PROCESS CONER II

Electrical Parts

Contents
1 Troubleshooting......................................................... 1
1-1 Winding Unit Alarms
1-2 Main Machine Alarm
2 Winding Unit............................................................... 7

6
2-1 Layout of Electrical Equipment
2-2 Board Layout
2-3 Status Display
3 Main Machine............................................................12
3-1 Layout of Electrical Equipment
3-2 Principal Functions for Main Machine Chapter
4 Maintenance..............................................................17
5 Consumables............................................................18

2018.4 Doc No. P362

Sec 1 Troubleshooting
1-1 Winding Unit Alarms

Alarm Recovery Method

● Package alarms
Alarm LED Upper level light on
Status display *

* After checking the conditions of the end of the yarn on a package, press the illuminated reset switch
(upper level).

● Bobbin alarms
Alarm LED Lower level light on
Status display *

* After checking the conditions of the bobbins, press the illuminated reset switch (lower level).

● Other alarms
Alarm LED Mid-level light on
Status display Other displays

* If the alarm continues to sound, clear it by following the clearing procedure from the VOS screen.
1
Sec

Alarm Type & Description

Status
Alarm Type Cause
Display
Compiling Error Program fault
Calculation Error Program fault
Calculation Error (latch) Program fault
Sequence Arithmetic Stop Error Program fault
Carrying Error Program fault
Backup Error Data initialization
Compatibility error with system program and sequence
Program incompatible
program
DISPLAY PCB Alarm DISPLAY PCB error
SPLICER PCB Alarm SPLICER PCB error
MIDDLE PCB Alarm MIDDLE PCB error
BALCON PCB Alarm BALCON PCB error
M/G CAN PCB Alarm M/G CAN PCB error
DRUM BLD: Communication Timeout Communication error with UNIT-SPC
Between SPC
DRUM BLD: CPU Error CPU error
DRUM BLD: Low Voltage Low voltage
DRUM BLD: High Voltage High voltage
DRUM BLD: Drum Sensor Error Drum sensor input error

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Status
Alarm Type Cause
Display
DRUM BLD: CS Sensor Error CS sensor input error
DRUM BLD: Speed Deviation Speed Deviation
DRUM BLD: Motor Overheat Protection
Motor temperature high
(Thermistor)
DRUM BLD: Overload (Thermal) Overload occurred
DRUM BLD: Over Current Overcurrent occurs
DRUM BLD: IPM Fault IPM fault
DRUM BLD: CS Sensor Input Error CS sensor input error
DRUM BLD: CS Sensor Reverse
Drum rotated in reverse
Rotation Error
DRUM BLD: IPM Temperature Error High IPM temperature, abnormal value
DRUM BLD: Ground Fault Ground fault protection
DRUM BLD: Ready OFF Ready signal OFF
Air heater overheat alarm Overheating error on air heater
Air heater disconnect alarm Air heater is disconnected
Air temperature is fluctuating excessively from the set
Air heater temperature fluctuation alarm
temperature
Sensor that monitors the heater temperature is damaged or
Temperature sensor disconnect alarm
disconnected
Temperature control PCB
communication alarm
Communication error between UNIT SPC and HOT SPLICER
controller 1
Sec
CPU error on temperature control PCB CPU error occurred on temperature control PCB
Yarn threading error
Yarn Threading Error (system)
Yarn break occurred right after drum start
Yarn Threading Error (AD) AD error
Take-up Tube Supply Error Take-up tube not ready
Rear Package Not Processed Doffing operation not possible due to package at rear
AD unit No. recognition error Infrared communication failure between the unit and AD
Bobbin Supply Error No bobbin supplied
Lower Yarn Pickup Error Lower yarn pickup error
--- ---
Start Up Cut Alarm Clearer cut occurs frequently
--- ---
Yarn Count Alarm (UQC)
Yarn Count Alarm (iQON) ---
Yarn Count Alarm (YM)
Yarn Count Alarm (KC)
Pearl Chain Alarm (UQC)
Pearl Chain Alarm (iQON) ---
CLUSTER Alarm (YM)
IPM Alarm (KC)
Moire Alarm (UQC) ---
Moire Alarm (iQON)
CV Alarm (UQC)
CV Alarm (iQON) ---
CV Alarm (KC)
Foreign Fiber Alarm (UQC)
Foreign Fiber Alarm (iQON) ---
Foreign Fiber Alarm (YM)
DM Alarm (KC)

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Status
Alarm Type Cause
Display
Hairiness Alarm (UQC)
Hairiness Alarm (iQON) ---
SFI Alarm (YM)
IPI Alarm (UQC) ---
IPI Alarm (iQON)
CMT Alarm (UQC) ---
CMT Alarm (iQON)
YF Alarm (UQC) ---
YF Alarm (iQON)
MFAlarm (UQC)
MFAlarm (iQON) ---
FF CLUSTERAlarm (YM)
Other Alarms ---
PPAlarm (UQC)
PPAlarm (iQON) ---
PAlarm (YM)
Clearer Zero Adjustment Alarm Clearer zero adjusting error
Clearer Slot Jammed Alarm Yarn waste clog in clearer slot
Insufficient Cut Alarm Clearer did not cut sufficiently
Clearer technical alarm occurred
Clearer Technical Alarm
* Refer to clearer alarm screen.
Clearer Initialization Alarm The clearer did not finish initializing
Drum Lapping Alarm Drum lapping occurred
Traverse Error Traverse error detected 1
Sec
Traverse Error (2W <-> 2.5W) Wind switching error detected
Splicer operation error
Splicer Home Position Sensor Alarm
Splicer home position sensor alarm
Splicer yarn guide lever home position Splicer yarn guide lever operation error
sensor alarm Splicer yarn guide lever home position sensor error
Bal-Con Sensor Alarm
Bobbin Sensor Alarm
Bobbin (package) detection sensor error
Package Diameter Detection Sensor
Alarm
--- ---
Drum Sensor Alarm (Reverse) When reversing, the drum did not rotate enough
Package Rotating Sensor Alarm Package rotating sensor error
Retie pipe operation error
Retie Pipe Home Position Sensor Alarm
Retie pipe home position sensor error
PLC21 yarn travel detection error
PLC21 Alarm
* Dirty receiver and transmitter windows, etc.
Lower yarn sensor error
Lower Yarn Sensor Alarm
* Dirty receiver and transmitter windows, etc.
PC sensor error
PC Sensor Alarm
Tension error detected
Upper Yarn Sensor Alarm Upper yarn sensor malfunction
Drum Lapping Detection Sensor Alarm Drum lapping or winding detection sensor error
Traverse Sensor Alarm Traverse sensor error
Waste Yarn Detection Sensor Alarm Waste yarn detection sensor error
Tensor opener operation error
Tensor Operation Check Sensor Alarm
Tensor operation check sensor error
Shutter mouth operation error
Suction Mouth Angle Sensor Alarm
Suction mouth angle sensor error

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Status
Alarm Type Cause
Display
Shutter operation error
Shutter Home Position Sensor Alarm
Shutter home position sensor error
Bal-Con operation error
Bal-Con Home Position Sensor Alarm
Bal-Con home position sensor error
Peg Home Position Sensor Alarm Peg operation error
Peg home position sensor error
Tray Eject Home Position Sensor Alarm Tray eject operation error
Tray eject home position sensor error
Magazine can operation error
Magazine Can Position Sensor Alarm
Magazine can home position sensor error
Yarn Guide Lever Home Position sensor Yarn guide lever operation error
Alarm Yarn guide lever home position sensor error
Yarn Pickup Lever Home Position Yarn pickup lever operation error
sensor Alarm Yarn pickup lever home position sensor error
Upper yarn sensor detection miss alarm Upper yarn sensor detection miss alarm occurs
Suction shutter cotton fly clog Cotton fly is clogged in the suction shutter
Bal-Con Up Alarm Bal-Con up error
Unconsumed Wax Alarm Wax application failure
No Wax Alarm No wax
No package alarm No package is mounted on the cradle
Upper Yarn End Find Error ---
Upper Double Yarn Alarm Double yarn detected during upper yarn end find operation 1
Sec
Sizing Alarm Package diameter exceeds the specified value
Package Brake Error Package does not stop within specified time
PJC Alarm (upper limit) Too many yarn breaks/packages
PJC Alarm (lower limit) Too few yarn breaks/packages
Package Half-locked Alarm Bad package rotation occurred
Vibration alarm Too much vibration while winding
R/W module communication alarm Communication error between UNIT SPC and R/W module
Tag communication alarm R/W module can’t communicate with tag on tray
Mis-splicing ---
Splicer Cut ---
Air Heater Temperature Change Air heater is out of range for set temperature
Tension Break Alarm Frequent breaks in tension
Tension error (LOW) detected
Tension Error (LOW)
* Tensor is off, etc
Tension Error (HIGH) Tension error (HIGH) detected
Winding tension error (H) The tension during winding is higher than other winding units
Winding tension error (L) The tension during winding is lower than other winding units
The applied tension level during winding is higher than other
Tensor level error (H)
winding units
The applied tension level during winding is lower than other
Tensor level error (L)
winding units
DC5V Power Supply Error Line voltage error detected on DC5V power supply
DC15V Power Supply Error Line voltage error detected on DC15V power supply
DC24V Power Supply Error Line voltage error detected on DC24V power supply

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1-2 Main Machine Alarm

Main Machine Fixer Call

Rotation Signal
Signal Tower Machine
Classification Alarm Type Warning Cause
Status
Red Yellow Red Yellow
Emergency Stop Machine Emergency stop switch pressed
Emergency Stop Flashing Lit operation
Wire switch is pulled
(Wire switch) stopped
Flashing Machine
Communication Communication error occurred
(High operation
Error between devices inside machine
Machine speed) continued
Momentary
Momentary outage or power
Outage, or Machine outage occurred
Blower Outage Flashing operation
stopped
Air Down Main air pressure low

Input fuse break

DC24V Input
(Main fiber SPC, expanded PCB
Power Alarm
or interface PCB)
Output fuse break
DC24V Output
(Main fiber SPC, expanded PCB
Power Alarm Machine
or interface PCB)
operation
Blower Inverter

Main control
Alarm
stopped Blower inverter alarm occurred
1
Sec
Conveyor, Blow Flashing Motor breaker trip on conveyor
box
Cleaner Trip or blow cleaner
Dust Collector Motor breaker trip on dust
Thermal Trip collector
High temperature inside
Control Panel
Machine control box, exceeds constant
Overheat Alarm
operation temperature level
Cooling Fan continued
Cooling fan overheating
Alarm
Blow
Blow Cleaner
cleaner
Blow cleaner Travel Error Flashing Blow cleaner travel error
operation
Alarm
stopped
Bobbin
Empty
Bobbin conveyor
Conveyor Clog Flashing Empty conveyor clog occurred
conveyor operation
Detection
stopped

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 Rotation signal
Signal Tower Machine
Classification Alarm Type warning Cause
Status
Red Yellow Red Yellow
Water Tank Level
Empty water tank
Alarm
Water Tank
Unit yarn
Pressure Down Low water tank pressure
Water splicer Flashing splicing
Alarm
stop
Water Pipe
Air bubbles present inside
Residual Air
water pipe
Alarm
Operation
Converter Error Converter error
stopped
Converter
Operation
Communication Converter communication error
continued
Error
Converter CPU
Converter CPU error
Error
Converter Output
Converter output short error
Short Error
Converter DB Error occurred on regenerative
Circuit Error circuit for converter
AC/DC Converter FET element damage inside
Flashing
converter FET Damage converter
Converter
DB Resistor
Operation
stopped
Overheating error occurred
on regenerative resistor for 1
Sec
Overheat Error converter
Converter Protective function on
DB Resistor regenerative resistor for
Protection converter enabled
Converter DB Break detected on
Resistor Break regenerative resistor for
Detection converter
Converter Output
Converter output voltage error
Voltage Error
Span Slave Machine
Output Short operation Span slave output short error
Error stopped
Span slave Flashing
Span Slave
Operation Span slave communication
Communication
continued error
Error
Flashing Package left unattended for
Package Package Operation
(High extended period of time on
conveyor Conveyor Alarm continued
speed) package conveyor

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Chapter 6 Version 160301
Sec 2 Winding Unit
2-1 Layout of Electrical Equipment

Operation & Display Parts

Maintenance LED (Red)

Status display (Used for maintenance
(Alarm code display) functions)
(Used for maintenance
functions)
Alarm reset button (Up)
Maintenance LED (Green) (Alarm reset)
(Used for maintenance (Yarn threading operation)
functions)
Alarm LED (Up)
(Lights up and flashes during
package alarm)

Alarm rest button (Center)

(Alarm reset)

Operator call LED (Red)

(Lights up during alarm)
AlarmLED (Center)
(Lights up and flashes during 2
Sec
bobbin alarm)
Operator call LED (Blue)
(Lights up when package
is full and flashes for full
package warning)
Maintenance button (Right)
(Used for maintenance
functions)

Alarm rest button (Down)

(Alarm rest)
(Forced bobbin ejection)

Alarm LED (Down)

Maintenance button (Left) (Lights up and flashes during
(Used for maintenance bobbin alarm)
functions)

Unit operation switch

(ON during operation)
(OFF during operation stop)

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Chapter 6 Version 160301
 2-2 Board Layout

Straight Magazine type Bobbin Tray type (Link Coner type)

DISPLAY PCB

Unit SPC

Clearer adapter

DRUM BLD

DC/DC converter

SPLICER PCB 2
Sec

MIDDLE PCB

HOT SPLICER
controller
(optional)

M/G CAN PCB

BAL-CON PCB

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Chapter 6 Version 160801
Cone to Cone Model-I Cone to Cone Model-II

DISPLAY-PCB

Unit SPC

Clearer
adapter
DRUM-BLD

DC/DC converter

SPLICER-PCB

MIDDLE-PCB
2
Sec

HOT SPLICER
controller
(optional)

BAL-CON PCB

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Chapter 6 Version 160801
Rewind Magazine type

DISPLAY-PCB

Unit SPC

DRUM-BLD
DC/DC converter

Clearer
adapter

MIDDLE-PCB
SPLICER-PCB 2
Sec

M/G CAN PCB

HOT SPLICER
controller
(optional)

BAL-CON PCB

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Chapter 6 Version 160801
2-3 Status Display
● Status display
Spindle No. display Machine stopped
" ” Lit Omit spindle
" ” Flashing Yarn splicing stop signal received
" ” Progress display Cancelling yarn splicing stop

● Alarm display
Displays the alarm code when an alarm occurs.
(Refer to Chapter 6, 1-1 in instruction manual or VOS screen ID <B0000>)

● Other displays
Displays data for each check mode when using the unit check mode.
(Refer to the VOS Screen ID <41110> for unit check mode settings)

* Display priority
The priority hierarchy of items shown on the unit status display is given below.

Display priority (high)

- Omit spindle
- Alarm
- Check mode
2
Sec
- Spindle No. or splicing stop

Display priority (low)

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Chapter 6 Version 160301
Sec 3 Main Machine
3-1 Layout of Electrical Equipment

Main Control Box

1 10 9 14 18 15

16

5 13
6
3 12 11 21
24
19
7 22
4
20
23 25
8
17 26
27
32
28
31
29
22

3
Sec

(1) Clearer control box (17) DC control power supply

(2) VOS III (18) Gateway PCB
(3) Stop button (19) PCB for main fiber SPC
(4) Start button (20) Expanded PCB for main fiber SPC
(5) Bobbin/Tray conveyor switch (21) PCB for power distribution
(6) Blow cleaner switch (22) Circuit breaker
(7) Clean mode button (23) Magnet contactor
(8) Main switch (24) AC/DC converter
(9) Signal tower (25) Interface PCB
(10) Cooling fan (Top) (26) Circuit breaker
(11) Cooling fan (Bottom-right) (27) Motor breaker
(12) Cooling fan (Bottom-left) (28) Magnet contactor
(29) C
 onnectors for machine wiring
(13) Package conveyor start button
connections
(14) Blower inverter (30) T1 trance
(15) DC reactor (31) P
 CB for power outage detection
(16) Noise filter (32) Soft starter
30 24
(80 winding
units only)

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VOS III

3 2

[Rear View]

(1) VOS CPU board (3) Compact flash

(2) MCU (Machine Control Unit) board (4) DC control power supply (for VOS and MCU)

3
Sec

Unit Duct

3 2 2 2 1 4 5 2 2 2

(Length of 1 span)

(1) Span slave print circuit board (4) Power supply branch connectors (winding unit)
(2) PCB for branching communications (5) Power supply branch connectors (dust collector [option] )
(3) Repeter print circuit board

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Chapter 6 Version 160301
3-2 Principal Functions for Main Machine

Machine Operation & Stop Controls

They control the overall start and stop operations for the machine.

Machine Alarm Detection & Support Method Display

The alarm is detected, the machine and devices are stopped, and the alarm location is displayed.
When an alarm occurs, the tower signal and rotation signal warning notify the surrounding personnel, and a
picture of the problem location and the support method are displayed.

Machine Operation Status Display

The signal tower on the main control box and the out-end rotation warning signal notify surrounding personnel
about the machine operation status.

Rotation signal warning

Signal tower

CBF

[Signal Tower on Main Control Box] 3

Sec
This tower notifies the surrounding personnel about the general alarms for the machine.
Flashing
Lit
At 0.2 second intervals At 2 second intervals

Red AD error Communication error Fixer call*

Yellow --- Operator call* ---

Stop during operation due to
Green Operating ---
clean mode (Cycle stop)
* Refer to Chapter 6, 1-2.

[Out-end Rotation Warning Signal of the Winding Unit (Link Coner, Bobbin Tray)]
This rotation warning signal notifies the surrounding personnel about the alarms related to the CBF.*
Flashing
Lit
At 1 second intervals At 2 second intervals
- CBF error - Bypass line full - Emergency stop
Red
- Steam setter problem - Bypass line 2 full - Spinning frame problem
- Bypass line 1 operator call
- Bypass line 2 operator call
- Bypass line 1 full
Yellow - Bypass line 2 full --- ---
- Parts feeder bobbin empty
- Parts feeder hoist at upper
end
* Refer to the Chapter 7 (VOS) for further details on the alarms.

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Blower Control
The blower control drives the blower motor at the frequency set on the VOS.

During machine standby Blower speed during machine standby

During startup sequence Operates at upper limit setting for blower speed
During machine standby Operates at lower limit setting for blower speed

Tray Conveyor & Bobbin Conveyor Control

This control drives either the bobbin conveyor
(Magazine Type) or the tray conveyor (Bobbin Tray
type) using the bobbin / tray conveyor switch on the
switch panel located in the main control box.
* There is also a drive switch on the out end side for
the bobbin conveyor.
* The tray conveyor controls the motor mounted on
the CBF side using the CBF control box.
Bobbin/Tray
conveyor switch

Blow Cleaner Control

The drive for our in-house made blow cleaner is
controlled using the blow cleaner switch on the switch
panel located in the main control box.
Intermittent operation is also possible. 3
Sec

* Intermittent operation is standard on equipment with

36 winding units or less, and optional on equipment
with 38 winding units or more.
Blow cleaner
switch

Dust Collector Control

There is a dust collector system for each span.
It is controlled using the dust collector operation switch
for Span No.1.

Dust collector operation switch

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Chapter 6 Version 160301
Package Shutter Control
The product type is set using the package conveyor product setting knob. Pressing the start button opens the
corresponding shutter for the product type.
* The product type for each span is set on the VOS.

Package Conveyor Control

The package conveyor is controlled using the package
conveyor operation switch located on the back side of
the main control box. The LED for the switch lights up
during drive cycle operation.
Package conveyor
* When equipped with a package shutter, the package operation switch
conveyor is driven after the package shutter operation.

[Manual Stop]
Pressing the switch again during drive cycle operation
stops the operation.
Product type
[Auto Stop] setting knob
Operation automatically stops when the package
detection sensor located on the end of the machine
does not detect any package for a certain amount of
time.
* The auto stop time varies depending on the machine
length.
3
Sec

Tray Level Control

This function stops and re-starts operation for the winding unit per span, depending on the supply bobbin
status of the winding unit. The tray detection sensor attached to each span detects the bobbin supply status.
* This function comes standard with the Bobbin Tray device and is optional on the link corner device.
* The criteria for the auto stop and restart operation for the winding unit are set on the VOS.

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Chapter 6 Version 160301
Sec 4 Maintenance
Main Control Box
● Inspection & Cleaning
The temperature inside the main control box will increase if yarn waste, cotton fly or other contaminants
have built up on the box’s filter. This temperature increase can reduce the life of the electrical components or
damage them.
In addition, the VOS panel may rise or pop up if the pressure inside the box increases.

Frequency Item Guideline

-Remove the side cover of the main control box and clean from
the inside part of the cover using an air gun, etc.
Monthly Filter * Loosen the seven fixing bolts, and remove the side cover.
-Check for clogging

Fixing bolt 4
Sec

Filter

Blower Inverter
● Replacement Procedure
Refer to the inverter instruction manual for details.

1. Remove the detachable terminal with parameter back-up function from the new inverter.
2. Turn off the main switch on the main control box.
Wait until the inverter CHARGE lamp goes out.
3. Remove the detachable terminal with parameter back-up function from the damaged inverter.
It is not necessary to remove the cable connected to the detachable terminal with parameter back-up
function.
4. Replace the damaged inverter with the new one and attach in original locations.
5. Attach the detachable terminal with parameter back-up function.
6. Check there are no shorts or earth faults with the circuits connected to the inverter.
7. If there are no problems, turn ON the main switch in the machine control box.
8. Test run the machine and check there are no problems with functionality.

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Chapter 6 Version 160301
Sec 5 Consumables
Main Switch UVT (Undervoltage trip device)
The main switch is equipped with a UVT (Undervoltage trip device) as an accessory device.
This device trips the main switch to prevent a malfunction or machine damage while recovering from the power
outage, or when the factory experiences a drop or low electrical power voltage.

The UVT has a product lifespan. If the life of the UVT is exceeded, it will stop tripping even when the trip
conditions are met.
(UVT function lifespan: 3500 trips)

* When the operator turns OFF the main switch, this operation does not impact the lifespan.

If the main switch does not trip during a power outage, replace the UVT with a new device.
* For further details on the replacement procedure, refer to the “UVT Device Installation Guide” that is
provided with the UVT.

5
Sec
UVT

Main switch

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