Start-up and trouble shooting instructions (Translation of original manual)

Allma CC3

Document No.: 677 820 0200 002 Oerlikon Saurer

Order No.: 380 36100 Zweigniederlassung der Oerlikon
Rajashree Polyfil Textile GmbH & Co. KG
Customer:
Date: October 2009
Allma Product Line
Leonhardstraße 19
87437 Kempten/Allgäu
Germany
Phone + +49 831 688-356, -258, -258
Fax +49 831 688-344
www.saurer.oerlikontextile.com
info-allma.saurer@oerlikon.com
Legal notice / Copyright

All rights reserved.

Any reproduction, in part or in whole, is expressly prohibited.

© 2009 by Oerlikon Saurer

Zweigniederlassung der Oerlikon Textile GmbH & Co. KG

All used trademarks and word marks, even if not expressly stated as such,
remain the property of their respective owners.

Limited rights:
Copying or printing for in-house purposes of the machine operator is
expressly permitted (e.g. for training of operating staff), however, a
copyright notice should be made.
Table of Contents

1 About This Document..................................................... 1-1

1.2 Validity ............................................................................ 1-2

1.3 Target Group................................................................... 1-2
1.4 Copyright......................................................................... 1-2

2 Safety............................................................................. 2-3

3 General preparations ..................................................... 3-4

3.1 Provision of measuring instruments ................................ 3-4

3.2 Connection of machine / headstock................................ 3-4
3.3 Menu survey ................................................................... 3-5
3.3.1 Menu structure ................................................................ 3-5
3.3.2 Password system/ Code levels ....................................... 3-7
3.3.3 Settings menu screens ................................................... 3-8

4 Starting-up the headstock installation........................... 4-11

4.1 Visual inspection and continuity check ......................... 4-11

4.1.1 Switches and fuses ....................................................... 4-11
4.1.2 DC link bar check.......................................................... 4-12
4.1.3 24VDC supply check..................................................... 4-12
4.1.4 Limit switch of traverse motion...................................... 4-14
4.1.5 Fuse circuit.................................................................... 4-14
4.1.6 Emergency signalling circuit ......................................... 4-15
4.1.7 Compressed air connection .......................................... 4-15
4.2 Protective conductor check and insulation check ......... 4-15
4.3 Power supply start-up ................................................... 4-16
4.3.1 380VAC supply cable start-up (or 400VAC) ................. 4-16
4.3.2 Starting-up the 24VDC supply ...................................... 4-17
4.3.3 Starting up the secondary supplies............................... 4-18
4.3.4 Braking current supply start-up ..................................... 4-18
4.4 Starting-up the frequency converter.............................. 4-19
4.5 Addressing the frequency converter ............................. 4-19
4.6 Starting-up the control software .................................... 4-21

Allma CC3 677 820 0200 002 October 2009 I

Table of Contents

4.7 Starting up the control modules .................................... 4-24

4.7.1 Addressing the control modules.................................... 4-24
4.7.2 Addressing test ............................................................. 4-28
4.8 Settings ......................................................................... 4-29
4.8.1 Setting the default values for all menus ........................ 4-29
4.8.2 Settings for spindle ....................................................... 4-30
4.8.3 Unit for length counting and yarn count ........................ 4-32
4.9 Parameterisation of drives ............................................ 4-33
4.9.1 Spindle drive ................................................................. 4-33
4.9.2 Winding drive ................................................................ 4-34
4.9.3 Capstan drive................................................................ 4-36
4.9.4 Traverse motion drive ................................................... 4-37
4.10 Testing the saving and loading procedures (with a
USB stick) ..................................................................... 4-38
4.11 Tests to perform............................................................ 4-40
4.11.1 Machine status.............................................................. 4-40
4.11.2 Testing the inputs.......................................................... 4-40
4.11.3 Testing the outputs ....................................................... 4-43
4.12 Checking the versions................................................... 4-44
4.13 Checking machine functions ......................................... 4-44
4.13.1 Preparation ................................................................... 4-44
4.13.2 Checking the headstock functions ................................ 4-45
4.13.3 Checking the direction of rotation of spindle
motors ........................................................................... 4-48
4.14 Checking the emergency stop function......................... 4-49
4.15 Battery charging test ..................................................... 4-49
4.16 Parameterisation of language ....................................... 4-51
4.17 Remote maintenance via modem ................................. 4-51

5 Starting up the section installation................................ 5-52

5.1 Visual inspection and continuity check ......................... 5-52

5.1.1 Switches and fuses ....................................................... 5-52
5.1.2 Wiring of contactors in power cable duct) ..................... 5-52
5.1.3 24V distribution ............................................................. 5-52

Allma CC3 677 820 0200 002 October 2009 II

Table of Contents

5.2 Protective conductor check and insulation check ......... 5-53

5.3 Starting up the braking current supply .......................... 5-53
5.4 Tests to perform............................................................ 5-53
5.4.1 Spindle status ............................................................... 5-53
5.4.2 Testing the inputs.......................................................... 5-54
5.4.3 Testing the outputs ....................................................... 5-54
5.5 Calibration of CordGuard .............................................. 5-56
5.6 Checking the spindle functions ..................................... 5-56
5.6.1 Preparation ................................................................... 5-57
5.6.2 Checking the spindle positions ..................................... 5-58
5.6.3 Checking the spindle motors......................................... 5-58

6 Start-up at customer's works ........................................ 6-61

6.1 Visual inspection and continuity check ......................... 6-61

6.2 Power supply start-up ................................................... 6-62
6.2.1 380VAC supply cable start-up (or 400VAC) ................. 6-62
6.2.2 Starting-up the 24VDC supply ...................................... 6-63
6.2.3 Starting up the secondary supplies............................... 6-64
6.2.4 Braking current supply start-up ..................................... 6-65
6.3 Protective conductor check (PE)................................... 6-65
6.4 Starting-up the frequency converter.............................. 6-65
6.5 Starting up the control modules .................................... 6-66
6.5.1 Addressing the control modules.................................... 6-66
6.5.2 Addressing test ............................................................. 6-70
6.6 Settings ......................................................................... 6-71
6.6.1 Unit for length counting and yarn count ........................ 6-71
6.6.2 Shift counter.................................................................. 6-72
6.6.3 Material ......................................................................... 6-73
6.6.4 Date and time................................................................ 6-74
6.6.5 Setting the ETHERNET address................................... 6-75
6.6.6 Setting the display......................................................... 6-77
6.7 Tests to perform............................................................ 6-78
6.7.1 Machine status.............................................................. 6-78

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Table of Contents

6.7.2 Testing the inputs.......................................................... 6-78

6.7.3 Testing the outputs ....................................................... 6-81
6.8 Checking the emergency stop function......................... 6-82
6.9 Checking machine functions ......................................... 6-82
6.9.1 Preparation ................................................................... 6-83
6.9.2 Setting the thread guide................................................ 6-84
6.9.3 Checking the functions.................................................. 6-84
6.10 Start-up of conveyor belt............................................... 6-86
6.11 Remote maintenance via modem ................................. 6-87

7 Replacement instructions ............................................. 7-88

7.1 Replacement of IPC+L-A1 ............................................ 7-88

7.2 Replacing frequency converters+L-T101 / +R-
T201+L-T104 / +R-T204 ............................................... 7-89
7.3 Replacing the power supply+L-G101 bis G103 /
+R-G201 bis G203+V-G1 ............................................. 7-90
7.4 Replacing the control module +FRn-A10 or +FLn-
A10................................................................................ 7-90

8 Machine diagnostics..................................................... 8-91

8.1 Logbook ........................................................................ 8-91

8.2 Machine menu .............................................................. 8-94
8.2.1 Overview submenu ....................................................... 8-94
8.2.2 Spindle submenu .......................................................... 8-95
8.2.3 Submenu CordGuard.................................................... 8-96
8.3 Servicing Menu ............................................................. 8-97
8.3.1 Submenu disabled and test mode ................................ 8-97
8.3.2 Diagnostics submenu.................................................... 8-98
8.3.3 Parameterisation submenu ......................................... 8-103
8.4 Reading out of software versions................................ 8-106

9 Trouble shooting instructions ..................................... 9-107

9.1 Machine messages ..................................................... 9-107

9.1.1 Error messages of machine ........................................ 9-107

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Table of Contents

9.1.2 Machine warnings ....................................................... 9-124

9.2 Spindle messages....................................................... 9-129
9.2.1 Switch-off causes of spindles...................................... 9-129
9.2.2 Start refusals of spindles............................................. 9-136
9.2.3 Spindle Warnings........................................................ 9-137
9.2.4 Blink codes of spindle position.................................... 9-139
9.3 Problems with control modules in network.................. 9-141
9.3.1 Survey......................................................................... 9-141
9.3.2 Fault repair.................................................................. 9-142
9.4 System messages....................................................... 9-144
9.4.1 Survey......................................................................... 9-144
9.4.2 Description .................................................................. 9-144

10 Service..................................................................... 10-145

11 Original parts and wearing parts .............................. 11-146

Allma CC3 677 820 0200 002 October 2009 V

1 About This Document

1 About This Document

These start-up and trouble shooting instructions form part of the machine and
describe how to safely and correctly start-up the machine and help in trouble-
shooting.

WARNING
Be careful with electronic parts!
The following instructions may only be carried out by qualified
personnel. The applicable accident prevention guidelines are to be
observed at all times.

Electrostatic charges

Walking on plastic floors leads to a separation of charges which is due to

friction of the soles of shoes on the floor covering. Thus the body is charged
electrostatically to up to 30,000 V. The stored energy in our bodies is small.
Therefore the "lightning" on the door handle or on other objects is not harmful
to human beings. Discharges of voltages below 2000 V are not perceived at all.

Electronic components, however, react differently. Electrostatic discharges

which are far beyond our perception lead to damage and destructions of the
increasingly closer and finer structures of the components.

When working on Electrostatic Sensitive Devices (ESD), please

note:

▪ Touch ESD only when it is absolutely necessary!

▪ Equip place of work in such a way that it complies with the requirements of
ESD. You can do this by using a conductive working plate, an earthing
wrist band, a soldering iron with earthed soldering bit.

▪ Before touching the ESD, discharge the body by touching an earthed

machine frame. The use of an earthing wrist band offers optimum
protection.

▪ Always use suitable ESD packages such as conductive ESD bags,

conductive plastic containers or cartons with conductive foamed material.
This also applies when returning defective prints in order to avoid additional
damage.
These measures apply to all electronic PCBs (e.g. spindle control, control,
frequency converter, etc.).

Allma CC3 677 820 0200 002 October 2009 1-1

1 About This Document

1.2 Validity

These start-up and trouble shooting instructions are only valid for the Allma
CC3.

For the following software versions and higher:

SOFTWARE IPC = V1.xx.xx
SOFTWARE OPERATING MODULE = B00.23 V20.20

1.3 Target Group

These start-up and trouble shooting instructions are intended for use by
qualified technicians and must be carried out by trained specialists only.

The machine may only be used by persons who have been instructed in its
proper handling and operation.

1.4 Copyright

Copyright of these start-up and trouble instructions remains with Oerlikon

Saurer, Allma Product Line. These start-up and trouble shooting instructions
should be treated as confidential and are only intended for erection, operating
and monitoring staff. They contain rulings and drawings of a technical nature
which may be neither used in an unauthorized manner for the purpose of
competition nor disseminated to third parties. Surrender to third parties is
strictly prohibited and will result in compensation for damages being
demanded. As the original text, the German version of this manual takes
precedence over any translations.

We reserve all rights, including the right to translate.

Allma CC3 677 820 0200 002 October 2009 1-2

2 Safety

2 Safety

NOTE The same basic safety regulations as described in the operating

manual shall apply.

Allma CC3 677 820 0200 002 October 2009 2-3

3 General preparations

3 General preparations

The following designations indicate the place of installation in the

machine:
+R = Control cabinet right
+L = Control cabinet left
+M = Control cabinet middle
+A = Headstock
+FRn = Section right (power cable duct right-hand side)
+FMn = Section middle (cable duct conveyor belt)
+FLn = Section left (power cable duct left-hand side)
+E = Machine end

3.1 Provision of measuring instruments

▪ Digital multimeter with 2 places behind the decimal point

▪ Clip-on ammeter

3.2 Connection of machine / headstock

▪ Connection to threephase mains 380VAC (or 400VAC), clockwise rotating

field

▪ The machine must be connected directly to the mains (fixed connection).

Plug-in connection is not allowed!

▪ Make sure the nominal voltage is correct! (See nameplate of the machine)

NOTE
Operating the machine at a wrong voltage may destroy the
electronic system of the machine

Allma CC3 677 820 0200 002 October 2009 3-4

3 General preparations

3.3 Menu survey

3.3.1 Menu structure

Table 3-1: Menu structure

Main menu Submenu Tab menu

Survey ----

Machine Spindle ----

CordGuard (option) ----

Machine ----

Material

Yarn path
Yarn
Delays

Creel yarn
tensioner
Settings
Basics

Fault
Package build-up
Thread reserve
(optional)

Yarn sensor ----

Length ----

Jobs Survey ----

Logbook ----

Reports Shift ----

Versions ----

Allma CC3 677 820 0200 002 October 2009 3-5

3 General preparations

Main menu Submenu Tab menu

Disabled and test

----
mode

Machine status

IOs Machine

Spindles
Diagnosis

Archive

Battery test
(Option)

Servicing Spindles
Start-up CordGuard
(Option)

FC spindle

FC winding

FC capstan
Parameterisation
FC traverse
motion

FC operating unit

Admin Accounts ----

Date and Time

Shift Calendar
User interface
Units

Display

MC-configuration Machine

Spindles

Allma CC3 677 820 0200 002 October 2009 3-6

3 General preparations

Main menu Submenu Tab menu

Network

Options

3.3.2 Password system/ Code levels

▶ The code levels are described in the operating instructions

▶ For most settings in these instructions, code level Machine

engineer is required

Setting password 1. Press global button Password

2. Select user name Machine engineer
3. Enter password for machine engineer
4. Press Login

Fig. 3-1: Setting password

Allma CC3 677 820 0200 002 October 2009 3-7

3 General preparations

3.3.3 Settings menu screens

Fig. 3-2: Settings Æ Machine

Fig. 3-3: Settings Æ Yarn Æ Yarn path

Allma CC3 677 820 0200 002 October 2009 3-8

3 General preparations

Fig. 3-4: Settings Æ Package build-up Æ Basics

Fig. 3-5: Settings Æ Package build-up Æ Breathing

Allma CC3 677 820 0200 002 October 2009 3-9

3 General preparations

Fig. 3-6: Settings Æ Length

Allma CC3 677 820 0200 002 October 2009 3-10

4 Starting-up the headstock installation

4 Starting-up the headstock installation

PRECONDITION ▪ Test section or test stand must be properly connected

▪ Check distance of pulse generator (proximity switch) on traverse motion:

+L-B104 / +R-B204; distance: 2.0 ± 0.5mm

▪ Cooling units:
Set thermostat in cooling unit +L-E102 / +R-E202 to 35°C

▪ Fix the door switch +L-S106 / +R-S206 during start-up by using a rubber or
the like

4.1 Visual inspection and continuity check

4.1.1 Switches and fuses

Setting switches and fuses 1. Main switch OFF

2. Disconnect all fuses and power switches (see circuit diagram as well):

▫ Intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229

▫ Power switch of power supplies +L-Q102 / +R-Q202

▫ 24V fuses +L-F101 to F107 / +R-F201 to F207

▫ Fuse of braking transformer +L-F119 / +R-F219

▫ Power switch of braking transformer +L-Q104 / +R-Q204

▫ Power switch of roof fan +L-Q107 / +R-Q207

▫ Power switch of cooling unit or door fan (option) +L-Q108 / +R-Q208

▫ Power switch of fan transformer +L-Q110 / +R-Q210 (option when

using door fans or sockets)

▫ Power switch of conveyor belt +L-Q109

▫ Pull plug X10 from FC traverse motion+L-T101 / +R-T201

3. Pull the power supply plug on the PowerPanel
4. Set the power switches to the following values:

▫ Power switch of braking transformer +L-Q104 / +R-Q204 = 8.0 A

▫ Power switch of roof fan +L-Q107 / +R-Q207 = 0.29 A at 50 Hz (0.39 A

at 60 Hz)

▫ Power switch of cooling unit +L-Q108 / +R-Q208 = 5 A

▫ Power switch of door fan (instead of cooling unit) +L-Q108 / +R-Q208

= 0.9 A

Allma CC3 677 820 0200 002 October 2009 4-11

4 Starting-up the headstock installation

▫ Power switch of fan transformer (not with cooling unit) +L-Q110 / +R-
Q210 = see circuit diagram

▫ Power switch of power supplies+L-Q102 / +R-Q202 = 10 A

▫ Power switch of conveyor belt +L-Q109 = 2 A

▫ Emergency stop relay +L-K104 = 5 sec

4.1.2 DC link bar check

Testing the DC link bar 1. Main switch OFF

2. Visual check + = red – = black
3. Close intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229
4. Check Zk- connection:

▫ between +L-T104 / +R-T204:Zk- (FC spindle) and +L-T103 / +R-

T203:Zk- (FC capstan) Æ continuity (approx. 0 Ω)

▫ between +L-T104 / +R-T204:Zk- (FC spindle) and +L-T101 / +R-

T201:Zk- (FC traverse motion) Æ continuity (approx. 0 Ω)

▫ between +L-T104 / +R-T204:Zk- (FC spindle) and +L-T102 / +R-

T202:Zk- (FC winding) Æ continuity (approx. 0 Ω)
5. Check Zk+ connection:

▫ between +L-T104 / +R-T204:Zk+ (FC spindle) and +L-T103 / +R-

T203:Zk+ (FC capstan) Æ continuity (approx. 0 Ω)

▫ between +L-T104 / +R-T204:Zk+ (FC spindle) and +L-T101 / +R-

T201:Zk+ (FC traverse motion) Æ continuity (approx. 0 Ω)

▫ between +L-T104 / +R-T204:Zk+ (FC spindle) and +L-T102 / +R-

T202:Zk+ (FC winding) Æ continuity (approx. 0 Ω)
6. Open intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229

4.1.3 24VDC supply check

Power supply connection 1. Main switch OFF

check
2. Visual inspection of the 400V lines L1, L2, L3 at line reactor +L-R101 / +R-
R201 to power switch +L-Q102 / +R-Q202
3. Visual inspection of L1, L2, L3 between power switch +L-Q102 / +R-Q202
and terminal -X2

▫ -X2:1b = L1

▫ -X2:3b = L2

Allma CC3 677 820 0200 002 October 2009 4-12

4 Starting-up the headstock installation

▫ -X2:5b = L3
4. Check connection L1 between power switch and power supplies:

▫ between +L-Q102 / +R-Q202:2 and +L-G101 / +R-G201:L1

Æ continuity (approx. 0 Ω)

▫ between +L-Q102 / +R-Q202:2 and +L-G102 / +R-G202:L1

Æ continuity (approx. 0 Ω)

▫ between +L-Q102 / +R-Q202:2 and +L-G103 / +R-G203:L1

Æ continuity (approx. 0 Ω)
5. Check connection L2 between power switch and power supplies:

▫ between +L-Q102 / +R-Q202:4 and +L-G101 / +R-G201:L2

Æ continuity (approx. 0 Ω)

▫ between +L-Q102 / +R-Q202:4 and +L-G102 / +R-G202:L2

Æ continuity (approx. 0 Ω)

▫ between +L-Q102 / +R-Q202:4 and +L-G103 / +R-G203:L2

Æ continuity (approx. 0 Ω)
6. Check connection L3 between power switch and power supplies:

▫ between +L-Q102 / +R-Q202:6 and +L-G101 / +R-G201:L3

Æ continuity (approx. 0 Ω)

▫ between +L-Q102 / +R-Q202:6 and +L-G102 / +R-G202:L3

Æ continuity (approx. 0 Ω)

▫ between +L-Q102 / +R-Q202:6 and +L-G103 / +R-G203:L3

Æ continuity (approx. 0 Ω)

Checking the 24V 1. Main switch OFF

supply
2. Check connection from +24V on +L-G101 / +R-G201:+ to fuse strip +L-
F101 to F107 / +R-F201 to F207 visually
3. Check connection from +24V on +L-G102 / +R-G202:+ to fuse strip +L-
F101 to F107 / +R-F201 to F207 visually
4. Check connection from +24V on +L-G103 / +R-G203:+ to fuse strip +L-
F101 to F107 / +R-F201 to F207 visually
5. Check connection from Ground on +L-G101 / +R-G201:- to mounting plate-
GND20 visually
6. Check connection from Ground on +L-G102 / +R-G202:- to mounting plate-
GND21 visually
7. Check connection from Ground on +L-G103 / +R-G203:- to mounting plate-
GND22 visually

Allma CC3 677 820 0200 002 October 2009 4-13

4 Starting-up the headstock installation

4.1.4 Limit switch of traverse motion

Testing the limit switch 1. Main switch OFF

2. Pull plug +L-T101 / +R-T201:X210a (FC traverse motion)
3. Measure connection between terminal -X1:21 and +L-T101 / +R-T201-
X210a:3 Æ continuity (approx. 0 Ω)
4. Switch limit switch +L-S104 / +R-S204 and +L-S105 / +R-S205 off and
back on again and check for interruptions
5. Re-insert plug +L-T101 / +R-T201:X210a (FC traverse motion)

4.1.5 Fuse circuit

Testing the fuse 1. Main switch OFF.

circuits
2. Pull plug +L-T104 / +R-T204:X210b (FC spindle)
3. Switch on the following circuit breakers and power switches:

▫ Circuit breaker +L-F119 / +R-F219 (braking transformer)

▫ Power switch +L-Q104 / +R-Q204 (braking transformer)

▫ Power switch +L-Q107 / +R-Q207 (roof fan)

▫ Power switch +L-Q108 / +R-Q208 (cooling unit or door fan)

▫ Power switch +L-Q110 / +R-Q210 (transformer in case of door fans or

socket)

▫ Power switch +L-Q109 (conveyor belt)

4. Measure connection between terminal -X1:+24V and +L-T104 / +R-T204-
X210a:7 Æ continuity (approx. 0 Ω)
5. Switch circuit breaker and power switch alternatively off and back on again
and check for interruptions
6. Disconnect circuit breaker and power switch again
7. Re-insert plug +L-T104 / +R-T204:X210b (FC spindle)

Allma CC3 677 820 0200 002 October 2009 4-14

4 Starting-up the headstock installation

4.1.6 Emergency signalling circuit

Testing the emergency 1. Main switch OFF

signalling circuit
2. Disconnect resistor +L-R108 (terminal +L-X5:15/16) on one side
3. Disconnect wire in terminal +L-X5:14b
4. Pull plug +L-T102 / +R-T202:X410a (FC winding)
5. Measure connection between terminal +L-X4:9 and +L-X5:14 Æ continuity
(approx. 0 Ω)
6. Switch +L-S102 (emergency stop switch), +A-S103 / -S203 (trip wire
switch) off and back on again and check for interruptions
7. Connect resistor +L-R108 (terminal +L-X5:15/16) again
8. Connect wire in terminal +L-X5:14b again
9. Re-insert plug +L-T102 / +R-T202:X410a (FC winding)

4.1.7 Compressed air connection

Checking the compressed 1. Main switch OFF

air
2. Disconnect the wires on terminals +L-X1:42b and +L-X1:43b
3. Compressed air > 550kP, pressure switch +A-S100 closed
4. Measure connection between terminal +L-X4:10 and +L-X1:42 Æ continuity
(approx. 0 Ω)
5. Compressed air < 500kP, check pressure switch +A-S100 for interruptions
6. Re-connect the wires on terminals +L-X1:42b and +L-X1:43b
7. Compressed air > 550kP

4.2 Protective conductor check and insulation check

▶ See separate test instructions677 000 9100 300

Allma CC3 677 820 0200 002 October 2009 4-15

4 Starting-up the headstock installation

4.3 Power supply start-up

4.3.1 380VAC supply cable start-up (or 400VAC)

Supply cable 1. Disconnect all fuses and power switches (see circuit diagram as well):
start-up
▫ Intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229

▫ Power switch of power supplies +L-Q102 / +R-Q202

▫ 24V fuses +L-F101 to F107 / +R-F201 to F207

▫ Fuse of braking transformer +L-F119 / +R-F219

▫ Power switch of braking transformer +L-Q104 / +R-Q204

▫ Power switch of roof fan +L-Q107 / +R-Q207

▫ Power switch of cooling unit or door fan +L-Q108 / +R-Q208

▫ Power switch of transformer door fan/socket +L-Q110 / +R-Q210

▫ Power switch of conveyor belt +L-Q109

▫ Pull plug X10 from FC traverse motion+L-T101 / +R-T201

2. Pull the power supply plug on the PowerPanel
3. Switch on main switch
4. The following components must measure approx. 380VAC (or 400VAC)
(threephase current):

▫ Line reactor +L-R101 / +R-R201 ,terminals U/V/W

▫ FC spindle +L-T104 / +R-T204, terminals L1/L2/L3

▫ Power switch of power supplies+L-Q102 / +R-Q202, terminals 1/3/5

▫ Power switch of roof fan +L-Q107 / +R-Q207, terminals 1/3/5

▫ Power switch of cooling unit or door fan +L-Q108 / +R-Q208, terminals

1/3/5

▫ Power switch of transformer door fan/socket +L-Q110 / +R-Q210,

terminals 1/3

▫ Power switch of conveyor belt +L-Q109, terminals 1/3/5

▫ Power switch of braking transformer +L-Q104 / +R-Q204, terminals 1/5

5. LED on FC spindle +L-T104 / +R-T204 flashes/is illuminated red or green
6. Switch on power switch of roof fan +L-Q107 / +R-Q207
7. The roof fan must suck air from underneath
8. In case of installed door fans and/or socket:

▫ Switch on power switch of transformer door fan/socket +L-Q110 / +R-

Q210

Allma CC3 677 820 0200 002 October 2009 4-16

4 Starting-up the headstock installation

Æ 230 V must be measured on terminals 1/3 of power switch of door

fan +L-Q108 / +R-Q208 or socket – X20

▫ Switch on power switch of door fan +L-Q108 / +R-Q208

▫ Check direction of rotation of door fan

Æ Air must be sucked into the control cabinet
9. Main switch OFF

4.3.2 Starting-up the 24VDC supply

Starting-up the 24V supply 1. Main switch OFF

2. 24V fuses +L-F101 to F107 / +R-F201 to F207 must be opened
3. Pull plug X10 from FC traverse motion +L-T101 / +R-T201
4. Close power switch of power supplies +L-Q102 / +R-Q202
5. Main switch ON
6. Green LED on power supplies +L-G101 to G103 / +R-G201 to G203 must
be illuminated
7. Output voltage must be set to 26.80±0.02VDC on power supplies (adjust
with potentiometer)
8. The voltage on the terminals of the 24V fuses +L-F101 to F107 / +R-F201
to F207 must be 26.80±0.02VDC
9. Main switch OFF
10. Insert fuse +L-F107 / +R-F207 (10A)
11. Main switch ON
12. The voltage on the outlet terminal of the 24V fuses +L-F107 / +R-F207
must be 26.80VDC
13. 13. The voltage on the 24V terminals of terminal strip -X1 must measure
approx. +26 VDC (pay attention to polarity!)
14. On terminal +L-K104:Y12 +24VDC must be applied to GND (emergency
stop circuit closed!)
15. Insert the power supply plug on the PowerPanel
16. The controller must be in operation
17. Green LED of FC spindle +L-T104 / +R-T204 flashes
18. Main switch OFF
19. Insert fuses +L-F101 to F106 / +R-F201 to 206 (if available!)
20. Main switch ON

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4 Starting-up the headstock installation

21. The voltage on the outlet terminals of the 24V fuses +L-F101 to F106 / +R-
F201 to 206 must be 26.80VDC
22. The voltage on all operating modules +FRn-A1 and +FLn-A1 (left / right
machine side) must be greater than 24V (ST1: 1 +) and (ST1: 2 -) (Pay
attention to polarity!)
23. Switch on power switch of cooling unit +L-Q108 / +R-Q208 (if available)
24. The cooling unit +L-E102 / +R-E202 must be running (if available)
25. Main switch OFF

4.3.3 Starting up the secondary supplies

Starting up the 1. Main switch OFF

braking transformer
2. Switch on power switch of braking transformer +L-Q104 / +R-Q204
3. Switch on main switch
4. Measure the primary voltage on terminals 1 and 2 (3) on transformer +L-
T100 / +R-T200Æ each must measure approx. 380VAC (or 400VAC)
5. Measure secondary voltage on terminals 31 and 32 (33) (see also circuit
diagram, table 1):

▫ Voltage between terminals 31 and 32 = 80VAC

▫ Voltage between terminals 31 and 33 = 100VAC

6. Main switch OFF

4.3.4 Braking current supply start-up

Starting up the braking 1. Main switch OFF

current supply
2. Disconnect cable -W114 on terminals -X6:1c and -X6:2c
3. Close fuse of braking transformer +L-F119 / +R-F219
4. Switch on main switch
5. On terminal -X6:1a there must be a d.c. voltage of approx. 75VDC (at
transformer connection 31-32) or approx. 100VDC (at transformer
connection 31-33) to ground (mounting plate)
6. Main switch OFF
7. Re-connect cable -W114 on terminals -X6:1c and -X6:2c
8. Open again fuse of braking transformer +L-F119 / +R-F219

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4.4 Starting-up the frequency converter

Starting-up the frequency 1. Main switch OFF
converter
2. Open intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229
3. Main switch ON
4. On intermediate circuit fuses, a d.c. voltage of approx. 540 VDC (or
565VDC) must be measured
5. Main switch OFF
6. Close intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229
7. Main switch ON
8. On terminals Zk+ of converters

▫ +L-T103 / +R-T203 (FC capstan)

▫ +L-T101 / +R-T201 (FC traverse motion)

▫ +L-T102 / +R-T202 (FC winding)

a d.c. voltage of approx. 540 VDC (or 565VDC) must be measured
9. Green LED of FC spindle flashes
10. Interior fans of converters must be running
⇒ Check air flow direction. The air is sucked in through the underside of
the converters

4.5 Addressing the frequency converter

Set the BUS addresses of the frequency converters with KP500

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4 Starting-up the headstock installation

Fig. 4-1: KP500

Setting the node numbers 1. Main switch ON

on frequency
2. Attach the KP500 to the frequency converter
converters
3. Press the ESC button until "-----" is displayed
4. Press ▼ until Para appears
5. Press ENT
6. Use ▲ ▼ to select parameter 28 (Control level)
7. Press ENT
8. Use ▲ ▼ to set parameter 3 (Control level 3)
9. Confirm with ENT
10. Return to parameter level with ESC
11. Use ▲ ▼ to select parameter 387 (Node number)
12. Press ENT
13. Use ▲ ▼ to set the value according to Table 4-1 , p. 4-21
14. Confirm with ENT
15. Return to parameter level with ESC

⇒ Checking:
16. Use ▲ ▼ to select parameter 385 (Baudrate)
17. Press ENT
18. Parameter value should be 6
19. Repeat the procedure for all frequency converters

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Table 4-1: Node numbers of the frequency converter

Frequency converter Node number

(FC traverse motion)+L-T101 / +R-T201 1

(FC winding)+L-T102 / +R-T202 2

(FC capstan),+L-T103 / +R-T203 3

(FC spindle)+L-T104 / +R-T204 4

4.6 Starting-up the control software

CAUTION
After the update the default values are loaded!
If you want the current settings to be effective for all menus after
updating, the settings have to be saved in advance and reloaded after
updating

▶ See operating instructions Æ Saving settings

▶ See operating instructions Æ Loading the settings

After the software update, the Ethernet address must be defined again

Installing new software 1. Main switch OFF

2. Remove the flash card from the slot in the PowerPanel
3. Insert a new flash card

For programming the flash card please refer to separate instructions

4. Main switch ON
5. After booting the screen must be calibrated
⇒ 4 circles appear one after the other. Each circle has to be touched:

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4 Starting-up the headstock installation

Fig. 4-2: View Calibration Touch

⇒ Finally an image appears in which a valid licence code and the desired
machine version has to be entered

Fig. 4-3: Entering licence code and selecting machine version

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4 Starting-up the headstock installation

6. Touch the licence code

7. Type licence code
8. Actuate OK
9. Actuate Accept
⇒ With a valid licence code appears next to the licence code.
⇒ Options are ticked depending on whether they are enabled

In case no valid licence code is available( ), please contact Oerlikon

Saurer Service in Kempten

10. Actuate Machine variant

⇒ Dialogue for entering the machine variant opens
11. Choose desired machine variant
12. Press OK
⇒ Then the IPC is rebooted and the system can be used

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4.7 Starting up the control modules

4.7.1 Addressing the control modules

If there are two or more control modules with the same address in the
machine (e.g. during the initial start-up of the machine or when
replacing a module), the control must be interrupted during the boot
sequence so that the addressing can be done.

Addressing the control 1. Main switch ON

modules
⇒ IPC begins to boot, BIOS messages appear, RAM test is performed,
and various messages are displayed. A blue screen appears next and
then the following display appears for 10 seconds

Fig. 4-4: Image for the branch to addressing

2. must be pressed within these 10 seconds. Then the following

appears:

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4 Starting-up the headstock installation

Fig. 4-5: Setup during booting

▫ Set the required language (German, English, etc.)

▫ Set the total number of spindles per machine side

▫ Actuate Start addressing for each machine side

Æ the following screen appears:

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Fig. 4-6: Addressing operation

⇒ all yellow indicator lights on the control modules for the respective
machine side begin flashing quickly
3. Starting from the headstock, actuate all start buttons on the control
modules one after the other:
⇒ the respective indicator light must stop flashing after actuating
⇒ the addressing progress can be viewed on the controller screen
4. On left side of the machine only:
⇒ After addressing last spindle Æ Addressing conveyor belt module

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4 Starting-up the headstock installation

Fig. 4-7: Addressing conveyor belt

5. Actuate Addressing module

6. Actuate Spindle start on control module of conveyor belt
⇒ After actuation of all spindle buttons, the display shows
7. Then all control modules are checked for type and software version
⇒ If an incorrect module type is detected, an error message will be
entered in the logbook. The respective message also appears on the
screen of the central controller after booting
⇒ If a different software status is detected, a software update is
performed on the respective module automatically

For further error messages (see 9.3 Problems with control modules in network,
p. 9-141)

The software update requires approx. 37 seconds per spindle. That

means approximately one hour for a complete machine.

▶ The machine must not be switched off during the software update!

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4.7.2 Addressing test

Addressing test 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Select menu item ServiceÆ Start-upÆ Spindle

Fig. 4-8: Fig. -: Service menuÆ Start-upÆ Spindle

3. Actuate Addressing test

⇒ The yellow LEDs on each spindle position will flash once each in the
sequence of the addressing

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4.8 Settings
4.8.1 Setting the default values for all menus

Settings 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Set the default values for all settings by pressing Default All in the menu
AdministrationÆ ConfigurationÆ Machine and answering the prompt with
"Yes"

Fig. 4-9: View Administration Æ Configuration Æ Machine

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4 Starting-up the headstock installation

4.8.2 Settings for spindle

Table 4-2: Setting of max. spindle current for spindle sizes 205, 230, 250

Spindle current
Altitude of installation
168 Spi 160 Spi 152 Spi ≤ 144 Spi
< 1000 m 1700 mA 1800 mA 1900 mA 2000 mA
1000 to 2000 m 1600 mA 1700 mA 1800 mA 1800 mA
2000 to 3000 m 1500 mA 1600 mA 1700 mA 1700 mA

Table 4-3: Setting of max. spindle current for spindle sizes 290, 310,

Spindle current
Altitude of installation
168 Spi 160 Spi 152 Spi ≤ 144 Spi
< 1000 m ---- 1800 mA 1900 mA 2000 mA
1000 to 2000 m ---- 1700 mA 1800 mA 1800 mA
2000 to 3000 m ---- 1600 mA 1700 mA 1700 mA

Settings 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Enter the following settings in menu AdministrationÆ ConfigurationÆ
Spindles

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Fig. 4-10: Menu AdministrationÆ ConfigurationÆ Spindles

▫ Value for Number of spindles

▫ Max. spindle current (see Table 4-2 , p. 4-30)

WARNING
Incorrect setting for the spindle current can lead to damaging the
spindle motors!

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4 Starting-up the headstock installation

4.8.3 Unit for length counting and yarn count

Length counter and yarn 1. Use the global button to enter Machine engineer (see 3.3.2 Password
count system/Code levels, p. 3-7)
2. Make the following settings in menu AdministrationÆ SettingsÆ Units

Fig. 4-11: AdministrationÆ SettingsÆ Units

▫ Titre to dtex

▫ Length to Metre

The setting Length to Metre and Titre to dtex is required for

correct operation of the start-up and trouble shooting instructions. The
conversion to Yard and/or den can be done according to the start-up
and troubleshooting instructions!

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4.9 Parameterisation of drives

4.9.1 Spindle drive

Parameterisation of 1. Use the Global Button to enter the password Machine engineer
Spindle drive
2. Set the spindle type in menu AdministrationÆ ConfigurationÆ Spindle

Fig. 4-12: Menu AdministrationÆ ConfigurationÆ Spindles

3. Set the parameters of the spindle drive in menu Service Æ

ParameterisationÆ FC Spindle (Actuate button Run)

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4 Starting-up the headstock installation

Fig. 4-13: Service menuÆ ParameterisationÆ FC Spindle

⇒ Symbols in the Status line show whether the parameter setting is running
( ), has been run ( ) or is faulty ( )
4. Re-insert plug X10 on FC traverse motion +L-T101 / +R-T201

4.9.2 Winding drive

Parameterisation of 1. Use the global button to enter Machine engineer (see 3.3.2 Password
winding drive system/Code levels, p. 3-7)
2. Set the parameters of the
winding drive in menu Service Æ
ParameterisationÆ FC Winding (Actuate button Run)

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4 Starting-up the headstock installation

Fig. 4-14: Service menuÆParameterisationÆFC winding

⇒ Symbols in the Status line show whether the parameter setting is running
( ), has been run ( ) or is faulty ( )

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4 Starting-up the headstock installation

4.9.3 Capstan drive

Parameterisation of 1. Use the global button to enter Machine engineer (see 3.3.2 Password
capstan drive system/Code levels, p. 3-7)
2. Set the parameters of the capstan drive in menu Service Æ
ParameterisationÆ FC capstan (Actuate button Run)

Fig. 4-15: Service menuÆ ParameterisationÆFC capstan

⇒ Symbols in the Status line show whether the parameter setting is running
( ),has been run ( ) or is faulty ( )
3. Re-insert plug X10 on FC traverse motion +L-T101 / +R-T201

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4 Starting-up the headstock installation

4.9.4 Traverse motion drive

Parameterisation of 1. Use the global button to enter Machine engineer (see 3.3.2 Password
traverse motion drive system/Code levels, p. 3-7)
2. Set the parameters of the traverse motion drive in menu Service Æ
ParameterisationÆ FC traverse motion (Actuate button Run)

Fig. 4-16: Service menuÆ ParameterisationÆFC traverse motion drive

⇒ Symbols in the Status line show whether the parameter setting is running
( ),has been run ( ) or is faulty ( )
3. Re-insert plug X10 on FC traverse motion +L-T101 / +R-T201

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4 Starting-up the headstock installation

4.10 Testing the saving and loading procedures (with a

USB stick)
Testing save/load 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Select service menuÆ DiagnosticsÆ Archive

Fig. 4-17: Service menuÆDiagnosticsÆArchive

Saving setting data 3. Select machine side.

4. Select button Setting all menus Saving
⇒ Input window appears
5. Enter any alpha-numeric file name no longer than 32 characters
6. Press Enter
⇒ Setting data is saved

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4 Starting-up the headstock installation

Fig. 4-18: Dialogue Saving

Loading setting data ⇒ The machine must be stopped

1. Change any setting (e.g. spindle rpm)
2. Back to menu ServiceÆ DiagnosticsÆ Archive
3. Select machine side
4. Select Loading settings
⇒ List of files appears
5. Choose desired file from table
6. Press Enter
⇒ Setting data of desired file is loaded

Fig. 4-19: Dialogue Loading

7. Check if the previously changed setting has the saved value

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4.11 Tests to perform

4.11.1 Machine status

Checking the 1. Go to menu ServiceÆ DiagnosticsÆ Machine status (see Fig. 8-7, p. 8-98)
machine status
⇒ The machine status is shown from bit 0 to F. ( = 24 VDC, = 0

VDC, = not assigned)

2. Check the status of the machine (Bit0=1, Bit4=1, Bit8=1). all others = 0)

4.11.2 Testing the inputs

▶ Always check both states (1 and 0) when testing

FC spindle 1. Go to menu ServiceÆ DiagnosticsÆ Machine status (see Fig. 8-8, p. 8-99)
inputs
2. Actuate and unlock again the emergency stop button +L-S102 (emergency
stop relay +L-K104 drops out)
⇒ After 5 sec: Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up)
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. With suction unit option. Disconnect wire on terminal X210A:5 from FC
spindle +L-T104 / +R-T204
⇒ Bit 3 = 1 (wire connected)
⇒ Bit 3 = 0 (wire disconnected)
5. Fuse of power supplies: Alternately connect and disconnect +L-Q102 / +R-
Q202
⇒ Bit 4 = 1 +L-Q102 / +R-Q202 ON)
⇒ Bit 4 = 0 +L-Q102 / +R-Q202 OFF)
6. Fuse circuit: Alternately connect and disconnect +L-F119 / +R-F219, +L-
Q104 / +R-Q204 (braking voltage), +L-Q107 / +R-Q207 (roof fan), +L-Q108
/ +R-Q208 (cooling unit) and +L-Q109 (conveyor belt Æ left side only)
⇒ Bit 5 = 1 (all ON)
⇒ Bit 5 = 0 (all OFF)
7. Power supply trouble. Alternately disconnect the signalling contacts +L-
G101 to G103 / +R-G201 to G203: 1+/ 2-

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4 Starting-up the headstock installation

⇒ Bit 6 = 1 (contact connected)

⇒ Bit 6 = 0 (contact disconnected)
8. Standby OFF

FC traverse 1. Go to menu ServiceÆ DiagnosticsÆ Machine status (see Fig. 8-8, p. 8-99)
inputs
2. Actuate and unlock again the emergency stop button +L-S102 (emergency
stop relay +L-K104 drops out)
⇒ After 5 sec: Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up)
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. Normally open button Standby on (clockwise)
⇒ Bit 3 = 1 (upon actuation)
⇒ Bit 3 = 0 (idle)
5. Normally closed button Standby off (anticlockwise)
⇒ Bit 4 = 1 (idle)
⇒ Bit 4 = 0 (upon actuation)
6. Standby OFF
7. Move traverse rod by hand. Sensor +L-B104 / +R-B204 is covered by the
referencing ruler for half of the traversing distance, the other half it is not
⇒ Bit 5 = 1 (traverse sensor covered by plate)
⇒ Bit 5 = 0 (traverse sensor not covered by plate)

FC winding 1. Go to menu ServiceÆ DiagnosticsÆ Machine status (see Fig. 8-8, p. 8-99)
inputs
2. Actuate and unlock again the emergency stop button +L-S102 (emergency
stop relay +L-K104 drops out)
⇒ After 5 sec: Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up)
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. Actuate button Machine start briefly, several times
⇒ Bit 3 = 1 (button pressed)
⇒ Bit 3 = 0 (button not pressed)
5. Pressure regulator fault: Switch off compressed air
⇒ Bit 4 = 0 and buzzer starts
6. Switch compressed air back on

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4 Starting-up the headstock installation

⇒ Bit 4 = 1 When the warning on the display is acknowledged, the buzzer

stops
7. Motor temperature contact: Disconnect wire in terminal X210B:6 on FC
winding +L-T102 / +R-T202
⇒ Bit 5 = 0
8. Connect wire in terminal X210B:6 again
⇒ Bit 5 = 1
9. Actuate emergency stop button +L-S102 and unlock again
⇒ Bit 6 = 1 (button released)
⇒ Bit 6 = 0 (button actuated)
10. Auxiliary switch of main switch:
⇒ Bit 7 = 1 (Main switch +M-Q101/-Q201 switched on)
11. Standby OFF

FC capstan inputs 1. Go to menu ServiceÆ DiagnosticsÆ Machine status (see Fig. 8-8, p. 8-99)
2. Actuate and unlock again the emergency stop button +L-S102 (Emergency
stop relay +L-K104 drops out)
⇒ After 5 sec: Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up)
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. Actuate button Machine stop briefly, several times
⇒ Bit 3 = 1 (button not pressed)
⇒ Bit 3 = 0 (button pressed)
5. Motor temperature contact: Disconnect wire in terminal X210B:6 on FC
capstan +L-T103 / +R-T203
⇒ Bit 5 = 0
6. Connect wire in terminal X210B:6 again
⇒ Bit 5 = 1
7. Standby OFF

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4.11.3 Testing the outputs

▶ Always check both states (1 and 0) when testing

Testing the FC outputs 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Go to menu ServiceÆ DiagnosticsÆ Machine status (see Fig. 8-8, p. 8-99)
3. Activate Test outputs
⇒ All outputs are set to 0
4. Test all outputs according to the following table

Table 4-4: Testing the outputs

Frequency Bit Action with activated output (= 1)

converter

FC spindle Bit 0 Operating hours counter +L-P103/ +R-P203

running

FC traverse Bit 0 LED button Standby (+L-P100) illuminated

motion Bit 1 Battery contactor (+L-Q103 / +R-Q203) picks up

Bit 2 Conveyor belt relay ( +L-K105) picks up

FC winding Bit 0 LED button Machine start (+L-P101/-P201)

illuminated

Bit 1 Signal lamp blue(+L-E100 / +R-E200) illuminated

Bit 2 Signal lamp yellow(+L-E101 / +R-E201) illuminated

Bit 3 Buzzer (+L-E102 / +R-E202) sounds

Note: The remaining outputs are not assigned.)

▶ The outputs cannot be set unless standby mode of machine is

switched off

▶ Only one output can be set at a time!

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4.12 Checking the versions

Checking the versions 1. Go to menu Report Æ Versions (see 8.4 Reading out the software
versions, p. 8-106)
2. Enter software versions in control sheet

4.13 Checking machine functions

PRECONDITION ▪ Before switching the machine on, check the mechanical movement of the
winding, capstan and traverse drives

▪ Do not remove the spindle pot to allow the spindle to turn for checking the
rotation direction because the bearing will lose its lubricant

▪ Headstock test stand or test section is properly connected with headstock

4.13.1 Preparation

Making settings 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Make the following settings:

Table 4-5: Settings for test of machine functions

Menu Setting Value Graphics

Settings Æ Machine Machine start mode Single Fig. 3-2,

p.3-8

SettingsÆ YarnÆ Overfeed -2% Fig. 3-3,

Yarn path Twists 600 tpm p.3-8

spindle speed 6000 RPM

Twist direction: S

SettingsÆ Package Traverse length 264 mm Fig. 3-4,

build-upÆ Basics Crossing angle 37.0° p. 3-9

Settings Æ Package Number of 84,00 Fig. 3-5 ,

traverses N1
build-up Æ Breathing p.3-9
Number of 18,00
traverses N2

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4 Starting-up the headstock installation

Menu Setting Value Graphics

Antipatterning 1,0°
angle α
Settings Æ Length Nominal length 400 m Fig. 3-6 ,
Prewarning doffing 100 m p.3-10

Reset spindle Yes

length counter

3. Wound a rubber around the CordGuard at each spindle to simulate thread

4.13.2 Checking the headstock functions

Checking machine 1. Use the global button to enter Machine engineer (see 3.3.2 Password
functions system/Code levels, p. 3-7)
2. Standby ON
⇒ Standby LED illuminated
3. Actuate Machine start (2-3 s)
⇒ Lamp in the button flashes
⇒ Buzzer sounds
⇒ Machine starts running
⇒ Machine run-up is ended, when the button is illuminated continuously

4. Start one spindle

5. Go to menu MachineÆ SpindleÆ (see Fig. 8-4, p. 8-95)
⇒ 60 seconds after the spindle run-up, the slippage regulation adjusts the
spindle speed
6. Perform a check of the rpm of the started spindle (6000 RPM ± 20 RPM)

7. Go to menu MachineÆ OverviewÆ (see Fig. 8-3, p. 8-94)

8. Check Current vDel = 10.0 ± 0.1 m/min
9. Check Current vWind. = 9.2 ± 0.1 m/min
10. Check the rotation direction of capstan and winding

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4 Starting-up the headstock installation

Fig. 4-20: Check the rotation direction of capstan and winding

11. Go to menu ServiceÆ ParameterisationÆ FC traverse motion (see Fig.

8-10, p. 8-103)

▫ Parameter = 240 (actual speed)

▫ Data record = 0

▫ Type = DINT
⇒ The rpm of the traverse is changed continually.
The value deviates between 0 and ± 120 RPM
12. Actuate Machine stop
13. Pay attention to the traverse motion
⇒ Traverse remains at home position (Traverse centre)
14. Go to menu SettingsÆ YarnÆ Yarn path (see Fig. 3-3, p. 3-8)

▫ Turns = 200 TPM

▫ Spindle speed = 4000 RPM

15. Actuate Machine start (2-3 s)
16. Start one spindle

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4 Starting-up the headstock installation

17. Go to menu MachineÆ SpindleÆ (see Fig. 8-4, p. 8-95)

⇒ 60 seconds after the spindle run-up, the slippage regulation adjusts the
spindle speed
18. Perform a check of the rpm of the started spindle (4000 RPM ± 20 RPM)
19. Go to menu MachineÆ OverviewÆ (see Fig. 8-3, p. 8-94)
20. Check Current fDel = 20.0 ± 0.1 m/min
21. Check Current vWind. 18.6 ± 0.1 m/min
22. Actuate Machine stop
23. Pay attention to the traverse motion
⇒ Traverse remains at home position (Traverse centre)
24. Standby OFF

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4 Starting-up the headstock installation

4.13.3 Checking the direction of rotation of spindle motors

Checking the direction of 1. Use the global button to enter Machine engineer (see 3.3.2 Password
rotation system/Code levels, p. 3-7)
2. Go to menu SettingsÆ YarnÆ Yarn path (see Fig. 3-3, p. 3-8)

▫ Direction of twist = S
3. Standby ON
4. Actuate Machine start (2-3 s)
⇒ Machine starts running
5. Switch on spindle position 1
6. Spindle motor turns to the left (top view!)
7. Check the rotation direction of capstan Clockwise (viewed from headstock)
8. Check the rotation direction of winding: Clockwise (viewed from
headstock)
9. Actuate Machine stop
10. Wait until all motors stop completely

11. Go to menu SettingsÆ YarnÆ Yarn path (see Fig. 3-3, p. 3-8)

▫ Direction of twist = Z
12. Actuate Machine start (2-3 s)
⇒ Machine starts running
13. Switch on spindle position 1
14. Spindle motor turns to the right (top view!)
15. Check the rotation direction of capstan Clockwise (viewed from headstock)
16. Check the rotation direction of winding: Clockwise (viewed from
headstock)
17. Actuate Machine stop
18. Wait until all motors stop completely

19. Go to menu SettingsÆ YarnÆ Yarn path (see Fig. 3-3, p. 3-8)

▫ Direction of twist = S
20. Standby OFF

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4 Starting-up the headstock installation

4.14 Checking the emergency stop function

Safety first!

Checking the 1. Standby ON

emergency stop function
2. Actuate Machine start
3. Start all spindles
4. Actuate the emergency stop button.+L-S102
⇒ Winding drive, capstan drive and traverse drive all stop immediately
⇒ Spindle motors brake to a stop as quickly as possible (depends on the
number of spindles running)
5. Release the emergency stop button again
6. Acknowledge message in logbook (see 8.1 Logbook, p. 8-91)

4.15 Battery charging test (option)

Battery charging test 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Select service menuÆ DiagnosticsÆ Battery test

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4 Starting-up the headstock installation

Fig. 4-21: Service menuÆ DiagnosticsÆ Battery test

3. Touch Battery test on left and right side

⇒ Status changes to active ( )
4. Main switch OFF
⇒ Time measurement starts simultaneously
5. Wait until buffer time of about 15 minutes is over
⇒ During this time display must not go off, i.e. machine must not switch
off
6. Touch Battery test again
⇒ The respective machine side is switched off after a few seconds
7. Main switch ON
8. Measure the charging current of the battery by means of the clamp
ammeter
⇒ Charging current is > 2 ADC
9. Charge batteries for several hours

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4 Starting-up the headstock installation

4.16 Parameterisation of language

Setting the language 1. Touch the global button Selection of language (top/right of screen)
⇒ Dialogue Language selection opens

Fig. 4-22: Dialogue Language

2. Set the customer language

3. Main switch OFF

4.17 Remote maintenance via modem (option)

For the connection test the phone number of the modem should be
known!

Modem test 4. Main switch OFF

5. Connect modem +L-1A12 with the telephone network
6. Main switch ON
7. Connect modem (e.g. by using a mobile)
⇒ The modem answers after a few seconds with a whistling sound
⇒ The connection LED on the modem is lit
⇒ Connection is thus okay!

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5 Starting up the section installation

5 Starting up the section installation

5.1 Visual inspection and continuity check
5.1.1 Switches and fuses

Setting switches and fuses 1. Main switch OFF

2. Set all power switches +FRn-Q1 and +FLn-Q1 in the circuits of each
section to 10 A
3. Switch on power switches +FRn-Q1 and +FLn-Q1
4. Remove all fuses +Fx-F1A/C

5.1.2 Wiring of contactors in power cable duct)

Wiring of contactors 1. Wiring of spindle motors on contactor -K1x:

▫ Terminal -K1x:2 = Colour of core: black

▫ Terminal -K1x:4 = Colour of core: blue

▫ Terminal -K1x:6 = Colour of core: brown

(x = A, B, C or D)
2. Connection of control cable of operating units on contactors -K1x and -K2x:

▫ Cable -W32:yellow on -K1x:

▫ Cable -W32:pink on -K1x:21

▫ Cable -W32:grey on -K2x:21

(x = A, B, C or D)
3. Make sure that core 1 of the brake cable is connected to -X1:1 and core 2
is connected to terminal -X1:2

5.1.3 24V distribution

Check polarity of the +24V-supply to the control modules on terminal strips X1

in middle of section!

▪ Terminal -X1:1 = +24V

▪ Terminal +FMn-X1:2 = earth

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5 Starting up the section installation

5.2 Protective conductor check and insulation check

▶ See separate test instructions677 000 9100 300

5.3 Starting up the braking current supply

Braking current supply 1. Main switch ON
start-up
2. On terminal +Fx-X1:1 there must be a d.c. voltage of approx. 75VDC (at
transformer connection 31-32) or approx. 100VDC (at transformer
connection 31-33) to ground (cable power duct)
3. Main switch OFF
4. Insert all fuses +Fx-F1A/C
5. Main switch ON
6. On terminal +Fx-K2:1 of the braking transformer there must be a d.c.
voltage of approx. 75VDC (at transformer connection 31-32) or approx.
100VDC (at transformer connection 31-33) to ground (cable power duct)

5.4 Tests to perform

5.4.1 Spindle status

Checking the 1. Go to menu ServiceÆ DiagnosticsÆ Spindle (see Fig. 8-9, p. 8-101)
spindle status
⇒ The spindle status is shown from bit 0 to F ( = 24 VDC, = 0

VDC, = not assigned)

2. Spindle stopped
⇒ Bit 0 = 1
3. Press Spindle start
⇒ Bit 1 = 1 (during run-up)
4. After run-up of spindle:

▷ Bit 2 = 1
5. Press Spindle stop
⇒ Bit 3 = 1 (during shutdown)
6. After spindle has stopped:

▷ Bit 0 = 1

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5 Starting up the section installation

5.4.2 Testing the inputs

▶ Always check both states (1 and 0) when testing

Spindle 1. Go to menu ServiceÆ DiagnosticsÆ Spindle (see Fig. 8-9, p. 8-101).

inputs
2. Press Spindle start
⇒ Bit 4 = 1 (as long as button is pressed)
3. Press Spindle stop
⇒ Bit 5 = 1 (as long as button is pressed)

5.4.3 Testing the outputs

▶ Always check both states (1 and 0) when testing

Testing the FC outputs 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Go to menu ServiceÆ DiagnosticsÆ Spindle (see Fig. 8-9, p. 8-101)
3. Activate Test outputs
⇒ All outputs are set to 0
4. Test all outputs according to the following table

Table 5-1: Testing the outputs

Bit Action with activated output (= 1)

Bit 0 Winding off (valve picket up)

Bit 1 Motor contactor picked up

Bit 2 Brake contactor picked up

Bit 3 Capstan clutch picked up

Bit 4 Control panel LED GREEN illuminated

Bit 5 Control panel LED YELLOW

illuminated

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5 Starting up the section installation

Bit Action with activated output (= 1)

Bit 6 Control panel LED RED illuminated

Bit 7 Control panel LED CAN illuminated

Bit 8 Creel yarn tensioner has picked up

Note: The remaining outputs are not assigned)

▶ The outputs cannot be set unless standby mode of machine is

switched off

▶ Only one output can be set at a time!

WARNING
The brake contactor output must only be set for max. 20 sec.
Otherwise the spindle motor may be damaged or destroyed!

Press the buttons + and – or Spindle to select the spindle to be displayed

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5 Starting up the section installation

5.5 Calibration of CordGuard (option)

Calibration of CordGuard 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Select menu Service Æ Start-upÆ CordGuard

Fig. 5-1: Menu Service Æ Start-upÆ CordGuard

3. Choose desired spindle

⇒ The current yarn tension actual value is displayed in Current value
4. Actuate Start calibration
⇒ CordGuard is being calibrated. 0 cN is displayed in Current value

5.6 Checking the spindle functions

▶ Do not remove the spindle pot to run the spindle or for checking the
rotation direction because the bearing will lose its lubricant

▶ Properly connect section to section test stand (see Instructions 677

850 0200 000)

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5 Starting up the section installation

5.6.1 Preparation

Settings 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Make the following settings:

Table 5-2: Settings for test of machine functions

Menu Setting Value Graphics

Settings Æ Machine Machine start mode Single Fig. 3-2,

p. 3-8

SettingsÆ YarnÆ Overfeed -2% Fig. 3-3,

Yarn path Twists 600 tpm p. 3-8

Spindle speed 6000 RPM

Twist direction S

SettingsÆ Package Traverse length 264 mm Fig. 3-4,

build-upÆ Basics Crossing angle 40.0° p. 3-9

Settings Æ Package Number of 24.00 Fig. 3-5 ,

traverses N1
build-up Æ Breathing p.3-9
Number of 6.00
traverses N2
Antipatterning 4.0°
angle α
Settings Æ Length Nominal length 10 m Fig. 3-6 ,
Prewarning doffing 5m p.3-10

Reset spindle Yes

length counter

3. Wound a rubber around the CordGuard at each spindle to simulate thread

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5 Starting up the section installation

5.6.2 Checking the spindle positions

Testing the spindle 1. Standby ON.

position
2. Actuate Machine start
⇒ Machine starts running

▶ The following test must be performed on every spindle position!

3. Start spindle Æ Actuate Spindle start

⇒ Package lifting pan disappears immediately (0.1 sec)
⇒ Spindle motor starts after a 1-second delay
⇒ Direction of rotation, left (top view)
4. Switch off spindle Æ Actuate Spindle stop
⇒ Spindle motor begins braking
⇒ Spindle motor stops completely after a 13 second delay
⇒ If the spindle motor stops, the package lifting pan moves up
5. Start spindle Æ Actuate Spindle start
6. Simulate thread break (Lift rubber)
⇒ Package lifting pan disappears immediately
⇒ Yellow signal lamp is permanently illuminated
⇒ Spindle motor stops completely after a 13 second delay
7. Start spindle Æ Actuate Spindle start
⇒ Prewarning doffing occurs after approx. 1 min (yellow signal lamp
illuminates briefly in intervals of 1 second)
⇒ Spindle shut-off occurs after approx. 2 min (Nominal length achieved!)
8. Continue with the next spindle
9. After all spindles have been tested:

▷ Standby OFF

5.6.3 Checking the spindle motors

Making settings 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Make the following settings:

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5 Starting up the section installation

Table 5-3: Settings for test of machine functions

Menu Setting Value Graphics

SettingsÆ YarnÆ Twists 400 tpm Fig. 3-3,

Yarn path p.3-8

Settings Æ Length Nominal length 10000 m Fig. 3-6,

Prewarning doffing 9800 m p.3-10

Checking the direction of 1. Standby ON.

rotation
2. Actuate Machine start (2-3 s)
3. Switch on spindle positions 18
4. Spindle motors turn to the left (top view!)
5. Actuate Machine stop
6. Wait until all motors stop completely

7. Go to menu SettingsÆ YarnÆ Yarn path (see Fig. 3-3, p. 3-8)

▫ Direction of twist = Z
8. Actuate Machine start (2-3 s)
9. Switch on spindle positions 18
10. Spindle motors turn to the right (top view!)
11. Actuate Machine stop
12. Wait until all motors stop completely

13. Go to menu SettingsÆ YarnÆ Yarn path (see Fig. 3-3, p. 3-8)

▫ Direction of twist = S

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5 Starting up the section installation

Testing the spindle motor 1. Actuate Machine start

2. Change to ReportsÆ Logbook (see Fig. 8-1, p. 8-91)
3. Actuate Active errors (see Fig. 8-28-93
⇒ Table should be empty
⇒ (If error messages are in the table, actuate Reset error and resolve
any respective faults if any exist)
4. Start all spindles (max. 3 spindles simultaneously within 10 seconds)
⇒ No start refusals are allowed
5. Watch display
⇒ No error messages are to appear during 10 minutes of running
operation
⇒ Make sure that no spindles are switched off by the process monitoring
system during this period

6. Go to menu MachineÆ SpindleÆ (see Fig. 8-4, p. 8-95)

7. Check the revolutions per minute for all spindle motors (6000 RPM ± 1%)
8. Standby OFF
9. Main switch OFF

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6 Start-up at customer's works

6 Start-up at customer's works

PRECONDITION ▪ Complete machine mechanically installed

▪ All necessary connecting lines are provided (Prior to installing the conveyor
belt, check the polarity of the +24V-supply to the control modules at the
terminal strips X1 in the middle of the section!)

▪ Visual check for transport damage

▪ Connection to 400V three-phase current (clockwise phase sequence)

▪ Check distance of pulse generator (proximity switch) on traverse motion:

+L-B104 / +R-B204; distance: 2.0 ± 0.5mm

▪ Fix the door switch +L-S106 / +R-S206 during start-up by using a rubber or
the like

6.1 Visual inspection and continuity check

Test points 1. Check polarity of the +24V-supply to the control modules on terminal strips
X1 in middle of section!
⇒ The polarity of the supply lines must be checked for each section
Terminal +FMn-X1:1 = +24VDC (brown)
Terminal +FMn-X1:2 = GND (blue)
(n = 1 … number of sections)

NOTE
Interchanged supply lines will destroy the control modules

2. Braking power supply must be checked

⇒ The polarity of the brake supply lines must be checked for each section
Terminal +FLn-X1:1 or +FRn-X1:1 = core 1 (RO)
Terminal +FLn-X1:2 or +FRn-X1:2 = core 2 (TO)
(n = 1 … number of sections)
3. All terminals in the control cabinet and in the sections must be tightened
with a torque wrench or torque screwdriver (see table for values)

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6 Start-up at customer's works

Table 6-1: Torque information

Marking Device Thread Torque

+M-Q101/-Q201 Main switch M10 20 Nm

+M-K101/-K201 Line filter M10 20 Nm

(optional)

+L-R101 / +R-R201 Line reactor M10 20 Nm

+L-K103 /+R-K203 Motor filter M10 20 Nm

6.2 Power supply start-up

6.2.1 380VAC supply cable start-up (or 400VAC)

Supply cable 1. Disconnect all fuses and power switches (see circuit diagram as well):
start-up
▫ Intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229

▫ Power switch of power supplies +L-Q102 / +R-Q202

▫ 24V fuses +L-F101 to F107 / +R-F201 to F207

▫ Fuse of braking transformer +L-F119 / +R-F219

▫ Power switch of braking transformer +L-Q104 / +R-Q204

▫ Power switch of roof fan +L-Q107 / +R-Q207

▫ Power switch of cooling unit or door fan +L-Q108 / +R-Q208

▫ Power switch of transformer door fan/socket +L-Q110 / +R-Q210

▫ Power switch of conveyor belt +L-Q109

▫ All power switches +FLn+Q1 sections on left side

▫ All power switches +FRn+Q1 sections on right side

2. Pull the power supply plug on the PowerPanel
3. Switch on main switch
4. Measure the voltage on the terminals of the main switch Æ each must
measure approx. 380VAC (or 400VAC) (three-phase current)
5. The following components must measure approx. 380VAC (or 400VAC)
(threephase current):

▫ Line reactor +L-R101 / +R-R201 terminals U/V/W

▫ FC spindle +L-T104 / +R-T204 terminals L1/L2/L3

▫ Power switch of power supplies+L-Q102 / +R-Q202 terminals 1/3/5

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6 Start-up at customer's works

▫ Power switch of roof fan +L-Q107 / +R-Q207 terminals 1/3/5

▫ Power switch of cooling unit or door fan +L-Q108 / +R-Q208

▫ Power switch of transformer door fan/socket +L-Q110 / +R-Q210

▫ Power switch of conveyor belt +L-Q109 terminals 1/3/5

▫ Power switch of braking transformer +L-Q104 / +R-Q204 terminals 1/5

6. LED on FC spindle +L-T104 / +R-T204 flashes/is illuminated red or green
7. Switch on power switch of roof fan +L-Q107 / +R-Q207
8. The roof fan must suck air from underneath
9. In case of installed door fans and/or socket:

▫ Switch on power switch of transformer door fan/socket +L-Q110 / +R-

Q210
Æ 230 V must be measured on terminals 1/3 of power switch of door
fan +L-Q108 / +R-Q208 or socket – X20

▫ Switch on power switch of door fan +L-Q108 / +R-Q208

▫ Check direction of rotation of door fan

Æ Air must be sucked into the control cabinet
10. Main switch OFF

6.2.2 Starting-up the 24VDC supply

Starting-up the 24V supply 1. Main switch OFF

2. 24V fuses +L-F101 to F107 / +R-F201 to F207 must be opened
3. Close power switch of power supplies +L-Q102 / +R-Q202
4. Main switch ON
5. Green LED on power supplies +L-G101 to G103 / +R-G201 to G203 must
be illuminated
6. The voltage on the terminals of the 24V fuses +L-F101 to F107 / +R-F201
to F207 must be 26.80±0.02VDC
7. Main switch OFF
8. Insert fuse +L-F107 / +R-F207 (10A)
9. Main switch ON
10. The voltage on the outlet terminal of the 24V fuses +L-F107 / +R-F207
must be 26.80VDC
11. The voltage on the 24V terminals of terminal strip -X1 must measure
approx. +26 VDC (pay attention to polarity!)

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6 Start-up at customer's works

12. On terminal +L-K104:Y12 +24VDC must be applied to GND (emergency

stop circuit closed!)
13. Insert the power supply plug on the PowerPanel
14. The controller must be in operation
15. Green LED of FC spindle +L-T104 / +R-T204 flashes
16. Main switch OFF
17. Insert fuses +L-F101 to F106 / +R-F201 to 206 (if available!)
18. Main switch ON
19. The voltage on the outlet terminals of the 24V fuses +L-F101 to F106 / +R-
F201 to 206 must be 26.80VDC
20. The voltage on all operating modules +FRn-A1 and +FLn-A1 (left / right
machine side) must be greater than 24V (ST1: 1 +) and (ST1: 2 -) (Pay
attention to polarity!)
21. Switch on power switch of cooling unit +L-Q108 / +R-Q208 (if available)
22. The cooling unit +L-E102 / +R-E202 must be running (if available)
23. Main switch OFF

6.2.3 Starting up the secondary supplies

Starting the 1. Main switch OFF

braking transformer
2. Switch on power switch of braking transformer +L-Q104 / +R-Q204
3. Switch on main switch
4. Measure primary voltage between terminals 1 and 2 (3) at transformer +L-
T100 / +R-T200
⇒ There must be approx. 380VAC (or 400VAC)
5. Measure secondary voltage on terminals 31 and 32 (33) (see also circuit
diagram, table 1):
⇒ Voltage between terminals 31 and 32 = 80V
⇒ Voltage between terminals 31 and 33 = 100V
6. Main switch OFF

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6 Start-up at customer's works

6.2.4 Braking current supply start-up

Braking current supply 1. Main switch OFF

start-up
2. Remove all fuse holders +FLn-F1A/C and +FRn-F1A/C from terminals -
X1:1 in the power duct cable of sections
3. Close fuse of braking transformer +L-F119 / +R-F219
4. Switch on main switch
5. Measure direct current to ground on terminal -X1:1 on all connected
sections of left and right machine side
⇒ This should measure approx. 80VDC (with transformer connection 31-
32) or approx. 100VDC (with transformer connection 31-33)
6. Main switch OFF
7. Re-insert all fuse holders +FLn-F1A/C and +FRn-F1A/C in terminals -X1:1
in the power duct cable of sections

6.3 Protective conductor check (PE)

▶ Visual inspection of the complete ground conducting system

including checking for solid connections

▶ Perform the protective conductor check according to separate

protocol677 000 9100 200

6.4 Starting-up the frequency converter

Starting-up the frequency 1. Main switch ON.
converter
2. On intermediate circuit fuses, a d.c. voltage of approx. 540 VDC (or
565VDC) must be measured
3. Main switch OFF
4. Close intermediate circuit fuses +L-F124 to F129 / +R-F224 to F229
5. Main switch ON.
6. On terminals Zk+ of converters

▫ +L-T103 / +R-T203 (FC capstan)

▫ +L-T101 / +R-T201 (FC traverse motion)

▫ +L-T102 / +R-T202(FC winding)

a d.c. voltage of approx. 540 VDC (or 565VDC) must be measured

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6 Start-up at customer's works

7. Green LED of FC spindle flashes

8. Interior fans of converters must be running
9. Main switch OFF

6.5 Starting up the control modules

6.5.1 Addressing the control modules

If there are two or more control modules with the same address in the
machine (e.g. during the initial start-up of the machine or when
replacing a module), the control must be interrupted during the boot
sequence so that the addressing can be done.

Addressing the control 1. Main switch ON

modules
⇒ IPC begins to boot, BIOS messages appear, RAM test is performed,
and various messages are displayed. A blue screen appears next and
then the following display appears for 10 seconds

Fig. 6-1: Image for the branch to addressing

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6 Start-up at customer's works

2. must be pressed within these 10 seconds. Then the following

appears:

Fig. 6-2: Setup during booting

▫ Set the required language (German, English, etc.)

▫ Set the total number of spindles per machine side

▫ Actuate Start addressing for each machine side

Æ the following screen appears:

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6 Start-up at customer's works

Fig. 6-3: Addressing operation

⇒ all yellow indicator lights on the control modules for the respective
machine side begin flashing quickly
3. Starting from the headstock, actuate all start buttons on the control
modules one after the other
⇒ The respective indicator light must stop flashing after actuating
⇒ the addressing progress can be viewed on the controller screen
4. On left side of the machine only:
⇒ After addressing last spindle Æ Addressing conveyor belt module

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6 Start-up at customer's works

Fig. 6-4: Addressing conveyor belt

5. Actuate Addressing module

6. Actuate Spindle start on control module
⇒ After actuation of all spindle buttons, the display shows
7. Then all control modules are checked for type and software version
⇒ If an incorrect module type is detected, an error message will be
entered in the logbook. The respective message also appears on the
screen of the central controller after booting
⇒ If a different software status is detected, a software update is
performed on the respective module automatically

For further error messages see 9.3 Problems with control modules in network,
p. 9-141).

The software update requires approx. 37 seconds per spindle. That

means approximately one hour for a complete machine.

▶ The machine must not be switched off during the software update!

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6 Start-up at customer's works

6.5.2 Addressing test

Addressing test 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Select menu item ServiceÆ Start-upÆ Spindle

Fig. 6-5: Fig. -: Service menuÆ Start-upÆ Spindle

3. Actuate Addressing test

⇒ The yellow LEDs on each spindle position will flash once each in the
sequence of the addressing

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6 Start-up at customer's works

6.6 Settings
6.6.1 Unit for length counting and yarn count

⇒ Set length counting an yarn count according to customer's specifications

Length counter and yarn 1. Use the global button to enter Machine engineer (see 3.3.2 Password
count system/Code levels, p. 3-7)
2. Make the following settings in menu AdministrationÆ SettingsÆ Units

Fig. 6-6: AdministrationÆ SettingsÆ Units

▫ Titre to dtex or den

▫ Length to Metre or Yard

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6 Start-up at customer's works

6.6.2 Shift counter

⇒ Enter shift times according to customer specifications

Setting the 1. Use the global button to enter Machine engineer (see 3.3.2 Password
shift times system/Code levels, p. 3-7)
2. Select menu item AdministrationÆ Operator interfaceÆ Shift

Fig. 6-7: Menu item AdministrationÆ Operator interfaceÆ Shift

3. Set the start time of the desired shift

⇒ A dialogue for entering the time is opened

Fig. 6-8: Dialogue time

4. To activate or deactivate, press the active? button

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6 Start-up at customer's works

6.6.3 Material

⇒ Set the material according to customer specifications

Setting the material 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Select menu item SettingsÆ YarnÆ Material

Fig. 6-9: Menu item SettingsÆ YarnÆ Material

3. Set Material

▫ Select either the preset type of material:

Fig. 6-10: Menu item SettingsÆ YarnÆ Material Selecting preset material

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6 Start-up at customer's works

▫ Or edit to define another material:

4. Enter Item number
5. Enter Type
6. Enter Titre
7. Enter Lot

6.6.4 Date and time

Setting date and time 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. For settings Date / time, go to menu AdminÆ Operator interfaceÆ Date /
Time

Fig. 6-11: Admin Æ Operator interface Æ Date / time

3. Set the date and confirm with OK

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6 Start-up at customer's works

Fig. 6-12: Dialogue date

4. Set the time and confirm with OK

Fig. 6-13: Dialogue time

6.6.5 Setting the ETHERNET address

Only with a modem (Remote maintenance)!

Setting the Ethernet 1. Use the global button to enter Machine engineer (see 3.3.2 Password
address system/Code levels, p. 3-7)
2. To set the Ethernet address, go to menu AdminÆ MC-Config.Æ Network

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6 Start-up at customer's works

Fig. 6-14: Admin Æ MC-Config. Æ Network

3. Set the desired IP address or Subnet Mask

▶ The first three positions (network recognition) of the Ethernet

address are predefined with 10.43.70.xxx and are to be left this
way – these must be the same on all machines!

▶ The last position in the Ethernet address can be defined as a

number between 1 and 99, which corresponds with the machine
address – here a separate address must be defined for each
machine!

▶ These addresses must be transferred together with the telephone

number of the modem to the Oerlikon Saurer, Allma Produktlinie so
that the machine can be called if remote maintenance is required

▶ The Subnet mask should also remain set to 255.255.255.0!

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6 Start-up at customer's works

6.6.6 Setting the display

Setting the display 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. To set the display, go to menu AdminÆ Operator interfaceÆ Display

Fig. 6-15: Admin Æ Operator interface Æ Display

3. Use buttons + and – to set the brightness

4. Use the Calibration button to calibrate the screen (More information can be
found in the Operating Manual)

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6 Start-up at customer's works

6.7 Tests to perform

6.7.1 Machine status

Checking the 1. Go to menu ServiceÆ DiagnosticsÆ Machine status (see 8.3.2, p. 8-98).
machine status
⇒ The machine status is shown from bit 0 to F ( = 24 VDC, = 0

VDC, = not assigned).

2. Check the status of the machine (Bit0=1, Bit4=1, Bit8=1). all others = 0)

6.7.2 Testing the inputs

▶ Always check both states (1 and 0) when testing

FC spindle 1. Go to menu ServiceÆ DiagnosticsÆ IOs (see 8.3.2, p. 8-99)

inputs
2. Actuate and unlock again the emergency stop button +L-S102 (emergency
stop relay +L-K104 drops out)
⇒ Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up)
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. With suction unit option disconnect wire on terminal X210A:5 from FC
spindle +L-T104 / +R-T204
⇒ Bit 3 = 1 (wire connected)
⇒ Bit 3 = 0 (wire disconnected)
5. Fuse of power supplies: Alternately, switch on and off +L-Q102 / +R-Q202
⇒ Bit 4 = 1 +L-Q102 / +R-Q202 ON)
⇒ Bit 4 = 0 +L-Q102 / +R-Q202 OFF)
6. Fuse circuit: Alternately, switch on and off +L-F119 / +R-F219, +L-Q104 /
+R-Q204 (braking voltage), +L-Q107 / +R-Q207 (roof fan), +L-Q108 / +R-
Q208 (cooling unit) and +L-Q109 (conveyor belt Æ left side only)
⇒ Bit 5 = 1 (all ON)
⇒ Bit 5 = 0 (all OFF)
7. Power supply trouble Alternately disconnect the signalling contacts +L-
G101 to G103 / +R-G201 to G203: 1+/ 2
⇒ Bit 6 = 1 (contact connected)

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6 Start-up at customer's works

⇒ Bit 6 = 0 (contact disconnected)

8. Standby OFF

FC traverse 1. Go to menu ServiceÆ DiagnosticsÆ IOs (see 8.3.2, p. 8-99)

inputs
2. Actuate and unlock again the emergency stop button +L-S102 (Emergency
stop relay +L-K104 drops out)
⇒ Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up)
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. Normally open button Standby on (clockwise)
⇒ Bit 3 = 1 (upon actuation)
⇒ Bit 3 = 0 (idle)
5. Normally closed button Standby off (anticlockwise)
⇒ Bit 4 = 1 (idle)
⇒ Bit 4 = 0 (upon actuation)
6. Standby OFF
7. Move traverse rod by hand. Sensor +L-B104 / +R-B204 is covered by the
referencing ruler for half of the traversing distance, the other half it is not
⇒ Bit 5 = 1 (traverse sensor covered by plate)
⇒ Bit 5 = 0 (traverse sensor not covered by plate)

FC winding 1. Go to menu ServiceÆ DiagnosticsÆ IOs (see 8.3.2, p. 8-99)

inputs
2. Actuate and unlock again the emergency stop button +L-S102 (Emergency
stop relay+L-K104 drops out)
⇒ Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up)
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. Actuate button Machine start briefly, several times
⇒ Bit 3 = 1 (button pressed)
⇒ Bit 3 = 0 (button not pressed)
5. Pressure regulator fault: Switch off compressed air
⇒ Bit 4 = 0 and buzzer starts
6. Switch compressed air back on

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6 Start-up at customer's works

⇒ Bit 4 = 1 When the warning on the display is acknowledged, the buzzer

stops
7. Motor temperature contact: Disconnect wire in terminal X210B:6 on FC
winding +L-T102 / +R-T202
⇒ Bit 5 = 0
8. Connect wire in terminal X210B:6 again
⇒ Bit 5 = 1
9. Emergency stop: Alternately, actuate button +L-S102 or trip wire switch +A-
S103 / -S203 and unlock again
⇒ Bit 6 = 1 (button released)
⇒ Bit 6 = 0 (button actuated)
10. Auxiliary switch of main switch:
⇒ Bit 7 = 1 (Main switch +M-Q101/-Q201 switched on)
11. Standby OFF

FC capstan inputs 1. Go to menu ServiceÆ DiagnosticsÆ IOs (see 8.3.2, p. 8-99)

2. Actuate and unlock again the emergency stop button (Emergency stop
relay +L-K104 drops out)
⇒ Bit 0 = 0, Bit 1 = 0 and Bit 2 = 0
3. Standby ON (Emergency stop relay +L-K104 picks up).
⇒ Bit 0 = 1, Bit 1 = 1 and Bit 2 = 1
4. Actuate button Machine stop briefly, several times
⇒ Bit 3 = 1 (button not pressed)
⇒ Bit 3 = 0 (button pressed)
5. Motor temperature contact: Disconnect wire in terminal X210B:6 on FC
capstan +L-T103 / +R-T203
⇒ Bit 5 = 0
6. Connect wire in terminal X210B:6 again
⇒ Bit 5 = 1
7. Standby OFF

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6 Start-up at customer's works

6.7.3 Testing the outputs

▶ Always check both states (1 and 0) when testing

Testing the FC outputs 1. Main switch ON

2. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
3. Go to menu ServiceÆ DiagnosticsÆ IOs (see 8.3.2, p. 8-99)
4. Activate Test outputs
⇒ All outputs are set to 0
5. Test all outputs according to the following table

Table 6-2: Testing the outputs

Frequency Bit Action with activated output (= 1)

converter

FC spindle Bit 0 Operating hours counter +L-P103/ +R-P203

running.

FC traverse Bit 0 LED button Standby (+L-P100) illuminated.

motion Bit 1 Battery contactor (+L-Q103 / +R-Q203) picks up.

Bit 2 Conveyor belt relay ( +L-K105) picks up.

FC winding Bit 0 LED button Machine start (+L-P101/-P201)

illuminated.

Bit 1 Signal lamp blue(+L-E100 / +R-E200) illuminated.

Bit 2 Signal lamp yellow(+L-E101 / +R-E201)

illuminated.

Bit 3 Buzzer (+L-E102 / +R-E202) sounds.

Note: The remaining outputs are not assigned)

▶ The outputs cannot be set unless standby mode of machine is

switched off

▶ Only one output can be set at a time!

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6 Start-up at customer's works

6.8 Checking the emergency stop function

Safety first!

Checking the 1. Standby ON

emergency stop function
2. Actuate Machine start
3. Start all spindles
4. Actuate the emergency stop button.+L-S102
⇒ Winding drive, capstan drive and traverse drive all stop immediately
⇒ Spindle motors brake to a stop as quickly as possible (depends on the
number of spindles running)
5. Release the emergency stop button again
6. Standby ON
7. Pull left emergency trip wire
⇒ Winding drive, capstan drive and traverse drive all stop immediately
⇒ Spindle motors brake to a stop as quickly as possible (depends on the
number of spindles running)
8. Unlock trip wire switch again
9. Standby ON
10. Pull right emergency trip wire
⇒ Winding drive, capstan drive and traverse drive all stop immediately
⇒ Spindle motors brake to a stop as quickly as possible (depends on the
number of spindles running)
11. Unlock trip wire switch again

6.9 Checking machine functions

PRECONDITION ▪ Before switching the machine on, check the mechanical movement of the
winding, capstan and traverse drives

▪ Do not remove the spindle pot to allow the spindle to turn for checking the
rotation direction because the bearing will lose its lubricant

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6 Start-up at customer's works

6.9.1 Preparation

Making settings 1. Use the global button to enter Machine engineer (see 3.3.2 Password
system/Code levels, p. 3-7)
2. Make the following settings:

Table 6-3: Settings for test of machine functions

Menu Setting Value Graphics

Settings Æ Machine Machine start mode Single Fig. 3-2,

p. 3-8

SettingsÆ YarnÆ Overfeed -2% Fig. 3-3,

Yarn path Twists 600 tpm p. 3-8

spindle speed 6000 RPM

Twist direction: S

SettingsÆ Package Traverse length 264 mm Fig. 3-4,

build-upÆ Basics Crossing angle 37.0° p. 3-9

Settings Æ Package Number of 84,00 Fig. 3-5 ,

traverses N1
build-up Æ Breathing p. 3-9
Number of 18,00
traverses N2
Antipatterning 1,0°
angle α
Settings Æ Length Nominal length 400 m Fig. 3-6 ,
Prewarning doffing 100 m p. 3-10

Reset spindle Yes

length counter

3. Wound a rubber around the CordGuard at each spindle to simulate thread

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6 Start-up at customer's works

6.9.2 Setting the thread guide

Setting the thread guide 1. Standby ON

2. Actuate Machine start (2-3 s)
⇒ Lamp in the button flashes, buzzer sounds and a reference run is
executed
3. Pay attention to the traverse motion in the headstock!
⇒ Traverse motion pauses briefly at the home position
4. Actuate Machine stop
⇒ The machine interrupts the start sequence and stops again
5. All thread guides are set to the traverse centre with the setting gauge

6.9.3 Checking the functions

Checking machine 1. Use the global button to enter Machine engineer (see 3.3.2 Password
functions system/Code levels, p. 3-7)
2. Standby ON
⇒ Standby LED illuminated
3. Actuate Machine start (2-3 s)
⇒ Lamp in the button flashes
⇒ Buzzer sounds
⇒ Machine starts running
⇒ Machine run-up is ended, when the button is illuminated continuously

4. Start all spindles

5. Go to menu MachineÆ SpindleÆ (see Fig. 8-4, p. 8-95)
⇒ 60 seconds after the spindle run-up, the slippage regulation adjusts the
spindle speed
6. Perform a check of the rpm of the started spindles (6000 RPM ± 20 RPM)

7. Go to menu MachineÆ OverviewÆ (see Fig. 8-3, p. 8-94)

8. Check Current vDel = 10.0 ± 0.1 m/min
9. Check Current vWind. = 9.2 ± 0.1 m/min
10. Check rotation direction of capstan and winding (clockwise)

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6 Start-up at customer's works

11. Go to menu ServiceÆ ParameterisationÆ FC traverse motion (see Fig.

8-10, p. 8-103)

▫ Parameter = 240 (actual speed)

▫ Data record = 0

▫ Type = DINT
⇒ The rpm of the traverse is changed continually.
The value deviates between 0 and ± 120 RPM
12. Actuate Machine stop
13. Pay attention to the traverse motion
⇒ Traverse remains at home position (Traverse centre)

14. Go to menu SettingsÆ YarnÆ Yarn path (see Fig. 3-3, p. 3-8)

▫ Turns = 200 TPM

▫ Spindle speed = 4000 RPM

15. Actuate Machine start (2-3 s)
16. Start all spindles
17. Go to menu MachineÆ SpindleÆ (see Fig. 8-4, p. 8-95)
⇒ 60 seconds after the spindle run-up, the slippage regulation adjusts the
spindle speed
18. Perform a check of the rpm of the started spindles (4000 RPM ± 20 RPM)
19. Go to menu MachineÆ OverviewÆ (see Fig. 8-3, p. 8-94)
20. Check Current fDel = 20.0 ± 0.1 m/min
21. Check Current vWind. 18.6 ± 0.1 m/min
22. Actuate Machine stop
23. Pay attention to the traverse motion
⇒ Traverse remains at home position (Traverse centre)
24. Standby OFF

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6 Start-up at customer's works

6.10 Start-up of conveyor belt

Pay attention to correct running of the conveyor belt!

Start-up of conveyor belt 1. Main switch OFF

2. Switch on power switch of conveyor belt +L-Q109
3. Main switch ON
4. Standby ON
5. Press ON button on conveyor belt keypad
⇒ Conveyor belt motor starts running
⇒ Green LED on conveyor belt keypad is lit
⇒ Make sure direction of rotation is correct!
⇒ Pay attention to correct running of the conveyor belt!
6. Press OFF button on conveyor belt keypad
⇒ Conveyor belt motor stops
⇒ Green LED on conveyor belt keypad goes off
7. Press ON button on conveyor belt keypad
8. Cover light barrier +E-B100
⇒ Conveyor belt stops
⇒ Green LED on conveyor belt keypad is lit
⇒ When the cover is removed, the conveyor belt starts running again
⇒ Green LED on conveyor belt keypad is lit
9. Press OFF button on conveyor belt keypad
10. Main switch OFF

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6 Start-up at customer's works

6.11 Remote maintenance via modem

For the connection test the phone number of the modem should be
known!

Modem test 1. Main switch OFF

2. Connect modem +L-1A12 with the telephone network
3. Main switch ON
4. Connect modem (e.g. by using a mobile)
⇒ The modem answers after a few seconds with a whistling sound
⇒ The connection LED on the modem is lit
⇒ Connection is thus okay!

To check the data exchange via modem with the Oerlikon Saurer
Service in Kempten, please send the modem phone number and the
Ethernet addresses of all connected machines to Oerlikon Saurer,
Allma Produktlinie. An Oerlikon Saurer Service technician will then
check the connections to each connected machine.

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7 Replacement instructions

7 Replacement instructions

NOTE
The following instructions may only be carried out by qualified
personnel
▶ The applicable accident prevention guidelines are to be observed
at all times

▶ Connectors are never to be plugged in or disconnected for any

devices/modules/boards that are under power!

7.1 Replacement of IPC+L-A1

Replace IPC 1. Main switch OFF. and secure against switching on again
2. Remove the Flash card from the defective IPC. This card contains all
customer settings
3. Replace the IPC controller
4. Exchange the Flash card in the IPC with the card from the defective device
5. Main switch ON
If the IPC boots correctly, execute the following sections of the start-up
manual:

▫ 6.6 Settings, p. 6-71

▫ 4.10 Testing the saving and loading procedures (with a USB stick), p.
(4-38)

▫ 6.7 Tests to perform, p. 6-77

▫ 6.8 Checking the emergency stop function, p. 6-82

▫ 6.9 Checking the machine functions, p. 6-82

▫ 4.16 Parameterisation of language, p. 4-51

or:
If the old Flash card is also defective, it must be replaced with the new one
again.
The following sections of the start-up instructions are to be executed:

▫ 4.6 Start-up the control software, p. 4-21

▫ 4.8.1 Setting the default values for all menus, p. 4-29

▫ 4.8.2 Spindle settings, p. 4-30

▫ 4.9 Parameterisation of drives, p. 4-33

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7 Replacement instructions

▫ 6.6 Settings, p. 6-71

▫ 4.10 Testing the saving and loading procedures (with a USB stick),
p. 4-38)

▫ 6.7 Tests to perform, p. 6-77

▫ 6.8 Checking the emergency stop function, p. 6-82

▫ 6.9 Checking the machine functions, p. 6-82

▫ 4.16 Parameterisation of language, p. 4-51

7.2 Replacing frequency converters+L-T101 / +R-

T201+L-T104 / +R-T204
Replace 1. Main switch OFF. and secure against switching on again
frequency converter
2. Replacing the frequency converter
3. The following sections of the start-up instructions are to be executed:

▫ 4.3.1 380VAC Supply cable start-up (or 400VAC, p. 4-16

▫ 4.3.3 Secondary current supply start-up, p. 4-18

▫ 4.4 Starting-up the frequency converter, p. 4-19

Parameterise the replaced frequency converters:

▫ 4.9.1 Spindle drive, p. 4-33

or:

▫ 4.9.2 Winding drive, p. 4-34

or:

▫ 4.9.3 Capstan drive, p. 4-36

or:

▫ 4.9.4 Traverse motion drive, p. 4-37

▫ 6.8 Checking the emergency stop function, p. 6-82

▫ 6.9 Checking the machine functions, p. 6-82

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7 Replacement instructions

7.3 Replacing the power supply+L-G101 to G103 / +R-

G201 to G203+V-G1
Replacing the power 1. Main switch OFF. and secure against switching on again
supply
2. Replacing the defective power pack
3. The following sections of the start-up instructions are to be executed:

▫ 4.1.3 Checking the 24 VDC supply, p. 4-12

▫ 4.3.2 Starting-up the 24VDC supply, p. 4-17

7.4 Replacing the control module +FRn-A10 or +FLn-A10

Replacing the 1. Main switch OFF. and secure against switching on again
control module
2. Replace the affected control module
3. The following sections of the start-up instructions are to be executed:

▫ 4.7 Starting-up the control modules, p. 4-24

▫ 5.5 Calibrating the CordGuard, p. 5-56

▫ 5.6 Checking the spindle functions, p. 5-56

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8 Machine diagnostics

8 Machine diagnostics
The Allma CC3 is equipped with an extended machine diagnostics programme
that enables quick troubleshooting. Almost all error states that would lead to
the machine shutting down or a spindle position are registered and stored.

8.1 Logbook

Fig. 8-1: Menu Report Æ Logbook

The error messages that are generated by the system and the machine are
displayed via the ÆReports > Logbook area.

⇒ "Historical" errors, with dates, error description and error number

The following messages are entered in the logbook:

▪ Machine error messages

If an error occurs, the running machine is stopped
For a complete list of errors see 9.1.1 Error Messages of machine, p. 9-107

▪ Machine warnings
The machine can still be operated when a warning is active.
For a complete list of warnings see 9.1.2 Machine warnings, p. 9-124

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8 Machine diagnostics

▪ Spindle shut-off causes

Reason for shutting off the spindle
For a complete list of switch-off causes see 9.2.1 Switch-off causes of
spindles, p. 9-129

▪ Spindle start refusals

Reason that a spindle is not able to start
For a complete list of start refusals see 9.2.1 Start refusals of spindles, p.
9-129

▪ Spindle warnings
Warnings do not lead to the spindle position being shut off, but should bring
the attention of the operator to a non-critical irregularity
For a complete list of warnings see 9.2.2 Spindle warnings, p. 9-136

▪ Problems with the control modules in the network

In case of detecting a network failure (e.g. during booting or in operation),
the respective control module is no longer addressed by the control and an
error message appears
For a complete list see 9.3 Problems with control modules in network, p. 9-
141

▪ System messages
For a complete list see 9.4 System messages, p. 9-144

Use button Active error to switch to a view in which only the active errors are
listed.

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8 Machine diagnostics

Fig. 8-2: Menu Report Æ Logbook Active errors

Use button Reset error to delete the list (these will remain in the error history
list).

If errors still exist, these are entered into the logbook again as active.

Spindle messages (shut-off cause, start refusal and warning) cannot be

acknowledged here. These are acknowledged automatically with the
next spindle start.

Back to historical list.

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8 Machine diagnostics

8.2 Machine menu

8.2.1 Overview submenu

Fig. 8-3: Menu MachineÆ Overview

Display of:

▪ Current delivery speed

▪ Current winding speed

▪ Average spindle motor current

The average spindle motor current is only determined and displayed if

at least 10 spindle motors are in operation.

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8 Machine diagnostics

8.2.2 Spindle submenu

Fig. 8-4: Menu MachineÆ Spindle

Display of:

▪ Current spindle speed

▪ Yarn tension actual value (average determined via 130 yarn tension
values)

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8 Machine diagnostics

8.2.3 Submenu CordGuard (option)

Fig. 8-5: Menu MachineÆ CordGuard

Display of:

▪ Yarn tension actual value (average determined via 130 yarn tension
values)

▪ Reference value (determined with moving averaging from 5200 yarn

tension values)

▪ The number of unwinding troubles during package formation that do not

lead to switching the spindle position off

▪ Machine average (value over column actual value) as average of yarn

tension values from all running spindle positions

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8 Machine diagnostics

8.3 Servicing Menu

8.3.1 Submenu disabled and test mode

Fig. 8-6: Menu Service Æ Disabled and test mode

It is possible to put a spindle position into test operation mode for trouble
shooting.

⇒ All monitoring systems are switched off

PRECONDITION ▪ Machine is in operation

▪ Spindle position is not in operation

▪ No spindle position is already in test mode

⇒ During test mode, the yellow LED on the respective spindle position
flashes once per second
⇒ Test mode is cleared automatically with the next machine start (single,
complete or blockdoff)

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8 Machine diagnostics

8.3.2 Diagnostics submenu

Tab menu Machine status

Fig. 8-7: Service menuÆ DiagnosticsÆ Machine status

Machine status display for diagnostic purposes

Bit allocation:

0 = Machine stopped
1 = Machine run-up
2 = Machine in operation
3 = Machine shutting down (in power failure or emergency stop as well!)
4 = Machine start mode SINGLE
5 = Machine start mode COMPLETE
6 = Machine start mode BLOCKDOFF
7 = Tensioning yarns with Blockdoff
8 = Status Button Reset Spindle length counter (1 = yes, 0 = no)
9 = Reset shift counter
A = Power-save mode (1 = active, 0 = off)
B = Power failure (> 1 sec)
C = Power failure (< 1 sec)
D = Parameter change
E = EMERGENCY STOP
F = -----

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8 Machine diagnostics

Tab menu IOs machine

Fig. 8-8: Service menuÆ DiagnosticsÆ IOs machine

The states of the digital inputs of frequency converters (FC) are displayed.

Bit allocation inputs:

▪ FC spindle
0 = Controller enable
1 = Quick stop
2 = Secure stop
3 = Option suction faults
4 = Power pack fuse
5 = Fuse circuit
6 = Fault power supply
7 to 9 Not used

▪ FC traverse motion
0 = Controller enable
1 = Quick stop
2 = Secure stop
3 = Button Standby ON
4 = Button Standby OFF
5 = Reference sensor signal

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8 Machine diagnostics

6 = Temperature contact
7 to 9 Not used

▪ FC winding
0 = Controller enable
1 = Quick stop
2 = Secure stop
3 = Button ON
4 = Fault Pressure controller
5 = Temperature contact
6 = Emergency stop circuit
7 = Main switch ON
8 to 9 Not used

▪ FC capstan
0 = Controller enable
1 = Quick stop
2 = Secure stop
3 = Button OFF
4 = Not used
5 = Temperature contact
6 to 9 Not used

Bit allocation Outputs:

▪ FC spindle
0 = Operating hours counter
1 to 3 Not used

▪ FC traverse motion
0 = Signal lamp Standby
1 = Battery contactor
2 = Conveyor belt contactor
3 Not used

▪ FC winding
0 = Signal lamp Button ON
1 = Signal lamp blue
2 = Signal lamp yellow
3 = Buzzer

▪ FC capstan
0 to 3 Not used

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8 Machine diagnostics

With Test outputs, the outputs can be tested.

▪ Easy testing of inputs and connected contactors, signal lamps, etc.

▪ Procedure see 4.11.3 Testing the outputs, p. 4-43

Tab menu Spindle

Fig. 8-9: Service menuÆ DiagnosticsÆ Spindle

The states of the inputs and outputs of every spindle position are displayed.

⇒ Easy testing of buttons and sensors

Bit allocation:

▪ Spindle status
0 = Spindle stopped
1 = Run up
2 = Spindle in operation
3 = Shutdown spindle
4 = Warning
5 = Spindle was in operation and manually set to status Stopped
6 = Prewarning Doffing
7 = Start refusal

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8 Machine diagnostics

8 = Not used
9 = Button OFF activated
A = Button OFF for a time longer MTR_RESETTIME activated
B = Not used
C = Calibration of CordGuard carried out
D = Not used
E = Not used
F = Module status: Preoperational = 1 / operational = 0

▪ Input byte
0 = Hall sensor
1 to 3 Not used
4 = Button ON
5 = Button OFF
6 and 7 Not used

▪ Output byte
0 = Winding
1 = Motor contactor
2 = Brake contactor
3 = Capstan clutch
4 = Control panel LED GREEN
5 = Control panel LED YELLOW
6 = Control panel LED RED
7 = Control panel LED CAN
8 = Creel yarn tensioner
9 to F Not used

With Test outputs, the outputs can be tested.

▪ Easy testing of outputs and connected contactors, LEDs, etc.

▪ Procedure see 5.4.3 Testing the outputs, p. 5-54

Press the buttons + and – or Spindle to select the spindle to be displayed.

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8 Machine diagnostics

8.3.3 Parameterisation submenu

Tab menus of frequency converters (FC)

Fig. 8-10: Menu ServiceÆParameterisationÆFCxxxx

Possibility to read out all objects from the frequency converters.

Table 8-1: Important variables

Variable Format Parameter Type Data record

Stator frequency xxx.xx Hz 210 LONG 0

Output current Ieff xxxx.x A 211 UINT 0

Output voltage Ueff xxxx.x V 212 UINT 0

Active power xxxx.x kW 213 INT 0

Active current xxxx.x A 214 INT 0

D.C. link voltage xxxx.x V 222 INT 0

Heat sink temperature x °C 255 INT 0

Inside temperature x °C 256 INT 0

Current error 259 STRING 0

Operating hours xxxx h 245 LONG 0

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8 Machine diagnostics

NOTE See also operating manual Allma CC3.

Tab menu Operating unit

Fig. 8-11: Service menuÆ ParameterisationÆ Operating unit

Possibility to read out all objects from the control modules.

Table 8-2: Important objects

Designation Index Sub- Type Bit allocation

index

State of CordGuard 2000 4 UINT 0 Yarn break monitoring ON

1 Averaging and evaluation windows 1– 3 ON
2 ----
3 Warning limit Short-time yarn tension errors reached
4 Yarn break (Switch Off 1 exceeded)
5 Yarn break (Switch Off 1 not reached)
6 Yarn break (Switch Off 2 exceeded)
7 Yarn break (Switch Off 2 not reached)
8 Yarn break (manual specifications exceeded)
9 Yarn break (manual specifications not reached)
A Yarn tension reference value ≠ yarn tension average
B Upper yarn tension limit value exceeded

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Designation Index Sub- Type Bit allocation

index

C Lower yarn tension limit value not reached

D ----
E ----
F ----

State of speed monitoring 2000 7 BYTE 0 Overload monitoring of spindle motor ON

1 Monitoring of speed Spindle motor ON
2 Warning limit Spindle speed off tolerance
3 Tolerance speed exceeded
4 Tolerance speed not reached
5 No speed pulses registered
6 Max. slip speed exceeded
7 ----

State of metre counter / shift 2000 6 BYTE 0 Metre counter ON

1 ----
counter
2 ----
3 ----
4 Set number of metres reached
5 Prewarning doffing
6 ----
7 Shift counter ON

State of switching-on frequency 2000 8 BYTE 0 Monitoring of switching-on frequency ON

1 Spindle started (auxiliary state for counter)
2 Start disabled
3 ----
4 ----
5 ----
6 ----
7 ----

Spindle control word 2000 3 UINT 0 Spindle disabled

1 Spindle reset
2 Diagnostics mode
3 Reset of length counter
4 0 = CordGuard mode of operation: Manual
1 = CordGuard mode of operation: Self learning function
5 0 = Length measuring in metres
1 = Length measuring in yards
6 ----
7 Spindle test mode active? 1 = yes 0 = no)
8 Yarn tension monitoring active? 1 = yes 0 = no)

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8 Machine diagnostics

Designation Index Sub- Type Bit allocation

index

9 Creel yarn tensioner control at machine stop active? 1 =

yes 0 = no)
A Function of capstan start prior to spindle start active? 1 =
yes 0 = no)
B ----
C ----
D ----
E ----
F Carry out calibration of CordGuard

8.4 Reading out of software versions

Fig. 8-12: Menu Report Æ Versions

Software versions of the IPCs, control modules and the different drives can be
read out.

Scrolling by lines with the arrow buttons.

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9.1 Machine messages
9.1.1 Error messages of machine

Survey

Table 9-1: Error messages

No. Description

E01 Emergency stop

E02 Power failure

E03 Winding speed off tolerance

E04 No pulses Winding

E05 Capstan speed off tolerance

E06 No pulses Capstan

E07 Network failure FC spindle

E08 Network failure FC winding

E09 Network failure FC capstan

E10 Network failure FC traverse motion

E11 Error FC spindle

E12 Error FC winding

E13 Error FC capstan

E14 Error FC traverse motion

E15 Fuse of power supplies:

E16 Overcurrent Spindles

E17 Overtemperature Control cabinet FC spindle

E18 Overtemperature Control cabinet FC winding

E19 Overtemperature Control cabinet FC capstan

E20 Overtemperature Control cabinet FC traverse motion

E21 Overtemperature Heat sink FC spindle

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No. Description

E22 FC spindle Timeout

E23 FC spindle Nodeguarding

E24 FC spindle slipp. >8%

E25 FC winding Nodeguarding

E26 FC capstan Nodeguarding

E27 FC traverse motion Timeout

E28 FC traverse motion Nodeguarding

E29 Network failure General

E30 FC traverse motion Overrun

E31 Temperature of capstan motor

E32 Temperature of winding motor

E33 Monitoring Compressed air

E34 Temperature of traverse motion motor

Description

Generally, when a machine error occurs, the machine side is brought to a

standstill.

In case of an emergency stop and power failure, the machine start

mode is automatically set to Single.

E01 EMERGENCY STOP

All emergency stop switches are connected in series to an emergency stop
relay.

Signalling circuit interrupted:

⇒ All important units are switched off through the emergency stop relay
⇒ Machine is brought to a standstill as quickly as possible

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Possible causes:
▪ Check all emergency switches:

▫ Trip wire switch on left or on right+A-S103 / -S203

▫ Emergency stop button+L-S102

▪ Emergency stop relay+L-K104

E02 POWER FAILURE

If the supply voltage fails for more than 1 sec., the machine is shut down in a
controlled manner.

E03 WINDING SPEED OFF TOLERANCE

The speed of the winding shaft is measured by means of the HTL encoder at
the winding motor. The pulses are detected by the winding converter and
evaluated by the control.

If the speed of the winding shaft is off tolerance:

⇒ Error message is displayed and machine is switched off after about 20 sec

Possible causes:
▪ HTL encoder +A-B102/-B202 defective or not correctly adjusted

▪ Frequency converter Winding +L-T102 / +R-T202 defective or not enabled

▪ Pilot frequency signal from frequency converter Spindle +L-T104 / +R-T204

missing

▪ In the event that the aforementioned causes do not apply, check pulses at
the terminals X210A:6 and X210A:7 of winding converter +L-T102 / +R-
T202 (machine in operation)
⇒ If pulses are measured, replace the frequency converter module

E04 NO PULSES WINDING

The speed of the winding shaft is measured by means of the HTL encoder at
the winding motor. The pulses are detected by the winding converter and
evaluated by the control.

The central control does not detect any pulses for more than 2 seconds when
the machine is running or after actuating Machine ON.

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Possible causes:
▪ HTL encoder +A-B102/-B202 defective or not correctly adjusted

▪ Frequency converter Winding +L-T102 / +R-T202 defective or not enabled

▪ Pilot frequency signal from frequency converter Spindle +L-T104 / +R-T204

missing

▪ In the event that the aforementioned causes do not apply, check pulses at
the terminals X210A:6 and X210A:7 of winding converter +L-T102 / +R-
T202 (machine in operation)
⇒ If pulses are measured, replace the frequency converter module

E05 CAPSTAN SPEED OFF TOLERANCE

The speed of the capstan shaft is measured by means of the HTL encoder at
the capstan motor. The pulses are detected by the capstan converter and
evaluated by the control.

Speed of capstan shafts off tolerance (can be set at the display):

⇒ Error message appears and machine is switched off after about 20 sec

Possible causes:
▪ HTL encoder +A-B103/-B203 defective or not correctly adjusted

▪ Frequency converter Capstan +L-T103 / +R-T203 defective or not enabled

▪ Pilot frequency signal from frequency converter Spindle +L-T104 / +R-T204

missing

▪ In the event that the aforementioned causes do not apply, check pulses at
the terminals X210A:6 and X210A:7 of capstan converter +L-T103 / +R-
T203 (machine in operation)
⇒ If pulses are measured, replace the frequency converter module

E06 NO PULSES CAPSTAN

The speed of the capstan shaft is measured by means of the HTL encoder at
the capstan motor. The pulses are detected by the capstan converter and
evaluated by the control.

The central control does not detect any pulses for more than 2 seconds when
the machine is running or after actuating Machine ON.

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Possible causes:
▪ HTL encoder +A-B103/-B203 defective or not correctly adjusted

▪ Frequency converter Capstan +L-T103 / +R-T203 defective or not enabled

▪ Pilot frequency signal from frequency converter Spindle +L-T104 / +R-T204

missing

▪ In the event that the aforementioned causes do not apply, check pulses at
the terminals X210A:6 and X210A:7 of capstan converter +L-T103 / +R-
T203 (machine in operation)
⇒ If pulses are measured, replace the frequency converter module

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E07 NETWORK FAILURE FC SPINDLE

The frequency converter communicates with the control via the CAN bus. The
frequency converter is parameterised via this data line and obtains the
necessary operating data (e.g. spindle rpm).

In case of an error, the data transfer is interrupted in one or both directions.

Possible causes:
▪ CAN bus line to frequency converter +L-T104 / +R-T204 interrupted.
⇒ Check by using an ohmmeter (pin configuration see circuit diagram)

▪ Terminating resistor +E-R110/-R210 at the last control module on machine

side is missing

▪ CAN bus interface on control +L-A1 defective

⇒ Replace control unit

▪ Frequency converter +L-T104 / +R-T204 not configured

⇒ Carry out configuration as described in start-up instructions

▪ Frequency converter +L-T104 / +R-T204 defective

⇒ Replace frequency converter

▪ Network address of frequency converter +L-T104 / +R-T204 not correctly

adjusted
⇒ Set address according to start-up instructions

E08 NETWORK FAILURE FC WINDING

The frequency converter communicates with the control via the CAN bus. The
frequency converter is parameterised via this data line and obtains the
necessary operating data (e.g. spindle rpm).

In case of an error, the data transfer is interrupted in one or both directions.

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Possible causes:
▪ CAN bus line to frequency converter +L-T102 / +R-T202 interrupted
⇒ Check by using an ohmmeter (pin configuration see circuit diagram)

▪ Terminating resistor +E-R110/-R210 at the last control module on machine

side is missing

▪ CAN bus interface on control +L-A1 defective

⇒ Replace control unit

▪ Frequency converter +L-T102 / +R-T202 not configured

⇒ Carry out configuration as described in start-up instructions

▪ Frequency converter +L-T102 / +R-T202 defective

⇒ Replace frequency converter

▪ Network address of frequency converter +L-T102 / +R-T202 not correctly

adjusted
⇒ Set address according to start-up instructions

E09 NETWORK FAILURE FC CAPSTAN

The frequency converter communicates with the control via the CAN bus. The
frequency converter is parameterised via this data line and obtains the
necessary operating data (e.g. spindle rpm).

In case of an error, the data transfer is interrupted in one or both directions.

Possible causes:
▪ CAN bus line to frequency converter +L-T103 / +R-T203 interrupted
⇒ Check by using an ohmmeter (pin configuration see circuit diagram)

▪ Terminating resistor +E-R110/-R210 at the last control module on left

machine side is missing

▪ CAN bus interface on control +L-A1 defective

⇒ Replace control unit

▪ Frequency converter +L-T103 / +R-T203 not configured

⇒ Carry out configuration as described in start-up instructions

▪ Frequency converter +L-T103 / +R-T203 defective

⇒ Replace frequency converter

▪ Network address of frequency converter +L-T103 / +R-T203 not correctly

adjusted
⇒ Set address according to start-up instructions

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E10 NETWORK FAILURE FC TRAVERSE MOTION

The frequency converter communicates with the control via the CAN bus. The
frequency converter is parameterised via this data line and obtains the
necessary operating data (e.g. spindle rpm).
In case of an error, the data transfer is interrupted in one or both directions.

Possible causes:
▪ CAN bus line to frequency converter +L-T101 / +R-T201 interrupted
⇒ Check by using an ohmmeter (pin configuration see circuit diagram)

▪ Terminating resistor +E-R110/-R210 at the last control module on left

machine side is missing

▪ CAN bus interface on control +L-A1 defective

⇒ Replace control unit

▪ Frequency converter +L-T101 / +R-T201 not configured

⇒ Carry out configuration as described in start-up instructions

▪ Frequency converter +L-T101 / +R-T201 defective

⇒ Replace frequency converter

▪ Network address of frequency converter +L-T101 / +R-T201 not correctly

adjusted
⇒ Set address according to start-up instructions

E11 FAILURE FC SPINDLE (+V-T4)+L-T104 / +R-T204

E12 FAILURE FC WINDING (+V-T2)+L-T102 / +R-T202
E13 FAILURE FC CAPSTAN (+V-T3)+L-T103 / +R-T203
E14 FAILURE SERVO TRAVERSE MOTION (+V-T1)+L-T101 / +R-T201
This error message appears whenever one of the frequency converters notices
a fault (e.g. short circuit or short to earth of output voltage).
The current error number is automatically shown on the display. The error
number is hexadecimal and consists of the type of error (higher byte) and a
specificator (lower byte) which provides further information about the error.

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Table 9-2: Vectron error numbers

Type of error (high Specificator (low-byte, Possible causes

byte, hexadecimal) hexadecimal)

00 No error 00 --- ---

01 Overload 00 Frequency converter ---

overloaded

02 Frequency converter ---

overloaded (60 sec)

03 Short-time overload (1 ---

sec)

02 Heat sink 00 Overtemperature of heat ▪ Fan +M-M104/-204 in ventilation duct of

headstock dirty or defective
temperature sink
▪ Heat sink (final stage) of frequency
converter dirty

▪ Fan on heat sink defective or wrong

direction of rotation

01 Insufficient temperature ▪ Temperature sensor defective

of heat sink ▪ Ambient temperature too low

03 Inside 00 Overtemperature ▪ Cooling unit +L-E102 / +R-E202 defective

temperature ▪ Filter pads in control cabinet dirty

01 Insufficient temperature Ambient temperature too low

04 Motor 00 Motor temperature too ▪ Motor too hot

connection high ▪ Temperature sensor defective

03 Motor phase failure ▪ Check motor

▪ Check wiring at plug X2 (UVW)

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Type of error (high Specificator (low-byte, Possible causes

byte, hexadecimal) hexadecimal)

05 Output current 00 Overload (ramps) There is a short-circuit at the frequency

03 Short-circuit or short to converter output, e.g. defective spindle motor
04 earth Æ Check motors
05 Overload (current limit)
Asymmetric motor
06 current
07 Motor phase current too
high
Message from phase
monitoring

07 D.C. link 00 Ud too high Check mains power supply (voltage at

voltage 01 Ud too low frequency converter input max. 440 VAC)
02 Power failure

08 Circuitry 00 Circuitry voltage too low ▪ Producing machine switched off with Main
switch OFF
voltage (24V)
▪ Check output voltage of power supply +L-
G101 to G103 / +R-G201 to G203 (see
4.3.2 Starting up the 24VDC supply, p. 4-
17)

▪ At terminal X210A:1 26 V must be present

01 Circuitry voltage too high ▪ Check output voltage of power supply +L-
G101 to G103 / +R-G201 to G203 (see
4.3.2 Starting up the 24VDC supply, p. 4-
17)

▪ At terminal X210A:1 26 V must be present

11 Output 00 Output frequency too Check control signals or contact the Oerlikon
frequency 01 high Saurer Service in Kempten
Max. frequency reached
by control system

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Type of error (high Specificator (low-byte, Possible causes

byte, hexadecimal) hexadecimal)

12 Safety function 01 Diagnostics error of At least one of the switch-off paths STOA and
STO function STO STOB is faulty

▪ Check the devices connected to the switch-

off paths

▪ Check wiring

04 Internal error in software Parameter 262 describes cause of error

selfdiagnosis ⇒ Contact customer service of BONFIGLIOLI

05 Error message of 5s- The switch-off paths STOA and STOB have not
monitoring been switched simultaneously, but with a time
lag of more than 5 sec
⇒ Check activation of switch-off paths or
operation of safety device

13 Motor 00 Short to earth at output Check motor and wiring

connection 01 Asymmetrical load
10 Minimum current
monitoring

14 Control current 01 Setpoint signal on MFI1 Check signal on X210B:6

connection faulty
07
Overcurrent on MFI1

21 Resolver Check resolver signal for parasitic coupling

synchronisation not
22 successful. Resolver
counting error

23 Number of resolver pairs The ratio from number of motor pole pairs to
is not valid. number of resolver pole pairs must be integer.
Check parameters Number of pole pairs 373 for
the motor and Number of pole pairs 381 for the
resolver and correct if necessary

24 Line break Check resolver connections and lines

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Type of error (high Specificator (low-byte, Possible causes

byte, hexadecimal) hexadecimal)

30 Encoder signal faulty Check connections X210A:6 and X210A:7

31 Track of the encoder
missing
32 Encoder's direction of
rotation wrong

0B Optional 13 CM-CAN module fitted Switch off mains voltage

components without disconnection of
mains supply voltage

If the error cannot be corrected, the frequency converter may be

defective

▶ Replace frequency converters (see 7.2 Replacing frequency

converters +L-T101 / +R-T201 to +L-T104 / +R-T204, p. 7-89)

E16 OVERCURRENT SPINDLES

(see also W03 in 9.1.2 Machine warnings, p. 9-124)

Possible causes:
▪ Spindle motor overloaded because of heavy material
⇒ Reduce spindle speed

▪ Frequency converter settings must be checked as described in start-up

instructions (see 4.8.2 Spindle setting, p. 4-30)

▪ Check power consumption of spindles

E17 OVERTEMPERATURE CONTROL CABINET FC spindle

E18 OVERTEMPERATURE CONTROL CABINET FC winding
E19 OVERTEMPERATURE CONTROL CABINET FC capstan
E20 OVERTEMPERATURE CONTROL CABINET FC traverse motion
The temperature in the control cabinet is monitored via a temperature sensor in
the frequency converter.

The temperature should not exceed 40°C. If the temperature reaches approx.
45 °C, the prewarning W04 to W07 is shown. In case of a further temperature
rise (approx. 50 °C), the machine is switched off.

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Possible causes:
▪ Temperature sensor defective

▪ Fan on heat sink of frequency converter defective or dirty

▪ Cooling unit +L-E102 / +R-E202 defective

▪ Filter pads dirty

E21 OVERTEMPERATURE HEAT SINK FC SPINDLE

The heat sink temperature of the frequency converter +L-T104 / +R-T204 is
monitored. If the temperature reaches 81°C, a prewarning W08 is displayed. If
the temperature rises to 86°C and more, the machine is switched off.

Possible causes:
▪ Check fan +M-M104/-204 for function

▪ Check heat sink of frequency converter +L-T104 / +R-T204 for

contamination and if necessary clean them

E22 FC SPINDLE TIMEOUT

The frequency converter +L-T104 / +R-T204 has not reached the speed
setpoint within a monitoring time.. The bit "Setpoint reached" is not transmitted!

Possible causes:
▪ Frequency converter overloaded

▪ Frequency converter error

▪ Setpoint not reached or frequency converter does not show the bit
"Setpoint reached" (monitoring time exceeded)

E23 FC SPINDLE NODEGUARDING

The frequency converter +L-T104 / +R-T204 is cyclically checked by
nodeguarding (= lifecheck). When the nodeguarding time is exceeded, the
machine is switched off.

Possible causes:
see E07

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E24 FC SPINDLE SLIPP. > 8%

The spindle motor speed and the rotating field frequency of the frequency
converter +L-T104 / +R-T204 are continuously monitored. The slip speed is
calculated from both values.

In the event of a slip > 8%, the machine switches off.

Possible causes:
▪ Failure IPC+L-A1

▪ Frequency converter fault+L-T104 / +R-T204 (rotating field frequency too

low)

E25 FC WINDING NODEGUARDING

The frequency converter +L-T102 / +R-T202 is cyclically checked by
nodeguarding (= lifecheck).. When the nodeguarding time is exceeded, the
machine is switched off.

Possible causes:
See E08

E26 FC CAPSTAN NODEGUARDING

The frequency converter +L-T103 / +R-T203 is cyclically checked by
nodeguarding (= lifecheck).. When the nodeguarding time is exceeded, the
machine is switched off.

Possible causes:
See E09

E27 FC TRAVERSE MOTION TIMEOUT

The reference switch +L-B104 / +R-B204 is monitored. If the switch does not
show alternating slopes within a monitoring time, the machine is switched off.

Possible causes:
▪ Reference switch defective (wire break?) or wrongly adjusted
⇒ Required distance of pulse generator +L-B104 / +R-B2042.0 ± 0.5 mm

▪ Defective timing belt

▪ Frequency converter fault +L-T101 / +R-T201

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E28 FC TRAVERSE MOTION NODEGUARDING

The frequency converter +L-T101 / +R-T201 is cyclically checked by
nodeguarding (= lifecheck). When the nodeguarding time is exceeded, the
machine is switched off.

Possible causes:
See E10

E29 GENERAL NETWORK FAILURE

Internal error IPC +L-A1

Possible causes:
Malfunction IPC +L-A1 Contact Oerlikon Saurer Service in Kempten and inform
them of the displayed CODE!

E30 FC TRAVERSE MOTION OVERRUN

The traverse is monitored by the limit switches +L-S104 / +R-S204 and +L-
S105 / +R-S205 When one of these two switches responds, the traverse drive
is stopped.

Possible causes:
▪ Drive belt of traverse gear defective

▪ One of the overload switches +L-S104 / +R-S204 and +L-S105 / +R-S205

has tripped

E31 TEMPERATURE CAPSTAN MOTOR

Temperature of capstan motor +A-M103/-M203 is too high. WARNING W11 is
displayed.

If the problem persists for more than 15 min, the machine is switched off.

Possible causes:
▪ Motor too hot. Temperature contact has tripped.

▪ Temperature sensor defective.

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E32 TEMPERATURE WINDING MOTOR

Temperature of winding motor +A-M102/-M202 is too high. WARNING W11 is
displayed.

If the problem persists for more than 15 min, the machine is switched off.

Possible causes:
▪ Motor too hot. Temperature contact has tripped

▪ Temperature sensor defective

E33 MONITORING COMPRESSED AIR

The pressure switch +A-S100 monitors the compressed air. If the pressure is
too low, the switch trips. WARNING W13 appears and the buzzer is activated.

In menu AdministrationÆMC ConfigurationÆMachine you can set if and if so

when the machine is to switch off after WARNING W13.

Fig. 9-1: Menu Administration Æ MC-Configuration Æ Machine

Possible causes:
Pressure switch has tripped. Compressed air is still < 5 bar after the set time.

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E34 Temperature of traverse motion motor

Temperature of traverse motion motor +A-M101/-M201 is too high. WARNING
W15 is displayed.

If the problem persists for more than 15 min, the machine is switched off.

Possible causes:
▪ Motor too hot Temperature sensor has tripped

▪ Temperature sensor defective

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9.1.2 Machine warnings

Survey

Table 9-3: Overview of warnings

No. Description

W01 Power supply fault

W02 Fuse circuit opened

W03 Prewarning Overcurrent Spindles

W04 Temperature warning Control cabinet Spindles

W05 Temperature warning Control cabinet Winding

W06 Temperature warning Control cabinet Capstan

W07 Temperature warning Control cabinet Traverse motion

W08 Temperature warning Control cabinet Heat sink Spindles

W09 Failure FC Spindle Nominal value error

W10 Start refusal

W11 Temperature of capstan motor

W12 Temperature of winding motor

W13 Compressed air is missing

W14 Suction fault

W15 Temperature of traverse motion motor

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Description

W01 Power supply fault

There is a fault in one of the uninterruptible power supplies +L-G101 to G103 /
+R-G201 to G203.

The machine is not switched off.

Check LEDs of power supplies and replace the respective power supply during
the next machine stop or correct the fault in order to avoid a permanent
overload of the still functioning power supplies.

Possible causes:

▪ Power supply defective

⇒ Replacing the power supply

▪ 2 Load current below 2A

⇒ Adjust all power supplies as described in start-up instructions

W02 Fuse circuit opened

The function of this error is produced by the signalling switches of the following
fuses and switches:

▪ +L-Q104 / +R-Q204 (braking transformer)

▪ +L-F119 / +R-F219 (braking current)

▪ +L-Q107 / +R-Q207 (roof fan)

▪ +L-Q108 / +R-Q208 (cooling unit)

▪ +L-Q109 (conveyor belt)

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The signalling circuit 1 (see circuit diagram) must be closed for a proper
function of the machine.

If a fuse or switch has tripped, the corresponding signalling contact is opened

and an error message displayed.

The machine is not switched off.

Possible causes:
▪ Fuse or switch has tripped.
⇒ Only when the cause of the tripped fuse (e.g. short-circuit) has been
removed, may the circuit be closed again.

▪ If no fuse has tripped:

▫ Check the individual signalling contacts for continuity (Ohm).

▫ On the terminal strip +L(/+R-X1:24, the voltage must be 24 VDC.

⇒ If required, replace the signalling contact concerned!

W03 Prewarning Overcurrent Spindles

The capacity of the spindle frequency converter is limited and dependent upon
the altitude of installation of the machine (see 4.8.2 Spindle settings, p. 4-30).

The frequency converter +L-T104 / +R-T204 regularly informs the control of the
total power consumption. This value is divided by the number of running
spindles. Thus the control obtains an average value of the power consumption
per spindle.

If this value is higher than the max. allowable current value plus 3 % tolerance,
this error message appears.

The user can reduce the spindle rpm of the respective machine side, thus
reducing the total power consumption.

If the current value is not within the set limits within 3 minutes, the machine is
switched off with error message E16.

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W04 Temperature warning Control cabinet Spindles

W05 Temperature warning Control cabinet Winding
W06 Temperature warning Control cabinet Capstan
W07 Temperature warning Control cabinet Traverse motion
A critical temperature (> 45°C) has been reached in the control cabinet.

Possible causes:
▪ Cooling unit +L-E102 / +R-E202 failed

▪ Temperature sensor defective

W08 Temperature warning Heat sink Spindles

The heat sink of the spindle frequency converter +L-T104 / +R-T204 in the
headstock has reached a critical temperature (> 81°C).

Possible causes:
▪ Fan of power section FC Spindles .+L-T104 / +R-T204 defective

▪ Fan of ventilation duct +M-M104/-204 defective

W09 FC Spindles Nominal value error

On frequency converter +L-T104 / +R-T204 the status bit "Nominal value
reached" disappears during operation, e.g. because no nodeguarding telegram
has been obtained.

Possible causes:
Software error. Please contact Oerlikon Saurer Service in Kempten!

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W10 Start refusal

If there is a reason because of which the machine cannot be started, a
message appears.

Possible causes:

Table 9-4: Start refusals Machine

No. Description Solution

1 No standby Switch on Standby by pressing the switch +L-

S100

2 FC Spindle not Parameterise FC spindle (see 4.9

parameterised Parameterisation of drives, p. 4-33)

3 FC Winding not Parameterise FC winding (see 4.9

parameterised Parameterisation of drives, p. 4-33)

4 FC Capstan not Parameterise FC capstan (see 4.9

parameterised Parameterisation of drives, p. 4-33)

5 FC Traverse motion not Parameterise FC traverse motion (see 4.9

parameterised Parameterisation of drives, p. 4-33)

W11 Temperature Capstan motor

Temperature of capstan motor +A-M103/-M203 is too high.

Possible causes:
▪ Motor too hot. Temperature contact has tripped

▪ Temperature sensor defective

W12 Temperature Winding motor

Temperature of winding motor +A-M102/-M202 is too high.

Possible causes:
▪ Motor too hot. Temperature contact has tripped

▪ Temperature sensor defective

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W13 Compressed air is missing

The pressure switch +A-S100 monitors the compressed air. If the pressure is
too low, the switch trips. A warning appears and the buzzer is activated.

Possible causes:
Pressure switch has tripped
Æ The air pressure must be min. 5 bar

W14 Failure Suction

Coupling relay +L-K110 of suction unit (option) has tripped.

Possible causes:
▪ Cooling unit +L-K110 defective

▪ Suction motor defective

9.2 Spindle messages

9.2.1 Switch-off causes of spindles

Survey

Table 9-5: Switch-off causes of spindle

No. Description

S01 Spindle disabled

S02 ----

S03 ----

S04 ----

S05 Yarn Tension > Switch Off 1

S06 Yarn Tension < Switch Off 1

S07 Yarn Tension > Switch Off 2

S08 Yarn Tension < Switch Off 2

S09 Yarn Tension > Manual value

S10 Yarn Tension < Manual value

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No. Description

S11 Yarn Tension Ref. Value <> Mean Value

S12 Yarn Tension > Upper limit

S13 Yarn Tension < Lower limit

S14 ----

S15 Spindle RPM > Tolerance

S16 Spindle RPM < Tolerance

S17 Overload Spindle motor

S18 No pulses Spindle motor

S19 Complete Machine stop at Spindle start

S20 Communication Lifecheck

S21 Error EEPROM

S22 Current of creel yarn tensioner off tolerance

S23 24V-monitoring

S24 Error Watchdog

Description

S01 SPINDLE DISABLED

Spindle position disabled in the menu Service Æ Disabled / Test mode. Before
starting again, you have to enable the spindle position in menu Service Æ
Disabled / Test mode.

S05 YARN TENSION > SWITCH OFF 1

S06 YARN TENSION < SWITCH OFF 1
S07 YARN TENSION > SWITCH OFF 2
S08 YARN TENSION < SWITCH OFF 2
With selflearning function, monitoring of yarn tension is carried out via three
different tolerance and time windows (see operating manual).

S05:
Tolerance window Switch-Off 1 (tolerance + measuring time) from SettingsÆ
CordGuard (selflearning function) exceeded.

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S06:
Tolerance window Switch-Off 1 (tolerance + measuring time) from SettingsÆ
CordGuard (selflearning function) not reached.

S07:
Tolerance window Switch-Off 2 (tolerance + measuring time) from SettingsÆ
CordGuard (selflearning function) exceeded.

S08:
Tolerance window Switch-Off 2 (tolerance + measuring time) from SettingsÆ
CordGuard (selflearning function) not reached.

Possible causes:
▪ Unwinding troubles of spindle or creel yarn

▪ Yarn break

▪ Defective yarn sensor+Fx-11A1

▪ Wrong adjustment of tolerance limits and evaluation times in SettingsÆ

CordGuard (selflearning function)

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S09 YARN TENSION > MANUAL VALUE

S10 YARN TENSION < MANUAL VALUE
In manual mode, the yarn tension is monitored via a tolerance or time window
(see operating manual).

S09:
Tolerance window (tolerance + measuring time) from SettingsÆ CordGuard
(manual) exceeded.

S10:
Tolerance window (tolerance + measuring time) from SettingsÆ CordGuard
(manual) not reached.

Possible causes:
▪ Unwinding troubles of spindle or creel yarn

▪ Yarn break

▪ Defective yarn sensor+Fx-11A1

▪ Wrong adjustment of tolerance limits and evaluations times in SettingsÆ

CordGuard (manual)

S11 YARN TENSION REF.VALUE <> MEAN VALUE

The yarn tension reference value obtained at the spindle position is off
tolerance compared with the average of all yarn tension values of one machine:

Possible causes:
▪ Wrongly adjusted spindle yarn tensioner

▪ Cord Regulator wrongly threaded

▪ Other yarn count

▪ Thread guiding roller not easy-running

▪ Defective yarn sensor+Fx-11A1

S12 YARN TENSION > UPPER LIMIT

The max. yarn tension value at the spindle position has been exceeded for a
defined time. Spindle position switches off automatically.

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Possible causes:
▪ Unwinding troubles of spindle or creel yarn

▪ Yarn break

▪ Defective yarn sensor+Fx-11A1

S13 YARN TENSION < LOWER LIMIT

The min. yarn tension value at the spindle position has been fallen below for a
defined time. Spindle position switches off automatically.

Possible causes:
▪ Unwinding troubles of spindle or creel yarn

▪ Yarn break

▪ Defective yarn sensor+Fx-11A1

S15 SPINDLE RPM > TOLERANCE

S16 SPINDLE RPM < TOLERANCE
Spindle motor rpm off tolerance.

Possible causes:
▪ Motor +Fx-M1…3 overloaded

▪ Defective motor +Fx-M1…4 (e.g. one phase missing)

▪ Speed sensor +Fx-B1 in motor defective

▪ Defective operating unit+Fx-11A1

▪ Plug or harness defective

S17 OVERLOAD SPINDLE MOTOR

Motor load is continuously checked by determining the slip speed. In case of
overload, spindle position switches off automatically.

Possible causes:
▪ Overload because spindle rpm are too high (reduce speed until motor is no
longer overloaded)

▪ Heavy material (wrong yarn count)

▪ Defective motor +Fx-M1…4 (e.g. one phase missing)

▪ Speed sensor +Fx-B1 in motor defective

▪ Defective operating unit+Fx-11A1

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S18 NO PULSES SPINDLE MOTOR

No speed pulses are measured after switching on the spindle motor. In this
case the spindle position is switched off immediately .

Possible causes:
▪ Power switch +Fx-Q1 has tripped

▪ Motor +Fx-M1…4 blocked

▪ Defective motor +Fx-M1…4 (e.g. one phase missing)

▪ Speed sensor +Fx-B1 in motor defective

▪ Defective operating unit+Fx-A1

S19 COMPLETE MACHINE STOP AT SINGLE START

If a spindle is started and shortly after a complete machine stop is initiated, the
spindle position switches off, because the run-up could not be terminated.

S20 COMMUNICATION LIFECHECK

The network connection to the operating units is constantly monitored. If the
connection to the central control unit is interrupted, the spindle position is
switched off.

Possible causes:
▪ Defective operating unit+Fx-A1

▪ Network to central control unit +L-A1 interrupted

▪ Central control unit +L-A1 defective

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S21 EEPROM ERROR

If a complete machine stop is initiated, in the operating unit the machine
variables (e.g. length counter, spindle state etc.) are saved in a permanent
storage.

Then the machine can be switched off by means of the main switch. When the
machine is switched on again, the machine variables in the operating unit are
checked.

In case an error is found, the above message appears. The operating unit is
reset and the default setting is loaded (length counter = 0, spindle state to
Spindle stopped).

Possible causes:
▪ Machine variables could not be completely saved (e.g. short-circuit in
24VDC mains)

▪ Operating unit +Fx-A1 defective

S22 CREEL YARN TENSIONER OFF TOLERANCE

The actual creel yarn tensioner current does not correspond to the required
nominal value.

Possible causes:
▪ Brake defective.

▪ Feed line interrupted.

▪ Defective operating unit+Fx-A1

S23 24V MONITORING

Diagnostics feedback of the 24V monitoring of all outputs in the control module.

Possible causes:
▪ Operating unit +Fx-A1 defective.

▪ Valve of winding unit +Fx-Q1 defective.

▪ Yarn sensor +Fx-11A1 defective.

▪ Contactors +Fx-K1 or +Fx-K2 defective.

S24 WATCHDOG ERROR

Communication to CAN-Bus is faulty.

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9.2.2 Start refusals of spindles

It is a start refusal when after pressing Spindle start the red LED lights up once
and the spindle does not start.

Survey

Table 9-6: Start refusals of spindle

No. Description

B01 Spindle disabled

B02 ----

B03 Timeout Start enable

B04 No start enable (number > x)

B05 Switching actuations

B06 ----

B07 ----

B08 CRC error

B09 24V-monitoring

Description

B01 SPINDLE DISABLED

Spindle position disabled in ServiceÆ Disabled / Test mode. When pressing
Spindle start, the spindle position is not started.

B03 TIMEOUT START ENABLE

When pressing Spindle start at the spindle position, start enable must be
obtained from the central control.

In case this is not obtained within approx. 0.5 sec, the above start refusal
cause appears.

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B04 NO START ENABLE (NUMBER > X)

When pressing Spindle start at the spindle position, start enable must be
obtained from the central control.

Start is disabled if more than 3 spindle positions are put in operation at the
same time within 10sec, in order to avoid overload of spindle frequency
converter.

B05 SWITCHING ACTUATIONS

If more than 4 consecutive starts of the spindle position are performed at short
intervals, a start refusal appears, in order to avoid overload of the spindle
motor.

After approx. 10 min. waiting time, the spindle position can be started again.

B08 CRC ERROR

An error has occurred during the CRC test of machine variables.

Æ Actuate control module +Fx-A1 to reset (press spindle stop for 3 sec b) or
replace module.

B09 24V MONITORING

Diagnostics feedback of the 24V monitoring of all outputs in the control module
in case of a short-circuit (see 9.2.1 Switch-off causes of spindles, p. 9-129)

9.2.3 Spindle Warnings

Survey

Table 9-7: Spindle warnings

No. Description

W01 CordGuard Limit Short-Time Troubles Reached

W02 Spindle rpm off tolerance

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Description

W01 YARN DETECTOR LIMIT SHORT-TIME TROUBLES REACHED

Any yarn winding troubles which do not lead to a spindle stop are counted.

When a defined number of yarn troubles (Settings Æ CordGuard Selflearning

function) Unwinding troubles Warning limit is reached, the above
warning appears for the relevant spindle position.

W02 SPINDLE RPM OFF TOLERANCE

In menu AdministrationÆ MC ConfigurationÆ Spindle, you can enter a
tolerance value in percent.

If the spindle rpm rise above or fall below this tolerance limit, the above
warning appears.

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9.2.4 Blink codes of spindle position

Survey

Table 9-8: Blink-codes of spindle

Signal form Description

OFF

Short flashing (1x flashing, 1 sec interval)

Slow flashing (every second)

Quick flashing (every 200 ms)

Lit up permanently

Flashing once (for 1 sec)

Description

States
Table 9-9: Blink codes

Description LED green LED yellow LED red

With capstan clutch only: Quick OFF OFF

Engage capstan flashing

Press Spindle start once:

Capstan engages and flashes
until button is pressed again or
timeout has elapsed

Spindle is running (run-up/shut- Lit up OFF OFF

down/production) permanently
Spindle stopped. OFF OFF OFF
"Single stop" mode (no complete
start possible)

Spindle stopped. Slow flashing OFF OFF

"Group stop" mode (Spindle
start at complete start)

Single stop due to a yarn break OFF Lit up OFF

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Description LED green LED yellow LED red

permanently

Prewarning doffing Lit up Short flashing OFF

permanently

Reset triggering Flashing Flashing Flashing

once once once

Programme download active Lit up Lit up Lit up

permanently permanently permanently

Start refusal when trying to start OFF OFF Flashing

spindles once
Test mode of spindle position OFF Slow flashing OFF

Invalid node number (>127 or 0) OFF Quick OFF

or node number allocation
flashing
selected

Error states Errors are shown via an error sequence:

3 short flashes + error number

Example:3 short flashes, 3 slow flashes Æ error 3

After a break of 2 sec., this sequence is repeated

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Table 9-10: Blink codes of error states

Description LED LED yellow LED

green red

Error state (for more information see display of OFF OFF 1x

central control unit):

▪ All speed monitorings

▪ Hardware monitoring (24 V, EEPROM-CRC

error)
Error CAN communication (e.g. cable OFF OFF 2x
unplugged or bus OFF) or Watchdog

Error state or spindle disabled OFF Quick 5x

flashing

9.3 Problems with control modules in network

9.3.1 Survey

Table 9-11: General Network failure

No. Description

M01 Module does not respond

M02 Wrong module type

M03 Download error

M04 CRC error

M05 Parameterisation error

M06 Nodeguarding error

M07 Wrong hardware version

M08 Error when saving

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9.3.2 Fault repair

The control modules communicate with the control +L-A1 via CAN bus.

In case of an error, the data transfer is interrupted in one or both directions.

If a network error has been detected (e.g. during the boot process or during
operation), the respective control module is no longer addressed by the control
and a respective message is generated.

Reset possible via the logbook (see 8.1 Logbook, p. 8-91).

If the problem persists, replace the respective module.

M01 MODULE DOES NOT RESPOND

A SDO service is not confirmed or responds with invalid telegram.

Possible causes:
▪ Control module +Fx-A1 is missing

▪ Control module +Fx-A1 is defective

▪ Operating voltage of control module +Fx-A1 is missing

▪ CAN bus line interrupted

▪ CAN bus interface on control +L-A1 defective

M02 WRONG MODULE TYPE

Wrong control module installed.

M03 DOWNLOAD ERROR

CAN error occurred during download.

Possible causes:
▪ Control module +Fx-A1 is defective

▪ CAN bus line interrupted

▪ CAN bus interface on control +L-A1 defective

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M04 CRC ERROR

Checksum error occurred during download.

Possible causes:
Control module +Fx-A1 is defective

M05 PARAMETERISATION ERROR

CAN error occurred during parameterisation.

Possible causes:
▪ Control module +Fx-A1 is defective

▪ CAN bus line interrupted

▪ CAN bus interface on control +L-A1 defective

M06 NODEGUARDING ERROR

Nodeguarding error (= Lifecheck) occurred. The module has not responded to
nodeguarding three times.

Possible causes:
▪ Control module +Fx-A1 is defective

▪ CAN bus line interrupted

▪ CAN bus interface on control +L-A1 defective

M07 WRONG HARDWARE VERSION

Control module has wrong hardware version.

M08 ERROR WHEN SAVING

Problem during parameter saving on the control module.

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9.4 System messages

9.4.1 Survey

Table 9-12: System messages

No. Description

M1 ---

M2 System initialising

M3 … 6 ---

M7 Battery empty

9.4.2 Description

System messages are generated by the IPC itself.

M2 SYSTEM INITIALISING
Is shown every time the IPC has booted.

M7 BATTERY EMPTY
The IPC is equipped with a lithium coin cell. This message appears when the
coin cell is empty.

Allma CC3 677 820 0200 002 October 2009 9-144

10 Service

10 Service
Sales of original parts

Oerlikon Saurer
Allma Product Line
Zweigniederlassung der Oerlikon Textile GmbH & Co. KG
Leonhardstraße 19
87437 Kempten/Allgäu
Germany

Tel.: +49 831 688-257, -247, -348, -256

Fax: +49 831 688-344

If you need a service fitter, please inform us of this requirement. He will then
visit you without you having to wait too long.

After-Sales Service

Oerlikon Saurer
Allma Product Line
Zweigniederlassung der Oerlikon Textile GmbH & Co. KG
Leonhardstraße 19
87437 Kempten/Allgäu
Germany

Tel.: +49 831 688-255, -381, -258, -356

Fax: +49 831 688-320

Allma CC3 677 820 0200 002 October 2009 10-145

11 Original parts and wearing parts

11 Original parts and wearing parts

You should keep original parts and wearing parts which cannot be
supplied quickly in storage on site.

The original parts catalogue provided by Oerlikon Saurer, Allma Product Line
will assist in repair work since it contains diagrams for localising the machine
parts to be replaced.

Orders

▶ When placing orders, please provide the following data:

▫ machine type and number

▫ order number and year of delivery

▫ assembly and position numbers provided in original parts catalogue

▫ part number and name

▫ volume needed

▫ type of shipment and address

Ordering original parts on the Internet

Original parts can be ordered on the Internet via: SECOS.

SECOS stands for Superior E-Commerce System.

When using SECOS, you can order all the original parts you need for your
machine as quickly as possible. The parts will be delivered quickly.

The only precondition for using SECOS is a standard PC and a connection to

the Internet. We can provide you with the installation kit for the software
needed and your personal certificate for SECOS access.

Once installed, you can order original parts straight away from the Internet.

If you are interested in SECOS, then simply register for the package at
www.secos.myoerlikon.com.

Allma CC3 677 820 0200 002 October 2009 11-146