 E-30.01.2008


4.3.1.4 Final adjustments and checks

Tab. 4.3-4

Se-quence Operation

1 Definitive commissioning of machine with style at minimum speed

2 Set and check pick count at the weaving machine terminal (Termi-nal Manual)

3 Set the shed closure

4 Adjust the weft brake (adjustment instructions)

5 Increase speed to nominal value

6 Check pressure on the relay nozzles

7 Check pressure on the stretching nozzle

8 Check start and arrival time of the thread at the weaving machine terminal

9 Set ABS functions

10 Adjust the tucking unit

11 Adjust F.A.R. device

12 Check weave quality

13 Proper functioning of the weaving machine – final check

14 Check that all screws have been tightened

15 Check all parts that are to be lubricated

16 Fill out adjustment form

E-30.01.2008 4.3-99


4.3-100 E-30.01.2008

4.4 Space requirements


4.4.1 Layout drawing

Fig. 4.4-1

These dimensions allow simple warp beams to pass through. If using a warp beam transport truck, its outer di-mensions must be taken into consideration.

> Mark out the front and side edges of the fabric side of the ma-chine on the floor in accordance with the layout drawing.

Nominal width [cm] A [mm]

< 230 2000

> 230 4000

Warp beam ø [mm] B [mm]

800 1200

1100 1400

E-30.01.2008 4.4-101


4.4.1.1 Positioning for the extending cleaning devices (example)

Fig. 4.4-2

4.4-102 E-30.01.2008


4.4.2 Dimensions

4.4.2.1 Weaving machine with cam/dobby

Tab. 4.4-1

The measurements marked (*) may vary depending on the type of weft feeder, number of heads and package size.

Nominal width [cm] A [mm]

B [mm]C * [mm] D [mm]EP11SL

D/EP11 Rat.28** Rat.XJ/QJ

170 2070

1100 1020 1085

4270

–

190 2270 4470

210 2470 4670

220 2570 4770

230 2670 4870

260 3090 5290 1270

280 3290 5490 1370

300 3490 5690 1470

320 3690 5890 1570

340 3890 6090 1670

360 4090 6290 1770

380 4290 6490 1870

400 4490 6690 1970

E-30.01.2008 4.4-103


• Warp beam ø 800 mm

Fig. 4.4-3

4.4-104 E-30.01.2008



Fig. 4.4-4

E-30.01.2008 4.4-105



Fig. 4.4-5

4.4-106 E-30.01.2008


4.4.2.2 Weaving machines with Jacquard device

Tab. 4.4-2

The measurements marked (*) may vary depending on the type of weft feeder, number of heads and package size.

Nominal width [cm] E [mm] F [mm] G *

[mm] H [mm] I [mm]

170 2070 2080 4270 1667 3055

190 2270 2280 4470 1767 3255

210 2470 2480 4670 1867

3455220 2570 2580 4770 1917

230 2670 2680 4870 1967

260 3090 3100 5290 2177 3655

280 3290 3300 5490 2277 3755

300 3490 3500 5690 23773855

320 3690 3700 5890 2477

340 3890 3900 6090 2577 3955

360 4090 4100 6290 2677 4055

380 4290 4300 6490 2777 4255

400 4490 4500 6690 2877 4455

E-30.01.2008 4.4-107



Fig. 4.4-6

l Ratio 20:38ll Ratio 19:20J 1408 to 1488 mm

4.4-108 E-30.01.2008


Weaving machine position 0°

Fig. 4.4-7

1 Lead wire with passage along the shaft of the first harness

E-30.01.2008 4.4-109



Fig. 4.4-8


4.4-110 E-30.01.2008



Fig. 4.4-9


E-30.01.2008 4.4-111



Fig. 4.4-10


4.4-112 E-30.01.2008



Fig. 4.4-11


4.4.2.3 Connecting the crossbars for machines with Jacquard device

Important!S Ensure that the return springs are at least 5 mm from the con-

necting plates on the crossbars.

E-30.01.2008 4.4-113


Fig. 4.4-12

Nominal width [cm] A [mm] B [mm] C [mm] D [mm]

190 2270 1164 - -

210 2470 1264 - -

230 2670 1364 - -

260 3090 1854 1154 -

280 3290 1954 1254 -

300 3490 2054 1354 -

320 3690 2024 1134 2614

340 3890 2124 1184 2764

360 4090 2224 1234 2914

380 4290 224 1284 3064

4.4-114 E-30.01.2008

4.5 Unloading/transportation


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

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

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

> Prepare a suitable unloading device; keep the machine weights in mind when doing this.

3.1.7 Preparing the floor

> Before unloading, ensure that the equipment and appliances required are in perfect working order.

E-30.01.2008 4.5-115


4.5.1 Using a forklift truck to unload the weaving machine

Two forklift trucks (l and ll): Imposed load > 7 t; minimum length of lifting fork 1.7 m

Hoisting rope 1: Breaking strength > 6 t; imposed load > 2 t

Fig. 4.5-1

> Hook one end of hoisting rope 1 onto forklift truck l and the other end onto console strut 2 (not onto machine parts).

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


es.

2 3

4

1

4.5-116 E-30.01.2008


Fig. 4.5-2

> Using the forklift truck l, carefully pull the weaving machine until it is protruding by a maximum of a quarter of its length out of the container.

> Drive the forklift truck l towards the timber beams 3.

> Adjust the length of the hoisting rope 1 accordingly.

> Using the forklift truck l, continue to pull the weaving machine carefully until the first marking 4 on the timber beam is visible.

> Position the forklift truck ll diagonally so that the fork prongs are immediately below the timber beams 3.

112 3

l

E-30.01.2008 4.5-117


Fig. 4.5-3

> Reverse the forklift truck l slowly until both markings 4 on the timber beams are level with the prongs on the forklift ll (or po-sitioned at equal distances from the left/right prong).The weaving machine is now balanced.

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



> Use the forklift truck ll to raise weaving machine a few centim-eters.

> Unhook hoisting rope 1 and reverse forklift truck l.

4 ll

l

4.5-118 E-30.01.2008


Fig. 4.5-4

> Drive goods truck forwards until the weaving machine has been completely removed from the container.

> Lower weaving machine to approx. 10 cm above the ground.

Provided that the conditions of the remaining traveling sur-face permit, the weaving machine can be transported fur-ther using the forklift truck (to the weaveroom, acclimatization room, etc).Otherwise the weaving machine must be set down on the ground so that it can be transported to its intended location later using a suitable means of transport.

E-30.01.2008 4.5-119


4.5.2 Using a crane to unload the weaving machine

M36 ring screws (4 pcs.)

Hoisting ropes (4pcs.): Load-bearing capacity 1.5 t; tearing load 7.5 t

Fig. 4.5-5

> Screw all ring screws 5 into the machine side frames until they can go in no further.

> Before lifting, check that the hooks on the hoisting rope have been hooked properly into the ring screws.




4.5-120 E-30.01.2008


Fig. 4.5-6

> Unload the weaving machine (follow strictly the instructions of the crane operator).

4.5.3 Moving the weaving machine

Mechanical winches with load-bearing capacity of approx. 5 t (4 pcs.)

Piece of iron piping 7 30x50x200 mm, 5 mm thick (supplied)

Piece of iron piping 8 30x30x200 mm, 5 mm thick (supplied)

Castored bogie with load-bearing capacity of >1.8 t (4 pcs.)

5

E-30.01.2008 4.5-121


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


es.

Fig. 4.5-7

> On the weaver side, insert the piece of iron piping 7 (left and right) as far as it will go into the location provided on the ma-chine side frame.

7

4.5-122 E-30.01.2008


Fig. 4.5-8

> On the warp side (left and right), place the piece of iron piping 8 under the screw 9 as shown.

> Keeping it level, lift the weaving machine until it is level with the castored bogie 10.

Fig. 4.5-9

> Place a castored bogie 10 under each foot of the machine.

> Lower the weaving machine evenly onto the castored bogie 10.

8 9

110010

10 10

E-30.01.2008 4.5-123


Danger!Slippage of the weaving machine on sloping surfaces.Uncontrolled slippage of the weaving machine is highly danger-ous and can cause fatal injuries.S Make sure there is no one in the danger zone on the sloping

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

cured and transported slowly and carefully.

> Move the weaving machine to its intended location.

4.5.4 Unloading the control cabinet

The weaving machine must stand flat on the floor

Suitable lifting device – load bearing capacity: > 500 kg

Fig. 4.5-10

> Undo screws 11.

1112

4.5-124 E-30.01.2008





> Lift the control cabinet.

> Remove the red holders 12.

> Lower control cabinet until it is flat on the floor.

The instructions for unloading the additional cabinet are the same as for the control cabinet.

E-30.01.2008 4.5-125


4.5-126 E-30.01.2008

4.6 Setting up the weaving machine


4.6.1 Positioning the weaving machine

4.6.1.1 Variant with warp beam ø<1000 mm

Mechanical winches with load-bearing capacity of approx. 5 t (4 pcs.)

> Align weaving machine according to the markings on the floor.

> Lift the weaving machine (keeping it level) with winches.

> Remove castored bogie.

Fig. 4.6-1

> Fasten iron plates 1 to the feet of the machine.

> Lay felt pads, Gripsol plates or rubber mats* 2 on the floor, un-der the iron plates 1.

> Keeping it level, lower the weaving machine until the feet are placed firmly on the padding/matting.

*) Instead of felt pads, self-leveling rubber mats can be used if required (e.g. because of floor properties). In this case, the rub-ber mats must first be soaked in water for 60 mins. Before use, the protective film must be removed from both sides.

1

2

E-30.01.2008 4.6-127


4.6.1.2 Variant with warp beam ø>1000 mm

The procedure is practically the same as for a weaving machine with a smaller warp beam diameter. The difference is that the feet of this weaving machine are fastened to a crossbar which in turn is screwed onto the iron plate 1.

Fig. 4.6-2

1 Iron plate2 Rubber mat3 Leveling plate

11 2

3

4.6-128 E-30.01.2008


4.6.2 Leveling the weaving machine

Caution!Damage caused by poor leveling.Poor leveling of the machine adversely affects running proper-ties. This will damage the machine and increase wear.S Level the machine according to the instructions (within toler-

ance).

Adjustable spirit level with 0.1 mm/m pitch

Mechanical winches (load-bearing capacity 5 t) – 2 pcs.

Minor unevenness in the floor can be compensated for us-ing the supplied plates (0.2/0.6/1.0/3.0 mm).Greater unevenness must be compensated for by dressing the floor or by manufacturing suitable plates.

> Make sure that all four feet are firmly on the floor.

> Clean the measuring surfaces on the weaving machine.

The higher machine wall is used as a reference for leveling pur-poses.

Fig. 4.6-3

3

E-30.01.2008 4.6-129


To Determine which is the higher machine wall.

> Place a spirit level 3 on one of the machined surfaces as shown.

> Place spirit level 3 on the machined surface of the higher ma-chine wall and adjust using screw until the air bubble is exactly centered.

Fig. 4.6-4

> Without adjusting, place spirit level 3 on the machined surface of the lower machine wall.

> Slacken screws 4 and lift the lower edge of the weaving ma-chine slightly.

> Place compensating plates 5 (supplied) as required under-neath (lengthways and across) the machine wall.The air bubble in the spirit level 3 is back in the middle again when placed lengthways and across.

> After it has been in operation for about 4 weeks, check that the machine is still level, and correct as necessary. An annual check will suffice thereafter.

If necessary,

> adjust the height of the central supports 6 (if present).

5

5

4

4

4.6-130 E-30.01.2008


Fig. 4.6-5

On weaving machines with a warp beam diameter of 1000 mm, the warp side is higher than the fabric side. Because of the tilt of the machine, the device 7 (scope of supply) must be used for leveling.

Fig. 4.6-6

6

7

E-30.01.2008 4.6-131


4.6-132 E-30.01.2008

4.7 Warranty claim

4.7 Warranty claim

Customer/plant: Customer no.:

WM type: WM no.: Module no.:

Style no.: Designation Series no.: Number No. of picks x106

Description of damage (as far as possible):

Suspected cause:

Actions taken:

State of adjacent components:

Please provide sketch overleaf and photos if possible.

State of weaving machine: stopped (waiting for parts) in production

Speed: rpm Efficiency:

Fabric style: Weave:

Warp (tex): Weft (tex):

Warp density: Weft density:

Warp tension: T-bar: mm °

Completed by: Date:

For Sultex SA internal use only

Charge code: Mode of transport:

Failure code: Mc order Nr.:

Parts to be delivered under reference No.:

Remark:

E-30.01.2008 4.7-133

4.7 Warranty claim

4.7-134 E-30.01.2008

Main chapter

5 Power supply / Installation

E-30.01.2008

E-30.01.2008

5.1 Electricity

5.1 Electricity

5.1.1 Electrical supply

5.1.1.1 Basic requirements

The controls comply with the following regulations:

The AC power supply must comply with the requirements of EN 60204-1.

5.1.1.2 General connected loadings

> Compare the electrical loadings for the weaving machines given in our order acknowledgement exactly with the values of your electrical installation (supply conditions and power de-mand).

EN 292-1, -2 Safety of machines(Basic terms, gen. arrangement of principles)

EN 60204-1 Safety of machines(Electrical equipment of machines)

EN ISO 11111 Safety requirements for textile machines

EN 50081-2 Electromagnetic compatibility(Basic specifications for interference emis-sions, Part 2)

EN 50082-2 Electromagnetic compatibility(Basic specifications for interference emis-sions, Part 2)

E-30.01.2008 5.1-137

5.1 Electricity

5.1.1.3 Types of power supply systems

The weaving machines can be connected to the following types of power supply systems:

Fig. 5.1-1

TN-C supply systemSupply with earth conductor but no neutral conductor

A Plant ownerS Sultex AG delivery1,2 Weaving machine

Fig. 5.1-2

TN-S supply systemSupply with earthed neutral conductor and additionalearth conductor

A Plant ownerS Sultex AG delivery1,2 Weaving machine

5.1-138 E-30.01.2008

5.1 Electricity

5.1.1.4 Frequency

The electrical equipment of the weaving machine is designed for connection to the following power supply frequencies:50 Hz or60 Hz

5.1.1.5 Voltage

The electrical equipment of the weaving machine is to be con-nected to power supply voltages in accordance with Chapter

5.3.1.4 Starter current

E-30.01.2008 5.1-139

5.1 Electricity

5.1.2 Fluctuations in voltage

5.1.2.1 Voltage

Continuous operating voltage: 0.9 to 1.1 times the nominal volt-age

5.1.2.2 Frequency

0.99 to 1.01 times the nominal frequency, continuous0.98 to 1.02 short periods only

5.1.2.3 Harmonic oscillation

The harmonic distortion for the sum of the 2nd up to the 5th har-monic must not exceed 10% of the total effective voltage be-tween the active conductors. In addition, 2% of the total effective voltage between the active conductors is permitted for the sum of the 6th up to the 30th harmonic.

5.1.2.4 Voltage asymmetry

With three phase AC power supplies neither the voltage of the negative phase-sequence system nor the voltage of zero phase-sequence system may exceed 2% of the positive phase-se-quence system.

5.1.2.5 Voltage interruptions

Interruptions of voltage or voltages of zero Volts may not occur for longer than 3 ms at any time during the period of supply. There must be a period of more than 1 s between interruptions following one after the other.

5.1.2.6 Voltage dips

Voltage dips must not exceed 20% of the peak supply voltage for more than one period. There must be a period of more than 1 s between voltage dips following one after the other.

5.1-140 E-30.01.2008

5.1 Electricity

5.1.3 Safety rules

The rules applicable to the installation location must be observed with regard to the electrical installation in the weaveroom and the connection to the weaving machine. A main switch with facility for locking with a padlock is integrated into the weaving machine. When the weaving machine has been connected to the electrical supply, only operate the main switch in the presence of the Sul-tex AG service technician after an acclimatization period of at least 24 hours.

5.1.1.1 Basic requirements

E-30.01.2008 5.1-141

5.1 Electricity

5.1-142 E-30.01.2008

5.2 Electrical characteristics


See the sign on the control cabinet for the electrical characteris-tics (mains voltage, frequency, etc.) of the weaving machine.

Fig. 5.2-1

Weaving machines with "HI DRIVE" can be connected directly to 380/400/415/440 V – 50/60 Hz mains supplies. For other voltag-es, an autotransformer must be installed between the supply mains and the machine. This autotransformer converts the ma-chine power supply to 400 V (as per 400 V sign on machine).

E-30.01.2008 5.2-143


5.2.1 Power requirement

Tab. 5.2-1

*) Nominal power

5.2.2 Power input

The power input and resulting energy consumption of the weav-ing machine depend on the following parameters:• Machine speed• Oil temperature• Lubricating unit• Weaving width• Shedding unit• Style typeThe details in the following tables are to be used as reference values only.

Shedding unit Main motor Apparent

power [kVA]Main trans-former [kVA]

Motor for warp let-off and cloth take-up [kVA]

Ext. devices [kVA]

Cam motionHI DRIVE 11.4

1.7 1.4 1.2

Dobby

Jacquard ma-chine

Asynchro-nous with in-verter

11.8(7.5 kW)*

Asynchro-nous with double speed

10.5(6.6 kW)*

5.2-144 E-30.01.2008


5.2.2.1 Basic machine

Tab. 5.2-2

On weaving machines with Jacquard equipment, the power input may vary by up to 2 kW from the values given, de-pending on the type.Moreover, the power input of a "cold" weaving machine is substantially higher.

5.2.2.2 Options

Tab. 5.2-3

Shedding unit Main motor

Power input

[kVA]

[kW]

Weaving ma-chine width 170 to 230 cm

Weaving ma-chine width 260 to 400 cm

Dobby HI DRIVE 15.7

3.5 to 5.5 4.5 to 7.0Jacquard ma-chine

Asynchronous with inverter 16.1

Asynchronous with double speed

14.8

Description Power input [kVA]

More powerful motors for warp let-off/cloth take-up + 0.9

Double warp let-offStandard motor + 0.3

Boosted motor + 0.4

Powered back-rest roller + 0.4

Suction devicestandard + 0.87

boosted + 1.35

Sealing device + 0.15

E-30.01.2008 5.2-145


5.2.3 Power factor

The power factor depends on the machine speed and the type of fabric.Only on weaving machines with a double-speed asynchronous motor does the power factor correspond to the phase shift angle. In other cases, the power factor is always lower than the phase shift angle. To calculate the short circuit currents, we therefore recommended that lower values (0.75 to 0.85) are used for the phase shift angle.In view of the frequent occurrence of harmonics in the current taken up by the converter on weaving machines with "HI DRIVE motors", we recommended a power factor of 0.67.The total harmonic distortion (THD) of the current taken up by the "HI DRIVE" machine is approx. 70-75%.

5.2-146 E-30.01.2008

5.3 Connection to the mains supply


5.3.1 Back-up fuse

Each weaving machine must be individually protected by fuses or a circuit breaker (set to trip at >12x nominal current).The back-up fuse is not supplied by Sultex AG.

It is not permissible to protect a group of weaving machines using only one fuse.

5.3.1.1 Mains filter

It is necessary to install a mains filter in order to achieve electro-magnetic compatibility in accordance with EN 50081-2 and EN 50082-2. This filter dissipates interference away via the earth connection (PE).

5.3.1.2 RCD Protection Devices

When installing RCD protection switches on the weaving ma-chine, note that mains filters can cause residual currents of up to 80 mA during operation.It is not possible to install an RCD protection device for the whole machine (EN 50178) if the weaving machine is fitted with a fre-quency converter. 1997, VDE 160).

E-30.01.2008 5.3-147


5.3.1.3 Protective devices

Please note the following when selecting protective devices:• A "cold" machine consumes significantly more power than

one which is "warm".Example (depending on style and shedding unit): – Weaving machine width 190 cm– Speed 900 rpm– Power consumption when "cold", approx. 23 to 25 A– Required automatic cut-out with nominal thermocurrent 32

A (possibly set to a lower value, e.g. 27 A)• It takes approx. 2 to 3 hours for the power consumption to

reach its nominal value• Due to the differential power consumption (influenced by the

mains filter or inverter), the sensitivity of the differential protec-tion must be delayed as follows:– >500 mA on HI DRIVE versions;– >300 mA on standard versions with inverter

• Differential protective devices must conform to class "B" (EN50178).

5.3.1.4 Starter current

• Weaving machine with "HI DRIVE" motor

When starting to weave, the electrical voltage of the machine may decrease by up to 15%. When dimensioning the supply lines, the (no-load mains voltage-dependent) voltage drop must be considered as well as the power consumption.The following table shows the maximum length of the supply line in relation to the cable cross-section and the no-load mains volt-age:

Speed [rpm] Power consumption (peak value) [A] Duration [ms]

900 180 130

5.3-148 E-30.01.2008


Tab. 5.3-1

The values in the table are based on the following: Copper conductor, three-pin cable, mains impedance and convert-er in the cabin 0.13 Ohm, power factor 0.65

• Weaving machine with Jacquard machine

Tab. 5.3-2

RecommendationThe duration of peak power consumption can be measured in milliseconds.S Retarding systems should be installed to prevent the protec-

tive devices from constantly interrupting the supply network.

Cross-section [mm2]Line length [m]

380 V 400 V 415 V 440 V

10 39 43 47 51

16 65 71 78 84

25 102 111 121 131

35 153 168 183 198

50 208 228 248 269

70 282 309 337 364

95 371 408 444 480

Voltage [V] Power consumption(peak value) [A]

220 approx. 70

400 approx. 35

575 approx. 25

E-30.01.2008 5.3-149


5.3.2 Electrical connection

Four-pin cable – for minimum cross-section of individual con-ductors; see table

Tab. 5.3-1

The cross-sections shown apply to max. 10 to 15 m con-nections. For longer connections, the cables must have larger cross-sections in order to prevent power drops dur-ing the main motor starting phase.

> Use a suitable power cable according to the information on the sign 1.

Fig. 5.3-1

Caution!Damage to electrics/electronics.An unsuitable voltage will damage electric/electronic compo-nents on the machine.S Check that the mains voltage is the same as that shown on

the sign on the control cabinet 1.

Mill electrician

1

5.3-150 E-30.01.2008


The mains voltage may fluctuate by a maximum of ± 10 %. An electronic protective device in the control cabinet switches off the power pack and stops the machine if the mains voltage fluctuates by more than ± 10 %.In addition, the message "Voltage outside limits" appears on the terminal.

Fig. 5.3-2

> Remove main switch cover 2.

> Feed cable 3 into the control cabinet as shown.

2

3

E-30.01.2008 5.3-151


Fig. 5.3-3

> Connect the three phases to terminals R, S and T.

> Connect ground cable 4 to the yellow-green terminal (PE).

If the weaving machine is fitted with an optional socket,

> connect neutral conductor to connection N1.

> Check direction of rotation of the ring blower.The ring blower must turn in the direction indicated by the ar-row.

If this is not the case,

> swap over 2 phases.

4

N

5.3-152 E-30.01.2008


5.3.3 Sockets

Fig. 5.3-4

Socket 1 is intended exclusively for connecting the weft yarn pre-measuring device. The voltage of this socket is the same as that of the mains supply.A single-phase socket 2 is available as an optional extra. The voltage of this socket is always 220 V.

1

2

E-30.01.2008 5.3-153


5.3-154 E-30.01.2008

5.4 Compressed air

5.4 Compressed air

As a source of energy, compressed air must be managed as economically as possible. For 1kW of work using compressed air, 10 kW of energy must be expended. When the following measures are taken, energy savings of up to 20% can be made, depending on the size of the plant. With a connected load of 500 kW, this represents a saving of € 80,000.- (8000 h /€ 0.10/kWh) over one year.

5.4.1 Planning for the compressed air plant

• Planning for an economical system begins with the assessment of requirements. It encompasses the most im-portant parameters, the time aspects and the possibilities for controlling demand.

• Economic viability: The costs of purchase, energy and maintenance must all be given equal consideration. In the case of a 37 kW plant with 80% utilisation, as much as 65% of the costs are energy costs. With increasing machine size and utilization this proportion increases.

• A measurement concept allows for later control of economic viability.

5.4.2 Operation, optimization• Type selection:

– Two-stage slow-running, reciprocating compressors have better efficiency than screw compressors of the same size.

– High-speed rotary compressors normally have lower effi-ciency (friction and oil circulation losses).

– Lubricated and oil-sealed compressors are more efficient than dry-running compressors (leakage from gaps) provid-ed dirty oil filters are not allowed to destroy this advantage.

• Dimensioning: A high level of utilization is to be aimed for.– Usage should be monitored with exact measurement.– Avoid unnecessary contingencies– Where usage is variable, install several units e.g. base

load and peak load machines, from which the most effi-cient combination can be selected by switching.

E-30.01.2008 5.4-155

5.4 Compressed air

• Limit/switch off pressure: This should be as low as possible (with consideration given to pressure differences from switch-ing, filters dryers and pipework) without, however, the setting of too-frequent switching.

• Filters, dryers, coolers: More expensive components are not necessarily better in their operation, but they can, however lead to smaller pressure losses.– Filters: More than 95% of filter costs can be traced back to

flow resistance, for which the compressor must compen-sate. Filters having a pleated surface can reduce the pres-sure drop by 0.2 bar, which with a compressor with a power consumption of 160 kW can result in annual savings of € 1,600 (8000 h /€ 0.10/kWh).

– Dryers: Refrigerating dryers avoid the use of filters and their associated pressure losses.

• Distribution system– Avoid pressure losses: In the case of a system pressure

at 10 bar, a pressure loss of 1 bar reduces the perform-ance for the user by up to 25%. Pressure losses can be re-duced by the use of large diameter pipes, low flow resistances (fittings, smooth surfaces) and the shortest and straightest pipe runs possible. It should be possible to limit pressure loss in the pipework of an industrial com-pressed air system with a length of 200 m to 0,1 bar and together with filters, dryer, cooler and maintenance unit, a value of 0,5 bar is achievable.

– Maintenance units should be adapted to air usage so that a minimum primary pressure can be constantly maintained above the secondary pressure.

– Plug-in couplings and hoses supplying the users are of-ten responsible for the greatest pressure losses. Spirally coiled hoses and couplings that are to small in diameter should be avoided.

• Making use of waste heat: 95% of the energy used in the compressor is converted to heat. If there is a possible use for this energy, then considerable cost savings can be made. Consequently, investments can be recouped in a reasonable time.– In the case of air-cooled reciprocating compressors, the

warm air can be used as heating for rooms in the vicinity.

5.4-156 E-30.01.2008

5.4 Compressed air

– In the case of oil injection reciprocating compressors, the hot cooling oil can be delivered directly to heat pumps for application in hot water heating or domestic hot water sys-tems.

5.4.2 Operation, optimization

• Inspection of the plant: An examination of the economic vi-ability of an existing plant should include the following param-eters (measurements taken during one week):– Pressure characteristics of the system– Compressor switch-on and switch-off times: From this,

the number of switching occurrences, level of utilization and required volume of compressed air can be found.

– Cooling water usage: When cooling water is not fully uti-lized, costs are increased.

– Cooling air temperature and room temperature: Raised values reduce efficiency.

– Delivery rate: The supplied volume can be reduced by up to 50% by the effects of wear, especially in the case of re-ciprocating compressors (e.g. through weak or corroded valve springs). The effective delivery rate can be deter-mined using the vessel filling method. The delivery rate can be calculated from the time required by the compres-sor to raise the pressure in the compressed air vessel from 8 to 10 bar with a closed outlet valve. In cases where the compressed air usage remains constant for a longer peri-od of time, exact statistics of the running hours, e.g. per day, can also be used to show a decrease in the compres-sor's performance.

• Maintenance– Intake filter: The pressure resistance of the intake filter in-

creases with age. Regular maintenance saves on energy costs.

– Intake temperature: A higher temperature of the intake air means not only increased energy expenditure for the same delivery volume, but also for the required cooling. Make sure there is sufficient room ventilation and proper removal of waste heat.

– Valves: Badly seating valves reduce performance enor-mously. Carry out regular inspections.

E-30.01.2008 5.4-157

5.4 Compressed air

– Drives: Regularly check the tension of vee belts, flat belts and coupling discs in order to minimize loss of power transmission.

– Cleaning: Regularly clean important parts such as oil and air coolers. This will prevent soiling that leads to reduced efficiency.

– Losses from leakage: A hole as small as 4 mm can lead to air loss of up to 1.2 m3/min and consequently to addition-al annual costs of over € 5,000 (at 6 bar/7.5 kW loss/8 000 h/€ 0.10/kWh). Make regular checks to locate and remedy losses from leakage.

5.4.3 Quality requirements

5.4.3.1 Classification

Industrial compressed air for general use in accordance withISO 8573-1.

5.4.3.2 Pressure level

The effective supply pressure of the weaving machine is essen-tially determined by the weft yarn that is to be drawn in.An effective supply pressure of 6.5 to 8.0 bar must be taken into consideration when designing the compressed air plant.

5.4.3.3 Residual oil content

A maximum of 0.01 mg/m3 (approx. 0.01 ppm) will be tolerated. (ISO 8573-1 Class 1).

5.4.3.4 Residual moisture

The pressure dew point of the compressed air must lie between +2 °C and +6 °C (ISO 8573-1 Class 4).

5.4.3.5 Temperature

The temperature of the weaving machine compressed air must not deviate by more than +/-5 °C from the weaveroom tempera-

5.4-158 E-30.01.2008

5.4 Compressed air

ture. The temperature of the compressed air must be maintained between the minimum limit of 18 °C and the maximum limit of 30 °C.

5.4.3.6 Solids content

5.4.4 Compressed air preparation

5.4.4.1 Comparison of oil-free and non oil-free compressors

In both processes, once the intake air is compressed, it must be prepared using cooling systems, dryers, filters, separators, reg-ulators, etc.The extent of the work depends on the process, and must be specified and performed in collaboration with the compressor supplier.

Max. particle size(ISO 8573-1 Class 3):

5 microns (=0.005 mm)

Max. occurring amount(ISO 8573-1 Class 1): 0.1 mg/m3

Oil-free compressorsCompressors with oil/liquid cooling (not oil-free compres-sors)

The "oil-free" designation refers to the compressor chamber, and not to the desired compressed air quality.

On compressors with oil or liquid cool-ing, the intake air undergoes a pre-cleaning effect, i.e. the coolant wash-es out any contaminants that have been drawn in with the air.

The oil-free compressor generates compressed air of a quality identical to that of the intake air, i.e. com-pressed air enriched with gaseous hy-drocarbons and particulate solids as environmental conditions dictate.

Another compressed air preparation is required, but has some advantages over the oil-free process, e.g.:filters last longer as a result of pre-cleaning the air in the compressor chamber, i.e. substantially longer filter replacement intervals.

This results in higher air preparation costs in order to maintain quality re-quirements.

Compressed air cooling is highly effi-cient thanks to the injection of oil or coolant into the compressor chamber.This means that single-stage com-pression is possible for pressure ra-tios of between 1:1 and 1:16.

E-30.01.2008 5.4-159

5.4 Compressed air

5.4.4.2 Supplementary information regarding compressed air prepa-ration

• All the components specified in the configuration are neces-sary in order to satisfy the quality requirements according to point 1.

• The compressed air equipment, e.g. the refrigeration dryer, must not be equipped with by-pass piping.Reason: Everything must be done to prevent compressed air with a residual moisture content above +6 °C being released into the compressed air system when carrying out mainte-nance work on the refrigeration dryer.

• To enable dry air to be pumped into the compressed air sys-tem as soon as the plant is started up, the refrigeration dryer must be switched on at least 30 minutes before the compres-sor to allow it to reach operational readiness.

• A compressed air valve prevents sudden overloading of the compressed air system if the compressed air is released fol-lowing a delay after the compressor is started.

• For professional support and maintenance of the compressed air plant, we recommend that a service contract is concluded between the operator of the compressed air plant and the compressor manufacturer.

• Filter service life:The energy loss through an increase in the pressure differ-ence caused by the degree of contamination is not constant over the service life of the filter elements. The pressure differ-ence only increases sharply towards the end.To prevent significant energy losses, we recommended that

Compressed air can only be cooled indirectly during compression. The process can only be mastered from an energetic and mechanical point of view by using multi-stage compres-sion with intermediate cooling.

Advantages of direct compressed air cooling:The compressed air leaves the com-pressor at a substantially lower tem-perature;Better condensate separation;Subsequent compressed air prepara-tion is less complicated

Higher specific output in [kW min/m3] than oil or coolant-filled compressors.

Significantly lower specific output in [kW min/m3] than with oil-free com-pressors.

Oil-free compressorsCompressors with oil/liquid cooling (not oil-free compres-sors)

5.4-160 E-30.01.2008

5.4 Compressed air

the filter elements are replaced when they have reached 90% of their service life.

5.4.5 Planning the number of compressors

5.4.5.1 One large compressor

Tab. 5.4-1

Fig. 5.4-1

v* – requirement

Variant Benefits DrawbacksA – No "stand-by capacity"

• Lower invest-ment costs

• Lower energy costs

• Less space re-quired

• No compressed air will be availa-ble while the compressor is being serviced (infrequent).

B – With "stand-by capacity"

• The demand for compressed air can always be fully covered.

• High investment costs, very ex-pensive solution.

E-30.01.2008 5.4-161

5.4 Compressed air

5.4.5.2 Several small compressors

At least 2 compressors are used for the compressed air supply.

Tab. 5.4-2

Fig. 5.4-2

v* – requirement

Variant BenefitsA – No "stand-by ca-pacity"

• Continuous production:One part of the production facility will continue to operate during a failure.

B – With "stand-by ca-pacity"

• Continuous production:All production continues during a failure

• Lower investment costs if "stand-by capacity" is necessary.

5.4-162 E-30.01.2008

5.4 Compressed air

5.4.6 Installation notes

5.4.6.1 What's important in the compressor room?

• Layout and design– alignment to compressed air system– in the vicinity of other machines– alignment to the sun– doors wide enough– sufficient space– preparations for maintenance activities– allow for future expansion– level floor

• ventilation– air flow max. 5 m/s with unobstructed inlet– air flow max. 2,5 m/s with louvers (60% unobstructed

throughput)– temperature increase kept to a minimum– suck in ventilation air from the coldest and cleanest area

outside the compressor room– not too close to floor– sun position, direction of wind– Louver boards prevent the ingress of dust, leaves, rain– sufficiently large openings

• intake air– clean– direction of wind– temperature data– separate intake ducts– above roof level– rain protection, grille– pre-filter– adequately dimensioned intake duct cross-section– duct bend

• Water cooling– open system (dubious quality)– semi-open system (certain amount of soiling and water

loss)– closed system (preferable)

E-30.01.2008 5.4-163

5.4 Compressed air

• Cooling water– free from particulate solids– less than 100 to 120 mg CaO/1– good quality– pressure: 3 bar– inlet stemperature: less than 35 °C– outlet temperature: less than 50 °C

• Sound level– use sound-absorbing panels– avoid hard surfaces

• Electrical system– voltage and frequency suitable for electric motor– power consumption during start-up– main switch, overcurrent trip– cable straps– local safety regulations

• Compressed air tank (min. 10% of compressor output per min)

• Installation– provide ducting and pipework to bypass filters and dryers

when carrying out maintenance– install differential pressure gage– provide connection for spare compressor

• Loss of efficiency– inadequate supply of cooling water or air to intermediate

cooler– under dimensioned pipework and filter (pressure loss!)– shoddy installation

5.4.7 Recommendations for compressed air pipework

5.4.7.1 Material quality

In order to provide good protection against corrosion, we recom-mend that galvanized steel tubes are used as a minimum (zinc coating approx. 0.046 mm). Pressure-resistant plastic tubes, stainless steel pipes or copper pipes provide substantially better corrosion protection.

5.4-164 E-30.01.2008

5.4 Compressed air

5.4.7.2 Installation recommendations

To Minimize leakage loss

> Weld/bond the pipework.

> Create closed circuit pipework.This pipe layout will help you achieve balanced pressure ra-tios.

Any loss in pressure must be compensated by further work on the compressor, which will increase energy costs.

> Dimension the pipework in such a way that the total loss of pressure between the compressed air tank and the weaving machine connection does not exceed 0.2 bar.

Under no circumstances must condensation form in the pipe-work.

If there is a chance of condensation:

> ensure that the condensation can be separated out (espe-cially from the corners that are furthest away from the com-pressor station).

> Split up larger networks so that individual sectors can be sealed off.This means that only one part of the system need be shut down when carrying out maintenance work.

> Lay pipework overhead or under the floor.

To remove dust and other particles,

> blow out the entire pipework under maximum pressure for a lengthy period before fitting the machine connection.

5.4.7.3 Connecting the individual weaving machines

An information sheet on the pneumatic connection of the L5500 weaving machines is available on request.

E-30.01.2008 5.4-165

5.4 Compressed air

5.4.8 Configuring a compressed air plant

Fig. 5.4-3

1 Intake filter2 Compressor3 Separator (water and aerosol droplets)4 Microfilter (0.1 µm)5 Cooler/dryer6 Microfilter (0.01 µm)7 Compressed air tank8 Coarse filter9 Constant pressure valve (slowly increases pressure in the

air system)10 L5500 weaving machines11 Closed circuit pipe

5.4-166 E-30.01.2008

5.4 Compressed air

Lk = f(Lw/T/M/LF)Lk: Volume of air taken in / compressor capacityLw: Air consumption L5500T: Max. outside temperature on the intake sideM: Sea levelLF: Max. relative humidity on the intake side

pk = pw + 2 barpk: Air pressure at the compressor outputpw: Air pressure at the weaving machine intake

E-30.01.2008 5.4-167

5.4 Compressed air

5.4-168 E-30.01.2008

5.5 Pneumatic properties


5.5.1 Measurement unit for air

• PressureThe most commonly used unit of measurement is [bar] (or, less often, kg/cm2); the imperial system uses [psi] (pound/square inch).

• PowerAs a general rule, [m3/h] (cubic meters per hour) or [l/s] (liters per second) is used.

The symbol "N" is very often placed before the unit of measurement (N=Norm, Nm3/h). It indicates that the given values relate to the ambient pressure.

In the imperial measurement system, the measuring unit [cfm] (cubic feet per minute) is used.

converts to:

bar kg/cm2 psi

given as: bar 1 1.02 14.5

kg/cm2 0.98 1 14.2

psi 0.069 0.07 1

converts to:

m3/h l/s cfm

given as: m3/h 1 0.277 1.698

l/s 3.6 1 2.118

cfm 0.589 0.472 1

E-30.01.2008 5.5-169


5.5.2 Characteristics of compressed air

5.5.3 Compressed air consumption

Consumption conforms to the following parameters:• Weft insertion rate (weaving machine speed [rpm] x fabric

width [m])• Weaving machine speed• Denier• Yarn type• Yarn qualityFormula for (provisional) calculation of compressed air con-sumption:

…where factor "K" is taken from the following table:

Recommended air pressure at entry into system 6.5 to 8.0 bar

Dew point of air at 6.5 to 8.0 bar 2 to 6 °C

Max. proportion of oil in the air 0.01 mg/m3

Highest amount / concentration of particles 0.1 mg/m3

Particle size 5 µm

Yarn Denier K

Cotton O.E.Ne 5 to Ne 10 0.053 to 0.043

Ne 10 to Ne 30 0.043 to 0.035

Carded cotton Ne 12 to Ne 30 0.040 to 0.032

Combed cotton Ne 30 to Ne 100 0.036 to 0.025

Synthetic filament fibers

Den 20 to Den 100 0.050 to 0.040

Den 100 to Den 500 0.040 to 0.050

Den 500 to Den 1000 0.050 to 0.060

Man-made fibers Den 30 to Den 400 0.032 to 0.040

Lv Drehzahl W× ebblattbreite K×=

5.5-170 E-30.01.2008


Tab. 5.5-1

Examples:

Tab. 5.5-2

The higher values apply to higher speeds and/or to yarns with a higher denier.Hairy yarns generally require less compressed air (the air "captures" the weft yarn better).For every 10 Nm3/h, 1 kW of compressor must be installed.

Highly twisted yarns Den 70 to Den 300 0.050 to 0.053

Wool Nm 60 to Nm 30 0.032 to 0.038

Fabric Weft yarn Width in reed [cm]

Speed [rpm]

Air con-sumption [Nm3/h]

Denim Cotton O.E. Ne 6 170 950 83

Home textiles Cotton O.E. Ne 30 315 700 90

ShirtingsCotton Ne 40 165 850 40

Cotton Ne 50 170 900 53

Dress materi-al

Cotton Ne 95 170 950 55

Carded cotton Ne 24 160 950 54

Viscose dtex 84 162 950 59

PES 1000 Den 170 700 76

PES 167/36 170 1000 67

Wool Nm 48/1 170 700 40

Yarn Denier K

E-30.01.2008 5.5-171


5.5.4 Machine compressed air plant

Fig. 5.5-1

1 Air intake2 Filter3 Main unit for regulating and distributing air4 Left-hand air container in the crossbar on the weaving ma-

chine for supplying the relay nozzles5 Right-hand air container in the crossbar on the weaving ma-

chine for supplying the relay nozzles6 Group of four relay nozzles with electrovalve7 Air container for supplying the tandem and main nozzles8 Unit for regulating and distributing air to the main nozzles9 Unit for regulating and distributing air to the tandem nozzles10 Tandem nozzles11 Main nozzles12 Air container for stretching nozzle13 Stretching nozzle14 Stretching nozzle electrovalve

5.5-172 E-30.01.2008


15 FAR suction nozzle16 Electrovalve for FAR suction nozzle17 Left-hand FAR blowing nozzle18 Electrovalve for FAR blowing nozzle19 Pre-measuring devices

5.5.5 Pneumatic connection

Rubber tube: resistance >20 bar, inside diameter 19 mm (3/4 "), outside diameter 30/32 mm (1.18/1.26 ")

Fig. 5.5-2

Two steel links – suitable for the pressure pipes

> Fit steel links 1 to both ends of the tube.

> Screw steel links 1 onto compressed air connection on the one side, and onto the air filter intake on the other, and tighten them both.

Fig. 5.5-3

E-30.01.2008 5.5-173


> Open ball valve 2.NTC (New Time Controller) is supplied with the required op-erating pressure.

5.5.6 Composition of a compressed air plant

Fig. 5.5-4

A Compressor roomB Weaveroom1 Compressor2 Dryers3 Compressed air outlet filter4 Container5 Distribution pipe

Important!The compressed air plant must be installed outside the weave-room for the following reasons:S Effect of air conditioning plant on operationS Rapid clogging of the filter by fluff and weft remnants present

5.5-174 E-30.01.2008


in the weaveroom airS Problems due to the presence of oil vapor from man-made fib-

ers

5.5.6.1 Air filter in intake

An air filter for separating dust and particles of 1 to 5 µm is enough to guarantee good air quality. It should be fitted as close to the compressor as possible.

5.5.6.2 Compressor

To compensate for the different amounts consumed (depending on the style type), the right safety margin and the consumption by auxiliary equipment must be taken into consideration when selecting the compressor type.On small plants, when lubricated compressors are necessary, a series of filters must be used to bring the air to the values spec-ified.

5.5.6.3 Dryer

…for dehumidification.A well-planned plant should not display any pressure losses greater than 0.140 bar between the intake and the outlet.

5.5.6.4 Compressed air tank

...serves as a compensation tank for peak plant demands, and notifies the control devices of the air pressure.

E-30.01.2008 5.5-175


5.5-176 E-30.01.2008

Main chapter

6 Lubricants

E-30.01.2008

E-30.01.2008

6.1 Regulations

6.1 Regulations

6.1.1 General

6.1.1.1 Validity

The lubricating instructions specify the lubricants needed and where they should be used. Information on lubrication intervals, lubrication points and lubrication equipment can be found in the "Lubrication Schedule" chapter of the operating instructions.The lubricating instructions regulate the responsibilities between Sultex AG, the customer and the lubricant supplier.For equipment not supplied by Sultex AG, the instructions of the relevant supplier apply.

6.1.1.2 Safety rules, legal requirements

The "general safety rules" also apply to the use of lubricants and must be observed.In particular, attention is drawn to the requirement to observe lo-cal regulations, over which Sultex AG has no influence.

6.1.1.3 Attention

If not otherwise regulated by legal requirements, attention should be paid to the following:• The information given here is based on experience which Sul-

tex AG considers reliable and must be used by technically trained personnel at their own discretion and risk.

• Since the use of these products is beyond our control, we can-not accept any guarantees, obligations or liability of any kind in connection with this information.

E-30.01.2008 6.1-179

6.1 Regulations

6.1.1.4 Designations

As far as possible standard designations and symbols are used for identification to assure international intelligibility for lubricant suppliers. Non-standard terms are used in a similar way. When sourcing lubricants, the entire specification and not just the sym-bol should be quoted.

6.1.1.5 Recommendation

Lubrication of state-of-the-art machines is essential for smooth operation and should not be neglected. We strongly recommend the use of check lists.The cheapest solution at any given point in time is not necessar-ily the best one in the long run.Sultex AG will not accept any liability in the event of non-compli-ance with these instructions, even during the guarantee period.

6.1.1.6 Responsibility

Responsibility for the choice of lubricants in accordance with the specified values and requirements shall be borne by the lubri-cant supplier. Sultex AG will not accept any liability in this re-spect.The wide range of brand names and the varying designations in different countries make it impossible for Sultex AG to assess the lubricants recommended by lubricant manufacturers.Sultex AG regrets that it is unable to perform brief analyses, as these are only of limited value.

6.1-180 E-30.01.2008

6.1 Regulations

6.1.2 Sourcing

6.1.2.1 Choice of supplier

The customer is free to select a lubricant supplier of his choice.The supplier must provide to the customer a legally binding guar-antee that the specified values will be adhered to and that deliv-eries will be of a uniform quality.

6.1.2.2 Changing supplier, brand and type

When changing supplier, brand or type, the supplier's instruc-tions with respect to compatibility or cleaning and other meas-ures must be strictly observed, since it is impossible to guarantee the compatibility of different lubricants.

6.1.3 Storage

6.1.3.1 Locality

Storage must comply with local regulations as well as the recom-mendations of the supplier.

6.1.3.2 Length of storage

The length of storage stipulated by the supplier must be ob-served. Aging criteria are brand-specific and cannot therefore be specified by Sultex AG.

6.1.4 Toxicity

6.1.4.1 Legal requirements

Lubricants and cleaning agents may contain ingredients which in some countries and locations are subject to toxicity regulations.Fire and similar regulations must be observed.The measures to be taken should be specified by the suppliers and the competent authorities.

E-30.01.2008 6.1-181

6.1 Regulations

6.1.4.2 Disposal

In some countries, disposal of lubricants and cleaning agents is subject to local regulations, compliance with which must be dis-cussed with the suppliers and local authorities.

6.1.5 Checks

The customer is responsible for checking and monitoring the fol-lowing:• Incoming deliveries in accordance with specifications• Storage facilities• Maximum storage life• Compliance with local regulations during storage, handling

and disposal.

6.1.6 Sultex AG as lubricant supplier

All the lubricants listed in the table below can also be obtained from the spare parts service of Sultex AG.

Sultex AG will not accept any liability in the event of non-compliance with the information given above.

6.1-182 E-30.01.2008

6.2 Lubricants

6.2 Lubricants

6.2.1 Oil specifications

Tab. 6.2-1

Symbol

Short designation Gear oil 150 Gear oil 680

Standard requirements DIN 51 517CLP 150

DIN 51 517CLP 680

Special requirements

Characteristic:

• Viscosity class ISO 150 680

• Viscosity class SAE

• Viscosity at 40 °C 150 680

• Viscosity at 100 °C 15.8 39.2

• Viscosity index 98 90

• Flashpoint °C 224 236

• Yield point °C -24 -6

• Additives EPAnti-corrosionAnti-oxidantAnti-foam

EPAnti-corrosionAnti-oxidantAnti-foam

Other properties according to standard according to standard

E-30.01.2008 6.2-183

6.2 Lubricants

6.2.2 Grease specifications

Tab. 6.2-2

Symbol

Short designation Lithium grease no. 3

Requirements

NLGI class 3

Thickening agent

Worked penetration (ISO 2137)

Worked durability penetration after 105 strokes

Penetration decrease

Viscosity of base oil in mm2/s (cSt) at 40 °C

Dropping point in °C

Maximum permitted working temperature

> 160

Additives

6.2-184 E-30.01.2008

6.2 Lubricants

6.2.3 Use and filling amount

Tab. 6.2-3

Short designation / symbol Usage on weaving machine

Approx. filling amount [l] / Com-ments

Gear oil 150 "HI DRIVE" group 1,8

Left-hand drive unit 3.0

Right-hand drive unit 1.8

Cardan unit 2.0

Creep speed unit 0.7

Gear oil 680 Helical gear – worm screw for cloth take-up regulator 1.2

Helical gear – worm screw for warp let-off motion 1.0

Lithium grease no. 3

Back rest roller bearings, warp beam gear wheel, cloth beam (bolt, chain, drive shaft, retaining rings)

E-30.01.2008 6.2-185

6.2 Lubricants

6.2-186 E-30.01.2008

Main chapter

7 Warp preparation

E-30.01.2008

E-30.01.2008

7.1 Processing of fiber yarns


As the performance of a weaving system increases, it becomes more and more important that the number and duration of any stoppages are kept to an absolute minimum. This requirement arises as a result of the following:To achieve an overall figure of 1 stoppage per weaving machine hour, the following number of stoppages per 105 picks are per-mitted, taking into account appropriate performance levels for each process:• rapier weaving machine, 3 to 5 stoppages• air-jet weaving machine, 2.0 stoppages,• multiphase weaving machine, 0.5 stoppages,• projectile weaving machine, 1 to 2 stoppages, and• shuttle weaving machine, 7.5 stoppages.The weaving preparation process therefore becomes the most significant factor in keeping stoppages to a minimum due to its impact on the reliability of the weaving operation. Weaving prep-aration is understood to cover all preparatory processes, such as spooling, warping and sizing.

7.1.1 Warping

The warping process, which uses the latest state-of-the-art tech-nology, has to satisfy the following requirements:• identical winding diameters and wound yarn lengths per

beam.• length differences of less than one mil are technically feasible.• able to prevent yarn ends rolling up when there is a yarn break

through a high-speed stop facility and reliable monitoring, as these invariably cause the sizing machine to stop. The use of warp feeders for yarn recovery is particularly recommended for lower quality yarns.

• a perfect, uncrossed yarn feed can be ensured by employing a horizontal and vertical comb movement and an automatic unleasing device. Yarn crossing, which occurs when the ma-chine starts up again following a stoppage and often results in yarn breaks on the comb of the sizing machine, can therefore be prevented.

E-30.01.2008 7.1-189


• Minimum yarn loading and maximum tension compensation from yarn to yarn (between spools positioned at the front and rear of the creel) through the use of modern yarn tensioning systems and automatic pretensioning.

• no accumulation of dust and fly by disposing of dust during beaming through the use of sophisticated dust removal sys-tems, or at least a device for blowing off the comb.

• warp speed set to a figure that takes frequency of yarn breaks into account rather than maximum speed. The frequency of yarn breaks during warping remains one of the most important indicators for an optimum sizing process and low-breakage warp travel on a high-performance weaving machine.

• the yarn quality and removal of weak points must take these requirements into account.

Guideline values for yarn break frequency during sizing are as follows:• ring yarns:< 5.0 yarn breaks per 107 yarn meters• OE rotor yarns:< 3.0 yarn breaks per 107 yarn meters

7.1.2 Sizing

Sizing continues to be an extremely important aspect of the weaving process.As warp yarns are subjected to complex wear patterns, sizing is designed to provide the yarn with a more resistant finish with low friction characteristics (yarn/yarn and yarn/metal) and as com-plete a film covering as possible. These requirements must be satisfied by selecting the correct sizing solution and implement-ing appropriate technical measures.The high warp speeds using during weaving mean that the neg-ative consequences of any errors made during warping and siz-ing, such as differing tensions from yarn to yarn, incorrect yarn patterns or yarn breaks, acquire added significance. All actions and settings must therefore be made with the utmost care and attention to detail. To satisfy these requirements, the latest and most modern sizing systems must be employed.The following aspects of sizing are of particular importance for the weaving process:• minimising the number of process stoppages during sizing by

optimising all technical factors. The targets are:

7.1-190 E-30.01.2008


– stoppage frequency: <0.1 per 1000 m warp length and 1000 warp ends

– requirement:yarn quality satisfies the requirements previ-ously laid down for the warping department

– sufficient abrasion resistance of yarn through use of the most appropriate sizing solution. The objective is to pro-vide the yarns with a good coating of film. In principle, any sizing solution, or a combination of different ones, can be used, providing there are no specific equipment-related re-quirements. For example, a synthetic sizing solution (PVA and/or acrylate), in its pure or blended form, could be a bet-ter alternative for cotton yarns (from a commercial point of view as well) if the number of yarn breaks that occur during weaving falls accordingly.

– a significant advantage is to use sizing control, which is now feasible (e.g. Telecoll sizing control).

– the use of automatic size preparation systems is especially recommended when using synthetic sizing solutions.

– Individual motor drive systems to achieve consistent warp shrinkage (to retain as much elasticity in the yarns as pos-sible) in the individual zones of the sizing machine.

– the high warp speeds used in weaving mean that any in-stances of yarn crossing become critically important. Yarn crossing is often inadvertently pre-programmed if the yarns are not spaced properly when the comb on the sizing machine is not used. As when sizing filament yarns, it is therefore strongly recommended, even when sizing fiber yarn warps, to draw the yarns into the comb.

– bearing in mind the importance of sizing in the weaving process, thorough employee training is vital. In addition to mastery of the technical aspects, proper sizing demands a great amount of care. Logging of the process sequences (error logging and storing of most important process data) and the evaluation of the results are prerequisites for opti-mum, reproducible sizing.

Determining the best recipes for each fabric style still requires a series of systematic trials. In light of the above, the initial exper-iments should always draw on the experiences of the customer.

E-30.01.2008 7.1-191


7.1-192 E-30.01.2008

Main chapter

8 Weft preparation

E-30.01.2008

E-30.01.2008

8.1 Package make-up

8.1 Package make-up

8.1.1 Requirements

High-quality packages require the most modern packaging sys-tems for constant angle cross winding. This applies equally to package winders on OE rotor and air-jet spinning machines, and to automatic winders that re-wind the cops of ring spinning ma-chines.

8.1.2 Causes of problems

The most serious cause of problems during thread unwinding at high draw-off speeds are the system-inherent ribbon windings.These diamond-shaped, parallel yarn layers within certain diam-eter ranges are caused when there is an integral relationship be-tween the speed of the yarn guiding drum (grooved drum) and the rotation of the package.When laying yarn through a grooved drum, the creation of these ribbon windings can only be controlled by upsetting this speed relationship through the introduction of slip.Due to their high cost, effective anti-patterning devices are only found on the most modern automatic winders, and not on the winding heads for cone and cheese packages of spinning ma-chines.Using a lower winding speed to produce a more exact yarn lay in the case of cone and cheese spinning machines only goes a little way to alleviating this restriction.The most obvious advantage of using cones and cheeses from OE and air-spinning machines is the longer unknotted yarn run compared with rewound ring-spun yarns.A crosswound package will have between 20 and 30 joints, in the form of splices or knots, as the result of cop connections.Recent experiments with properly set-up anti-patterning devices and the controlled winding tension provided by automatic wind-ers show that draw-off speeds for medium fine yarns of up to 1500 m/min can be expected in the future.The latest package winders on the market offer controllable, as far as the most important parameters are concerned, package make-up with regulated yarn lay. However for cost reasons,

E-30.01.2008 8.1-195

8.1 Package make-up

these will not be available in either automatic package machines or spinning machines for the time being.

8.1.3 Recommendations

• Constant angle cross winding with minimum ribbon winding patterning.For this purpose, the package winders should be equipped with an effective anti-patterning device. The latest generation of automatic winders also offer benefits in respect of yarn ten-sion control, i.e. uniform yarn tension at each stage of cop un-winding.

• Sensor-monitored packaging processes are used to minimise all visible and hidden winding room errors that still arise, even today, particularly in the case of older, poorly maintained or badly set-up package winders. These errors include:– sloughed-off picks (lengths of yarn on front of cheese or

cone)– fluctuating or too low cone density

(reference value: 0.4 g/cm3 by appropriate, in terms of number of spirals and crossing angle, choice of grooved drum)

– wound-in dropped yarns– poorly stored yarn reserve at base of former and insecure

yarn knots (splices)• Suitable package formats for yarns up to 17 tex (Nm 60, Ne

36) are:– cheeses with winding diameters of up to 320 mm and

traverses of up to 6"– cones: 4"20' with comparable winding diameters and

traverses of up to 6" (150 mm)• Undamaged, large diameter formers with a good grip to en-

sure smooth unwinding of yarn around the lower windings.• The unwinding characteristics of cones and cheeses up to

4"20' for this grade of yarn are practically identical.

8.1-196 E-30.01.2008

Main chapter

9 Weaving accessories

E-30.01.2008

E-30.01.2008

9.1 Warp beam

9.1 Warp beam

The full warp beams conform to ISO-DIN standards.Half warp beams are specifically intended for this machine.The design properties of the warp beam tube and the warp beam flanges must be suited to the yarn types used (especially when weaving with synthetic yarns).The descriptions concerning assembly of the warp beams and positioning of the warp beam flange can be found in the "L5500 Adjustment instructions" manual.

AM, 5.1

RecommendationMinimum measurement for warp beam tube diameter: 219 mm

9.1.1 Full warp beam

• Full warp beam (conforms to ISO-DIN standards) for weaving machine widths 170 to 230 cm

Fig. 9.1-1

1 Left flange2 Right flange3 Mounting flange

1 23 3

E-30.01.2008 9.1-199

9.1 Warp beam

• Full warp beam (conforms to ISO-DIN standards) for weaving machine widths 260 to 400 cm

Fig. 9.1-2

4 Spacer

9.1.2 Half warp beam

• Half warp beam for weaving machine widths 260 to 280 cm

Fig. 9.1-3

2 Flange4 Spacer5 Ring and hub

1 24 4

25 42 4 5

9.1-200 E-30.01.2008

9.1 Warp beam

• Half warp beam for weaving machine widths 300 to 400 cm

Fig. 9.1-4

6 Spacer

9.1.3 Warp beam mode of transport

Special transporting/lifting device

> Check maximum load-bearing capacity of the device in rela-tion to total weight (warp beam + warp ends).

> Select suitable take-up system (fork/balance) for the warp beam.

Fig. 9.1-5

25 62 6 5

E-30.01.2008 9.1-201

9.1 Warp beam

Combined with simultaneous transport of the warp beam and the harnesses.

Fig. 9.1-6

> Ensure that the special transporting/lifting device is fitted with the required safety devices.

> Ensure that the transport path is wide enough and free of ob-stacles.

9.1-202 E-30.01.2008

9.2 Cloth beams

9.2 Cloth beams

The cloth beams conform to the currently applicable ISO-DIN standards.

Fig. 9.2-1

Tab. 9.2-1

Nominal width [cm] 170 190 210 220 230 260 280 300 320 340 360 380

A [mm] 2006 2106 2306 2406 2506 2806 2906 3266 3466 3666 3866 4066

B [mm] 1846 1946 2146 2246 2346 2646 2746 3106 3306 3506 3706 3906

E-30.01.2008 9.2-203

9.2 Cloth beams

9.2-204 E-30.01.2008

9.3 Reed

9.3 Reed

9.3.1 "Normal" type

Application:• Two-color weaving machine with dobby/cam motion

Fig. 9.3-1

l Overall widthm Reed widthp Section with shaped drop wiresq Section with straight drop wires

E-30.01.2008 9.3-205

9.3 Reed

9.3.2 "Double cone" type

Application:• Four-color and multi-color weaving machine with cam/dobby• Weaving machine with Jacquard machine

Fig. 9.3-2

Tab. 9.3-1

(*) applies to Jacquard machine only

A [mm]Number of colors

4 6 8 (*)

40 x x

60 x x

9.3-206 E-30.01.2008

9.3 Reed

9.3.3 Variants

9.3.3.1 Adjustable reed

The overall width of the reed matches the drawn-in width of the warp and leno ends.

Fig. 9.3-3

w Warp ends

The advantage of this variant is that there is no limit to the ma-chine output.

9.3.3.2 Adjustable reed with auxiliary selvedge

The overall width of the reed is the sum of the width of the drawn-in warp and leno ends plus the width of the auxiliary selvedge.

Fig. 9.3-4

w Warp endsu Auxiliary reed

w

w u

E-30.01.2008 9.3-207

9.3 Reed

The advantage of this variant is that there is no limit to the ma-chine output.

9.3.3.3 Reed – overall width, including auxiliary selvedge

The overall width of the reed is the nominal width of the weaving machine exactly, or the nominal width plus 15 cm.

Fig. 9.3-5

w Warp ends

This variant is suitable for situations where the width of the fabric in the reed is changed frequently, while the number of reed dents/cm remains constant.The corresponding auxiliary selvedge device must also be at-tached (see adjustment instructions).

Caution!For this variant, the weaving machine speed must not exceed 1000 rpm.

w

9.3-208 E-30.01.2008

9.4 Heddle frames

9.4 Heddle frames

9.4.1 Heddle frame dimensions

9.4.1.1 Weaving machine width 170 to 230

Frame width 280 (cam motion only)

Fig. 9.4-1

Tab. 9.4-1

Machine width [cm] A [mm] B [mm] C [mm] D [mm]

170 1878 1716 1180 459

190 2078 1916 1380 549

210 2278 2116 1580 549

220 2378 2216 1680 549

230 2478 2316 1780 549

E-30.01.2008 9.4-209

9.4 Heddle frames

9.4.1.2 Weaving machine width 260 to 380

Frame width 280 (cam motion only)

Fig. 9.4-2

1 Central support, can be moved 40 mm when using the leno unit in the middle.

Tab. 9.4-2

Machine width [cm] A [mm] B [mm] C [mm] D [mm]

260 2898 1100 1100 1180

280 3098 1200 1200 1280

300 3298 1300 1300 1380

320 3498 1400 1400 1480

340 3698 1500 1500 1580

360 3898 1600 1600 1680

380 4098 1700 1700 1780

9.4-210 E-30.01.2008

9.4 Heddle frames

9.4.1.3 Weaving machine width 400

Fig. 9.4-3

1 Central support, can be moved 40 mm for using the leno unit in the middle.

Tab. 9.4-3

Machine width [cm] A [mm] B [mm] C [mm] D [mm] E [mm]

400 4298 2068 1800 940 725

E-30.01.2008 9.4-211

9.4 Heddle frames

9.4.2 Frame connections

9.4.2.1 Harness drive linkage

9.4.2.2 Terminals on dobby

Standard DRC10

normal ergonomic *

Stä

ubli

9.4-212 E-30.01.2008

9.4 Heddle frames

*) "Stäubli" type, 2861-2871 only; "Somet" type, SP QJ only

Som

et

normal ergonomic *

E-30.01.2008 9.4-213

9.4 Heddle frames

9.4-214 E-30.01.2008

9.5 Heddles

9.5 Heddles

If using heddles with asymmetric yarn eyelets, the shorter side must be above the warp ends.

RecommendationS Use heddles with "type J" connections.

Fig. 9.5-1

C Fabric side

> Fit heddles in such a way that the opening on the connecting eyelet is pointing towards the fabric side (not the warp side).

C

E-30.01.2008 9.5-215

9.5 Heddles

9.5-216 E-30.01.2008

Main chapter

10 Disposal

E-30.01.2008

E-30.01.2008

10.1 Deinstallation

10.1 Deinstallation

10.1.1 Procedure

> Disconnect weaving machine from the power supply.

> Obey the safety rules in respect of transportation.

> Observe special requirements in respect of lubricants (oils and greases), plastics and electrical components (batteries and capacitors).

10.1.2 Regulations

Disposal must take place in accordance with local waste dispos-al regulations and in accordance with national regulations in re-spect of environmental protection.

E-30.01.2008 10.1-219

10.1 Deinstallation

10.1-220 E-30.01.2008

Sultex LimitedJoweid Zentrum 3CH-8630 Rüti ZH, SwitzerlandPhone +41 (0)55 250 21 21 – Telefax +41 (0)55 250 21 01www.sultex.com