RUG LOOM USER'S MANUAL - AVL Looms :: Home Loom Manual 2010.pdfRUG LOOM USER'S MANUAL AVL Looms 2360 Park Avenue Chico, CA 95928 Sales: 800 626-9615 [email protected] August 2010 Page

RUG LOOMUSER'S MANUAL

AVL Looms2360 Park AvenueChico, CA 95928

Sales: 800 [email protected]

August 2010

Page TOC-1

Preface 1Before You Begin 1

• NecessaryTools 2• HelpfulTools 2• Figure1-HardwareIdentificationChart 3

• HardwareHints 4

• SideFrameAssembly AS-6• Figure2-RightSideFrameAssembly AS-7• Figure3-LeftSideFrameAssembly AS-8• LowerBack AS-9• Figure4-AssemblingLowerLeftBackCorner AS-10• SpringLeverAssembly AS-10• HarnessPulleySupportAssembly AS-10• SquaretheFrame AS-11• LowerFront AS-11• UpperBack AS-12• Figure5 AS-12• LeveltheFrame AS-13• DobbyAssembly AS-13• BeaterAssembly AS-13• Figure6 AS-14• AirSystem AS-15• Figure7-Dobby/SideView AS-15• Figure8 AS-16• Figure9-Dobby/FrontView AS-17• Figure10-BasicRugLoomAirSystem AS-19• Figure11 AS-20• HarnessesAssemblies AS-20• Figure12 AS-22• ClothStorageBeamAssembly AS-23• Figure13-ClothStorageBeam AS-23• Figure14-InstallingClothBeam AS-23• ClothBeamAssembly AS-24• Figure15 AS-25• SeparationRollers AS-26• Figure16-InstallingSeparationRoller AS-26• WormDrive AS-27• Figure17-ClothStorageCrankshaftAssembly AS-27• WarpBeams AS-28• Figure18-ClothBeamHandle AS-28• BrakeCableAssembly AS-29• Figure19 AS-29• BrakeDragStrap AS-30• Figure20-BrakeDragStrap AS-30

TABLE OF CONTENTS

TOOLS

HARDWARE

ASSEMBLYSEQUENCE

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TABLE OF CONTENTS

Special Instructions for the Automatic Advance and Pressure Rollers• PressureRollers A-1• PressureRollerPhoto A-1• ControlBox A-2• ControlBoxPhoto1 A-2• ControlBoxPhoto2 A-2• AutomaticAdvance A-3• AutomaticAdvancePhoto1 A-3• AutomaticAdvancePhoto2 A-3• DirectionoftheClothDiagram A-4

Installation A1-1Figure1 A1-1ToAdjusttheBeaterHeight A1-1Figure2 A1-1Figure3(sideviewillustrationofbeaterwithwarpthreads) A1-2ToInstalltheAirShuttleAssembly A1-3Figure4A-Left-SideAirShuttleBox A1-3Figure4B-Right-SideAirShuttleBox A1-3Figure5-AirShuttleControlBoxwithFrontCoverOn A1-3Figure6A A1-4Figure6B A1-4Figure7A A1-5Figure7G A1-5Figure8A A1-6Figure8B A1-6Figure8C A1-6Figure9A A1-7Figure9B A1-7Figure9C A1-8Figure9D A1-8

ADDENDA

AIR SHUTLEINSTALLATION ANDADJUSTMENTS

• Figure21-BrakeCableAdjuster AS-31• Figure22 AS-32• Apron AS-33• ConnecttheAirSystem AS-33 • Compressor AS-33 • SetMainAirPressure AS-34 • SystemTest AS-34 • AddOil AS-34

• SectionalBeamCalculation W-1• ExtensionCords W-3• FeedingtheSpoolRack W-3• AdjustingtheTensionDevice W-4• SettingaTrackingSystem W-4• TensionBox W-4• TensionBoxHeddleInstallationInstructions W-4• ThreadingtheTensionBox W-5• Figure7W-TensionBox W-6• WindingtheWarp W-7• Figure8W-WindingontheWarp-HalfYard SectionalBeaminLowerPosition W-7• Figure9W-WindingontheWarp-OneYard SectionalBeaminUpperPosition W-8• AdjustingtheSizeoftheSection W-8• Figure10W W-9• Figure11W W-9• CountingTurnsorYardage W-10• Figure12W-AttachingYardageCounterto TensionBox W-10• CreatingtheCross W-11• SticksintheTreadingCross W-11• RoutingtheWarp W-12• Figure13W-RoutingofWarpwithSectionalBeam W-12• ReadjustingtheTension W-12• CombiningSectionalandPlainWarping W-13

• Whendoyouneedtotensionyourwarpsseparately? T-1• SettingTwoBeams T-1• Figure14W T-2• Figure15W T-2• Figure16W T-3• MorethanTwoWarps,SeparateTensioning T-4

TABLE OF CONTENTS

WARPING THE SECTIONAL BEAM

TWO OR MORE WARPS

Page 1

Wehopethismanualwilldothreethingsforyou:

1.) Guideyou,stepbystep,throughtheassemblyofyourloom—soyou’llbeimmediatelysatisfiedwithitsfunction.

2.) Helpyoulearnaboutitsvarioussystemsandcomponents—soyou’llbeanevenmorecapableweaver.

3.) Informyouaboutthecareandmaintenanceofyourloom—soyou’llenjoyalifetimeofdependableservice.

Aswe'vealreadysaid,it’simportantthatyoureadthismanualandfollowitsinstructionsfrombeginningtoend.Aquickreadthroughbeforeyouactuallypickupatoolwillgiveyouagoodoverviewofthewholeassem-blyprocess.

TheTable of Contentswilldirectyoutoeachofthemajorsections.You’llnotethatatvariousplacesinthetext,we’veinserteda[ ].Thisisareward box.Justaddacheckmarkasyoucompleteeachsegmentofwork.You’llfeelgreatandit’llhelpyoustayorganized.

Weknowthatsometimesyou'vejustgottohaveapicture,sowe'vein-cludedgraphicsupportwhereitseemsnecessary.Youmaywishtophoto-copysomeoftheseillustrationsandbringthemforwardwithyouasyouworkthroughthemanual.Thiswillsaveyouagooddealofflippingback-and-forthinsearchofthatoh-so-helpfuldiagram.You'llprobablyfind,forexample,thatyouneedtoreferconstantlytotheHardware Identification Chart (Figure 1)andLoom Illustrations (Figures 2 through 4).

Onelastbitofadvice:

Eventhenarrowerrugloomswillrequiretheeffortsoftwopeopleformanyoftheassemblyoperations.Severalofthecomponentscanbequiteheavy,especiallyinlongerlengths.PLEASE TAKE PRECAUTIONS TO PROTECT YOUR BACK, YOUR FIN-GERS, AND FEET WHEN HANDLING THESE PARTS!

Now,readthroughthemanualquickly,thenwe'llboltthewholeshebangtogether.

PREFACE

BEFORE YOU BEGIN

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You’llneedafewbasichandtoolstoassemblyyourloom.Werecom-mendacoupleofothersthatwethinkwillmakeyourjobeasier.

Necessary Tools:

[ ] ratchetandsockets:7/16”,1/2”,and9/16”

[ ] standardscrewdriver

[ ] mediumphillipsscrewdriver

[ ] hammerormallet

[ ] 8”or10”adjustableendwrench

[ ] carpenter’slevel

[ ] framingsquare

[ ] pliers

[ ] threewoodenblocksorbooks(approximately2”thick)

[ ] stepstool

Helpful Tools:

[ ] powerscrewdriverwithassortedbits

[ ] extraratchetandsockets

TOOLS TOOLS

HARD

WARE

IDEN

TIFI

CATI

ON C

HART

- F

IGURE

1

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HARDWARE

Ifyoudon'tworkwithhardware,youmayfindsomeofthetermsalittlemystifying.Nottoworry,we'veprovidedthateasy-to-useidentificationchart(Figure 1)tohelpyoukeepthingsstraight.

Hardware Hints:

A.) Ifaboltisalittletightgoingintoahole,giveitalight,friendlytapwithahammer.

B.) Tostartthethreadsonanutina“nutaccesshole”(Figure 4),youmayneedtoholdthenutinplacewiththeendofascrewdriverorafingertip.

C.) Alwayshavethelarge"nutaccesshole"facingtowardtheinsideoftheloomunlessotherwisespecified.

D.) Squarenutsalwaysgoin"nutaccessholes"anddonottakeawasher.

E.) But,alwaysputawasherundertheheadofahexbolt.AnynutthatisNOTinanaccessholealsorequiresawasher.Thiswillpreventdamagetothewood.

F.) Ifyouhavetroubleturningascrewintothewoodonyourloom,trydressingthethreadswithalittlebarsoap.

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ASSEMBLY SEQUENCE

YourfirsttaskwillbetoconstructtheSIDE FRAMES,leftandright,towhichyouwilladdthevariousotherloomparts.Asyouworkthroughtheassemblysequence,youwilladdcomponentsinthefollowingorder:

[ ] lowerback

[ ] upperback

[ ] springleversupportassembly

[ ] harnesspulleysupportassembly

[ ] clothbeam

[ ] squareandlevel

[ ] clothstoragebeam

[ ] wormdriveassembly

[ ] beaterassembly

[ ] dobbyhead

[ ] harnesscables

[ ] harnessframes

[ ] harnesssprings

[ ] airsystem

[ ] separationroller

[ ] warpbeam

Thefollowingillustrations(OV-AthroughOV-P)areapictorialoverviewofthesequenceofstepsnecessarytoputyouloomtogether.Pleasedonotusethesepicturesasamanual.Theyareforreferencepurposesonly.

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ASSEMBLY SEQUENCEASSEMBLY SEQUENCE

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[ ] Side Frame Assembly(toolneeded:9/16”ratchet)

You’llneedanarearoughly10’x10’inwhichtoassemblethesideframes.Ifthefloorisconcrete,youmaywanttolayatarpdowntoprotectthelacquerfinishontheparts.

1.) LocateBox#1.

2.) Removethecontents.Notethateachcomponentisidentifiedbynumber.ThesenumberscorrespondtotheSideFrameAssemblydiagrams(see Figures 2and3).

3.) Arrangethepartsattheperipheryofyourworkarea.Youwillfindithelpfultoseparateparts,leftandright.Also,orientthemsothatthelargeaccessholesfaceup.

4.) Checkthecontentsofthehardwarebagagainstitspackinglistandgroupsimilarboltstogether.

5.) EachboltshouldhavebeenfittedatAVLwithalockwasher,aflatwasher,andsquarenut,inthatorder.

6.) Fityourratchetwitha9/16”socketandleaveitwiththehardware.

7.) It’spuzzletime.Beginningwiththelongestpart,1L,arrangeeachoftheeightleftsideframemembersasshowninFigure 3.

8.) CloselycompareFigure 3againsteachpart.Verifythattheholesarelinedup.

9.) Usetheappropriatebolts,“A”or“B”,tolooselyconnecteachparttoitsneighbors.

10.) Gobackandtightenthebolts(butnotsotightlyastocrackthewoodbeneaththeflatwashers).

11.) Removethecompletedleftsideframetomakeroomfortheright.

12.) Completetherightsideframeinthesameway.

Inthenextassemblyphase,you’llhangvariouscrossmembersbetweenthesideframes.Asyouprogress,theloomframewillbecomesturdierandfree-standing.Besuretomovetheframetoitsfinalpositionbeforeitbecomestooheavy.A12’RugLoomcanweighasmuchasahalf-ton.Movingthesteelbeamsintoplaceisheavywork,especiallyforthewiderlooms,andwerecommendthatyouhaveplentyofhelpathandatthatpoint.


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[ ] Lower Back

1.) FindBox#2andremoveandorganizeitscontents.Notethatthecrossmembershavepartnamesinsteadofnumbers.

2.) Locatethecrossmemberhardwarepack.Sortandverifyitscon-tents.

3.) Movetheleftsideframeintopositionandlayitonthefloorwiththeaccessholesfacingup.Theshort,round-topped,verticalmem-berisatthefrontoftheloom.

4.) BringtheLowerBacktotheloomandplaceitonthefloorwiththeaccessholesfacingwhatwillbethefrontoftheloom(see Figure 4).

5.) Usetwo3/8”x4”hexboltassemblies(bolt/lockwasher/flatwasher/squarenut)tosecuretheleftendoftheLowerBacktotherearoftheleftsideframe.Snugtheboltsdown,butdonottighten.

6.) Repeatfortherightsideframe.Theframewillnowstandun-sup-ported(seeFigure 5).

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[ ] Spring Lever Assembly

1.) BecauseeachRugLoomisunique,dependingonwidthandop-tions,theSpringLeverAssemblymaybepackedinadifferentbox.However,thecontentsofeachboxarelistedontheoutside.Lo-catetheSpringLeverAssembly.

2.) Locatetheappropriatemountingholesinthesideframesandpre-positionfour4”hexboltassemblies.

3.) BringtheSpringLeverAssemblyintoposition.Note:itiscor-rectlyorientedifthechainshangingfromtheleversfacethesideframes.Iftheyaretotheinsideoftheloom.ThereshouldbealabelaffixedtotheassemblythatindicatestheTop/Front.

4.) Lefttheassemblyintopositionandslidetheboltshome.

5.) Addthenutsandsnugthebolts.

[ ] Harness Pulley Support Assembly

1.) FindtheHarnessPulleySupportAssembly.Itiseasilyidentifiedbyitsthreesetsofblackplasticpulleys.

2.) Bringittotheloomandorientitsothatthemetalidentificationplatefacesfront.Onesetofpulleyswillbeoffsettothefarrightsideoftheloom.

3.) Thisassemblyboltsintotheloomfromthetop.

4.) Selecttwo8”hexboltassembliesandtwo10-1/4”or12-1/4”studassembliesfromyourhardwareassortment.Thestudswillhaveanylocknutcementedatoneend.

5.) You’llnowneedtohoisttheassemblyintopositionatoptheleftandrightTopHorizontals.Be very careful of your back; get extra help if you feel you need it.

6.) RaisetheassemblyintoplaceandorientitovertheappropriatemountingholesintheTopHorizontals.TheIDplateshouldfaceforward.

7.) Boltitintoplace.Thelongstudsinsertattherearholes,the8”hexboltsinthefront.

[ ] Square the Frame(toolneeded:25’tapeorcarpenter’ssquare)

Inorderfortheloomtofunctionwell,itmustbereasonablysquareandlevel.We’llcheckforsquarenessfirst.Youmaydothiswitheitheracar-penter’ssquareora25’tapemeasure.

1.) UsingaCarpenter’sSquare:

• Checktheloomframeatthelowerrearcorners.Bearagainstopposingcornerstoadjusttheframeuntilitcomesintosquare.

• Now,gobackandfirmlytightenallthecrossmemberboltsthatyoupreviouslyleftonlysnug.

2.) UsingaTapeMeasure:

• Youwillusethetapetochecktheloom’sdiagonalmea-surements.FirstmeasurefromtheinsidebottomoftheLeftFrontVertical,totheoutsidefrontoftherightRearVertical.Recordyourmeasurement.

• DothesamefromtheRightFrontVerticaltotheLeftFrontVertical.Recordandcomparethetwomeasurements.Whentheyareequal,theframewillbesquare.

• Fromopposingcorners,bearagainsttheframeasneededtobringtheframetosquare.

• Whenyouhaveputtheframesquare(within1/8”),gobackandtightenalltheconnectingbolts.

[ ] Lower Front(toolneeded:3blocksorbooks)

1.) BringtheLowerFrontintopositionbetweenthefree-standingsideframes.Inthiscase,orientitsothattheaccessholesfacethefloor(see Figure 5).

2.) Selectfourmore3/8”x4”boltassembliesandpre-positiontheboltsintheattachmentholes,fromtheoutsideofeachsideframe.

3.) PlaceblocksundereachFrontVertical,leftandright.Thiswillraisethefrontoftheloomenoughforyoutoinstallnutsontheboltendswheretheyemergeintheblindaccessholes.



4.) PlaceanadditionalblockundertherightendoftheLowerFront(see Figure 5).

5.) LifttheleftendoftheLowerFrontuntilitsboltholesareoppositethoseinthesideframe.Pushtheboltsintopositionandaddthesquarenuts(it’stightonthefingers,butthiswillbetheonlytimeyou’llbesocramped).Snug,butdon’ttighten.

6.) Repeatattherightend.

7.) Removetheblocks.Youwon’tneedthemagain.

[ ] Upper Back(you’requicklybecomingaworldclassloombuilder)

1.) Again,pre-positionconnectingboltassembliesintheappropriateholesattheupperrearofeachsideframe.

2.) BringtheUpperBacktotheloomandpushtheboltsintoplace.

3.) Addsquarenutsandsnug.

[ ] Level the Frame(toolneeded:carpenter’slevel)

1.) UsetheleveltochecktheframeacrossthecenteroftheFrontHar-nessPulleySupport.

2.) Ifthebubbleismorethanslightlybeyondtheplumblines,youmayneedtoshimoneormoreoftheverticals.Failuretoleveltheloomnowmayaffectthebeateroperationlevel.However,theframeneedstobeonlyreasonablylevel,notpreciselylevel.Youneedn’tbeoverlyconcernedunlessyourfloorisseriouslycatty-wompus.

[ ] Dobby Assembly

1.) TheDobbyHeadisshippedinitsownbox.Pleaselocateitnow.

2.) Unpacktheheadandsetasidetheotherboxconstituents(dobbybars,pegs,etc.).Bringtheheadtotherightsideoftheloom.Thecablearrayisatthetopoftheunit.

3.) Thethreeattachmentboltsarealreadyinplaceinthehead.Re-movethehexnutsandwashers.

4.) IdentifythemountingholesintheRightSideFrame,alignthebolts,andpushtheheadintoplace(see Figure 5).

5.) Addthenuts/washersandfirmlytightentheheadtotheframe.

[ ] Beater Assembly

1.) TheBeaterAssemblyisquiteheavyandyou’llneedhelptoinstallit!Notethatthemountingbracketsarealreadyinplaceonthesideframes.

2.) BringtheBeaterAssemblytothefrontoftheloom.

3.) Untapethehardwarebagandremovethefourshorthexboltswithwashers.Locateaswellthefourwoodenblocksweprovided.Placetwoboltsandtwoblocksonthefloortotheoutsideofeachsideframe.Youwillusetheseverysoon.

4.) Next,lifttheBeaterAssemblyintopositionandboltitintothemountingbrackets,usingthefourhexboltsyou’vepre-positionedateachsideoftheloom.Leavetheendboltslooseforthemoment—youstillneedtoadjusttheheightofthebeater.



5.) Ateachsideoftheloom,inserttwoblocksunderthesliderods,nearthefrontandrearbrackets.Theseblocksarepre-cuttoapar-ticulardimensionandwillestablishthecorrectheightofthebeater.LettheBeaterAssemblyrestontheblocks.

6.) Tightendownthefourendboltsthatconnectthesliderodstothesupportbrackets.Removetheblocks.

7.) Movetherubberwashersforeandaft,uptothebrackets.Youshouldhavetwowasherstothefrontofthebeaterandoneaft.

8.) Checkthetravelofthebeater.Itshouldmovesmoothlyfront-to-back,withoutbinding,andshouldofferverylittleresistance.Ifyoufindthatyouneedtoovercomeresistance,anotheradjustmentisinorder.

[ ] Air System

You’venowinstalledallthemajorframingmembers,theDobby,andtheBeaterAssembly.It’sagoodtimetomountthevariouscomponentsthatcomprisetheAirSystem,beforetheinterioroftheloombecomesanymorecongested.

The Rug Loom will support a variety of pneumatic systems in addition to the Basic Air System. If you purchased an Air Advance, Air Shuttle, and/or an Air Beater, please refer to the addenda provided separately with those systems. Otherwise, you’ll have the Basic Air System.

1.) Pleaseunpackthebasiccomponentsandlaythemoutonthefloor.Theyarejoinedbyplasticairtubingandyoumaythinkyou’veencounteredanoctopus,butthewholearrayshouldassumeshapewithoutmuchdifficultyonceit’soutofthebox.Notetoo,thatthetubeendsarecolorcodedtoappropriatefittings,soevenifsome-thingdoescomeundone,itwillbeeasyenoughtoreconnectlater.


FIGURE 6

2.) Identifyeachcompo-nentagainstFigure 6.Theyareindividu-allylabeledandtherearecorrespondinglabelsontheframe.It’sasimplematterofmatchingitemtolocation.



3.) YouwillinstalltheAirSysteminthefollowingorder:

Outside,RightSideFrame(belowDobby):

• FRL(Filter/Regulator/Lubricator)

• MainAirValve


Inside,RightSideFrame:

• Manifold(79)

• Four-WayPilotedValve(80)

• ShuttleValves(8’,10’,12’loomsonly)(81)

• UpperBrakeValve(82)

• LowerBrakeValve(optional)(83)

• RightLowerBrakeCylinder(optional)

• RightUpperBrakeCylinder(24)

• LeftLowerBrakeCylinder(optionaland8’,10’,12’looms)

• LeftUpperBrakeCylinder(optionaland8’,10’,12’looms)

Freestanding:

• FootControl(youwillhavetwocontrolswith8’,10’,12’looms)

4.) Themountingscrewsforeachaircomponentaretapedtoit.Pleaseattachtheindividualelementsnow,proceedingassuggestedinthelistabove.

5.) Whenallthecomponentsareinplace,returnandtiethetubingintothepre-installedwhiteplasticanchorsthatyoufindatvariousplacesontheframe.We’veprovidedanumberofplasticziptiesforthispurposeandafewextraanchorswhichyoucanusewhereneededtokeepthingsneat.

6.) Finally,returnandvisuallyinspecteachconnectiontobesurethatnoairlineshavecomeloose.Ifyoufindalooseend,simplypushitintotheappropriatelycodedconnectoruntilyoufeelitseat.




[ ] Harness Assemblies(toolneeded:phillipsscrewdriver)

1.) LocatetheHarnessCables,Heddles,Springs,andHarnessFrames.

2.) You’llneedtoloadtheheddlesontotheharnessesbeforeyouhangthem.Thisismostcomfortablydoneonatable.

3.) LayaharnessdownandremovetheHeddleSupportclipsfromtherightorleftend,upperandlower.

4.) WithdrawtheHeddleSupportsafewinchessotheendsarefreeoftheharnessframe.

5.) Unlayabundleofheddlesoppositethefreeendsofthesupports.

6.) Theheddlesarestrungoncords.TieeachofthecordsintotheholesattheendsoftheSupports.

7.) TransferanappropriatenumberofheddlesfromthebundletotheHeddleSupports.Weprovide100heddlesperframe.

8.) Loosenthecords,re-insertthesupports,andaddtheclips.

9.) Repeatforeachframe.

10.) UseaphillipsscrewdrivertoremovethetwoHarnessCableRe-tainersthatsitatoptheinboardsetsofHarnessPulleys.Orremovethefrontscrewineach,loosentherear,rotatetheretaineroutofyourway,andplacetheloosescrewbackinitsoriginalholeuntilit’stimetore-secureit.Thiswillsaveyoualostscrewlater.

11.) LocateandunwraptheHarnessCables.

12.) YouwillconnecteachharnesscabletoacorrespondingcableemergingfromthetopoftheDobby.

13.) Toconnectacable,loosentheknurledlockingsleeveontheovalconnectinglinkandslideitopen.UsethelinktoconnecttheHar-nessCabletotherightmost(rearmost)DobbyCable.

14.) TheHarnessCablenowhastwofreeends,alongandashort.Stringthecableoverthethreecorrespondingpulleysinlinewithit.Theshortlegofthecablewillfalloverthesecondpulley,thelongoverthethirdpulley(accountfor“Y”onlonglooms).

15.) Bringaharnessframetotheloomandconnectthehangingcableendsintothescreweyesinthetopofitsframe.Note:eachharnessframehasatopandabottom.Thiswillbeindicatedontheframe.Ifit’snot,justrememberthattheHarnessCablesshouldhangperpendicularly whenconnectedtoaharness.Another check:thescreweyesonthetopsoftheframesaresetclosesttothecenter,thoseonthebottomarefurtherapart.

16.) NotethearrayofSpringLeverssuspendedonaxlesfromtheSpringLeverSupports.Achainhangsfromeachlever.Findthetwoleversthatareimmediatelybelowtheharnessframeyoujusthung.Connectthelastlinkineachchaintothecorrespondingscreweyesinthebottomoftheharness.

17.) Bringthebundleofspringswithchainstotheloom.Selectoneoftheseassemblies.Connectthespringendintotheremainingscreweyeineitheroftheleversandthechainendintothescreweyeopposite.Youmaystartleftorright,justkeeptheorderconsistentasyouaddeachharnessassembly.



18.) ReturnnowandhangandconnecteachremainingHarnessFrame.

19.) Whenyou’veinstalledalltheHarnessFrames,gobackandbesurethatthecablesarenottwistedwheretheycrossthepulleys.Checktoo,thateachcableisproperlybeddedinitsappropriatepulleyset.

20.) Whenyouaresatisfiedthatallisinorder,replacetheHarnessPul-leyRetainers.Tightenthemdownjustenoughthatthefeltstriponthebottomoftheretainersisslightlycompressedbythepulleybelowit.Thepulleymustbeabletorotateastheharnessesliftoryouwillexperienceundowearonthecable.

[ ] Cloth Storage Beam Assembly

Thebeamsyouareabouttoinstallareextremelyheavyandweadviseyoutohaveatleasttworobustadultsonhandforhandlingthem.Athirdpersonmayberequiredforbeamslongerthan8’.



1.) LocatetheClothStorageBeamandthelargeDriveGear.

2.) Findtheseparateboxofpillowbearingsandmountinghardware.

3.) YouwillfirstneedtomounttheDriveGeartotherightaxleoftheClothStorageBeam.

4.) RemovethehardwarebagmarkedClothStorageBeam fromtheboxofpillowbearings.

5.) Mountthegeartotheaxle.Firstslidethekeyintothekeyway;thenslipthegearovertheaxleandalignitsslotwiththekey;pushthegearonandflushagainsttheendofthebeam;finally,tightendownthesetscrew.

6.) Bringthebeamtothefrontoftheloomandorientitsothatthegearisontheright(dobby)side.

7.) Ontheloom,identifythemountingholesforthepillowblocks.TherearetwoeachintheleftandrightClothStorageSupports(see Figure 2,7Rforexample).

8.) Slipthepillowblocksontothebeamaxles.Thegreasefittingontherightblock(Dobbyside)shouldpointtotherearoftheloom;thatontheleft,tothefront.

You’llneedtoliftthebeamandinsertitsleftendthroughtheframe.Thiswillgiveyouclearancetobringtherightendintopositionoverthemountingholes.

Positionthepillowblocksovertheirmountingholes.You’llnotethatwehavescribedindexlinesintotheframe.Aligntheblockswiththeselines.

9.) Addtheboltsandfirmlyboltthepillowblocksinplace.

[ ] Cloth Beam Assembly

Again,thisbeamisquiteheavyandyou’llneedtoobservetheusualpre-cautions.

1.) BringtheClothBeamtothefrontoftheloom.Itissymmetrical,end-to-end.

2.) Woodenblocksshouldalreadybeontheaxlesatbothends.Un-tapethehardwarebagsfromthebeam,removethefoursquarenuts,andinserttheboltsintotheholesintheblocks,fromtherecessedside.

3.) TheseblockswillrestatoptheFrontVerticals(see Figure 15).Liftthebeamintopositionnow.Engagetheboltendsintheappropri-ateholesintheverticals.

4.) Addthefournutsandtightendowntheblockononeend.

5.) Rotatethebeambyhandatimeortwotosettletheremainingblock.Tighten.

6.) Rotatethebeamagain.Ifitrubsattheends,loosenonesideandmakewhateveradjustmentiswarranted.


[ ] Separation Rollers

YouwillhaveoneSeparationRollerforeachWarpBeam.OneWarpBeam,oneroller.

1.) TheSeparationRollersfitintothesemicircularpocketsintheRearVerticals.IfyouplantouseyourWarpBeamintheupperposi-tion,itsSeparationRollerwillfittheinside pockets.IfyouwilluseyourWarpBeaminthelowerposition,placetheSeparationRollerintheoutsidepockets.Neitherpositionoffersaweavingadvantage,butmanypeoplefinditeasiertoworkfromahighbeamwhenwarping.

IfyouplantomounttwoWarpBeams,youhavenodecisionstomake—theSeparationRollersareexactlyalikeandyou’lluseboth.

2.) Bringarollertotherearoftheloom.

3.) Untapethehardwarebag.Inityouwillfindtwoflatretainersandfourboltassemblies.

4.) Removethehexnutandallbutoneflatwasheroneachbolt;insertaboltwithwasherintothelowerholeineachbracket.

5.) Installthetworetainersasshownin.

6.) Placetherollerinitspocketsandrotatetheretainersup.Securetheboltineachretainer.

7.) Addtheupperboltateachretainerandtighten.

8.) Repeatforthesecondroller(ifyouhaveone).

[ ] Worm Drive

Nowyouwilladdthedrivemechanismthatturnsthebeam.Youwillneedtwo3/4”wrenchestoaccomplishthis.

1.) Findthedrivemechanismandremovethepivotbolt,pivotblock,andwoodenspacer.

2.) Fastenthepivottotheloomasshownin(see Figure 17).

3.) UntapethefourwoodscrewsyoufindtapedtotheSlidingBracket.UsethesetosecurethebrackettotheinsideFrontVertical.

4.) Notethatthewormlaysatopthelargedrivegear.Movethewormdownuntilthetwogearsmesh.Youmayneedtopulloutonthesmallspringpinyouseeatthefrontofthebracket.Withdrawitenoughtofreetheslideplatesothatyoucanmovethewormdown.Oncedone,releasethepinintoit’shole.

5.) Nowthreadthestarhandledowntightly.Thishandlewillallowyoutolockthewormupandawayfromthegearifyouneedtodisengagethedrive.Thepullpinwillkeepthegearsseatedwhenthemechanismisunderstrain,however,youshouldalsokeepthestarhandlefirmlytightenedwhenyouareweaving.

6.) ConnecttheClothStorageCranktothefrontofthedriveshaft(see Figure 18).

7.) Turnthecrankinbothdirections.Itshouldoperatesmoothlyandthegearsandbeamshouldturneasily.



[ ] Warp Beams

Lastoftheheavylifting.YouwillhaveaSectionalWarpBeam,aPlainWarpBeam,oracombinationofbeams.Regardless,theyallmountinthesameway.

1.) BringaWarpBeamtotherearoftheloom.

2.) Hereagainyou’llfindaPillowBlockoneachaxle.

3.) Untapethehardware,striptheboltsoftheirwashers,andinsertthemintothemountingholesintheblocks.

4.) Remember,youhaveachoiceofpositionsforyourWarpBeams.YoudecidedoncewhenyouinstalledtheSeparationRoller(s),butifyouwanttochangeyourmindnow,nooneislooking.

5.) LifttheWarpBeamintopositionandpushtheboltsthroughtheVerticals.Addtheflatwashers,lockwashers,nuts,thentighten.

[ ] Brake Cable Assembly

YouwillhaveonebrakecableperWarpBeamfor4’and6’RugLooms;2cablesfor8’,10’,and12’looms.

1.) Locateabrakecableassembly.Itconsistsofasteelcableandabracketwithmountinghardware.

2.) Boltoneorbothassembliesintotherightsideframeasindicatedin(see Figure 19).

3.) Routethebrakecable(s)asindicatedin(see Figure 21).

4.) Continuetotheleftsideifyouhaveadditionalbrakeassemblies.

5.) Youwillnotethatthecablescanbeloosenedortightenedbychangingtheextensionoftheadjustingboltintheanchorbrackets.TheseadjustmentswerepresetatAVLandyou’lllikelynotneedtochangethemnow.Overtimeyourcablesmaystretchandyou’llneedtotightenthemabit.



[ ] Brake Drag Strap

OntheoppositesideoftheBrakeAssemblyistheBrakeDragStrap.Itisusedtohelpkeepthebeamfromtwisting.SeeFigure 20 fordetails.




[ ] Apron

YourRugLoomisprovidedwithaheavycanvasClothStorageApron.Thisprovidesaconvenientwaytotieoffyourwarpandconserveswarplength,severalyardsofwhichwouldbelostifyoutieddirectlytotheClothStorageBeam.

1.) Locateandunlaytheapron.

2.) Startingabout1/4”fromeitherendoftheClothStorageBeam,securethevelcrostripoftheaprontothatonthebeam.Takecaretokeepthisinterfacestraightandfreeofwrinkles.

3.) Youhavealsobeenprovidedwithseverallongsteelrods.Findonenowandslideitthroughtheloopsattheotherendoftheapron.LeavetheotherApronRodasidefornow.

4.) UsetheClothStorageCranktorolltheapronontothebeam.

5.) YouwillbeinstructedintheWeavingSectionabouttying-ontotheapron.

Youaresoalmostdone!It’saloom!It’saloom!—andthereonlyafewremainingdetailstoattend.

[ ] Connect the Air System

Compressor

It’sagoodtimetoconnecttheairdeliverylinefromthecompressortotheFRL.Installationsdiffer;forexample,theairlinefromyourcompressortoyourloommaybecopperpipe,PVC,orflexiblehose.Ifyouareusingarigidtubing,werecommendthatyoufitatleastafewfeetofflexiblehosebetweentheFRLconnectionandthemainline.Thiswillpreventstrainattheconnectioniftheloommovesduringweaving.

Werecommendthatyouusequick disconnect fittingstoconnecttheairhosetotheintakeportoftheFRL.Yourcompressorsupplier,oranyindustrialtooloragriculturalsupply,canhelpyouwiththis.Thefittingshouldbemalewith3/8”NPTthreads.It’shelpfulifyoubuyafittingthatalreadyhasasealantappliedtoitsthreads.Otherwise,wrapthethreadswithTeflontapetoavoidaleak.

Pleasedonotusepipedope;itbecomesscalyandcancontaminatetheaircomponents.

PageAS-34

Set Main Air Pressure

Wepre-setthepressureattheFRLat75p.s.i.Pleasecheckitnowandre-calibratethedialifnecessary.Yourloomwilloperateatbetween75and120p.s.i.,butit’sbesttostartatthelowersetting.

System Test

Thisisyourfirstopportunitytotesttheloom’sfunction.Thistestwillestablishthatyourairconnectionsaretight,thattheharnessestransitsmoothly,andthattheWarpBeamBrakesareworking.We’vepre-adjustedtheoperatingspeedsandpressures,butyoumayneedtoaddafewminortweakstoachieveaparticularresult.It’salwayspossiblethatsomethingwasputoutofadjustmentinhandling.

1.) PuttheMainAirValvehandleintheOFFposition.

2.) Turnonthecompressor.

3.) Listenforairleaksinyourmainairdeliveryline.

4.) OpentheMainAirValve.

Add Oil

Weprovidedyouwithasmallbottleoflubricatingoil.Consultthemanu-facturer’sinstructionsheetforanexplanationofhowtoaddoilattheFRL.Onceyou’veaddedtheoil,setthelubricationmeteratitlowestvalue.Yourairsystemrequiresalmostnooilandtoomuchcanfoulthesystem.

ASSEMBLY SEQUENCE

PageW-1

WARPING THE SECTIONAL BEAM

TheAVLsectionalbeamisdesignedtobewarpedinsectionswiththeuseofatensionbox.Theyarntravelsdirectlyfromconesorspoolswhicharemountedonarackbehindtheloom,throughthetensionbox,andontothebeam.Throughoutthewarpingprocess,thetensionboxautomaticallykeepsaconstantanduniformtensiononthewarp.Notonlydoesthissys-temsavetime,butitmakesitpossibletowindonverylongwarpswhichwouldneverfitonawarpingboardorreel.

Sectional Beam Calculation

First,youmustcalculatethenumberofspoolsorconesofyarnyouwillneed.Eachsectioniswoundontothesectionalbeamseparately,therefore,you’llneedtohaveonespoolorconeforeachendinthatsection(ifyoursectionis2"wide,withsixteenE.P.I.,thatwouldbethirty-twospoolsorconesofyarn).

NOTE:Itusedtobethatallsectionswere2"wide.OnanAVLsectionalbeamwithmetalpegs,youcandecidetouse1",2",oranynumberofinchessections.Youcansimplyaddmorepegsinthepre-madeholesortakethemout.

Toprepareforsectionalbeamwarping,weneedtocalculate:

a) howmanyspoolsweneedtowind

b) howmanyyardsdoweneedtowindoneachspool

c) totalyardagefortheproject

Page W-2 PageW-3

a) NUMBEROFSPOOLS? Sectionalbeamingrequirestheuseofasmanyspoolsloadedwith

threadperindividualsectionasyourplannedsettinthereeddic-tates.

Tocalculatetheactualnumberofspoolsrequired,weneedtoknow:

- howmanyEPIarewegoingtouseinthefabric - whatSIZESELECTIONwillwehavetouseinthefabric

Ifyourwarpissetat24epiper1”,youwillneed24spoolsforasectionalbeamwith1”sectionsor48spoolsforabeamwith2”sectionsl.

Thereforewecansay:

# OF SPOOLS = EPI x SIZE OF THE SECTION

b) NUMBEROFYARDSPERSPOOL? Tocalculatethenumberofyardspereachspool,weneedtoknow: - theLENGTHOFTHEWARP - NUMBEROFSECTIONSonthebeam

WecalculatethenumberofsectionsbydividingtheWIDTHOFTHEWARPbytheSIZEOFTHESECTION.Ifthewarpwidthis40”andweareusing2”sections,ournumberofsectionsis20.

Alltogether,wecansay:

# OF YARDS PER SPOOL =LENGTH OF THE WARP x # OF SECTIONS

c) TOTALYARDAGE?Ifitisasinglecolorwarporifacolorsequenceisrepeatingineachsec-tion,thesamespoolsorconescanbeusedtowindallthesectionsneededforthewarp.

TOTAL YARDAGE = # OF SPOOLS x # OF YARDS PER SPOOL

Itisimportanttomakethesecalculationsinadvancesothatyoucanpur-chaseyouryarninspoolsorconescorrespondingtotheamountofyardageneededoneach.Sometimesthisisnotpossibleandyouwillneedtowindyourownspoolsfromyarnthatisinlargerpackages.Fordoingthis,youwillneedemptyplasticspools,abobbinwinder(preferablyelectric),andayardagecounter.TheseitemsareavailablefromAVL.

Extension Cords

Youmightwanttomakeapermanentsetofextensioncordstousewhenwarpingthesectionalbeam.Extensioncordsarealsocalledaproncordsandhavethesamefunctionastheapronontheplainbeam.Theygiveyou"reach"fromthewarpbeamandallowyoutoweaveeverypossibleinchuntiltheendofthewarptouchesthelastshaftyouareusing.Makethemoutofastrongnon-stretchablelinenorcottoncord.Youwillneedtomakeoneextensioncordforeachsectioninyoursectionalbeam.Foreachextensioncord,cutapieceofcord.Takethetwoendsofthecordandknotthemtogether.Measuretomakesurethattheyarelongenoughtoreachallthewaytotheharnesses.Allextensioncordsshouldbeex-actlythesamesize.

Whenmeasuringthelengthofthecords,alsochecktobesurethatwhenthecordsarewoundontothebeam,theendoftheloopandanyknotsinthecordsfallbetweenthecrosspiecesofthesectionalbeam,notonthem.Asectionalbeamisusuallynotsolid.Itisaframethathasmetalpegs.Thatwayyoucankeepthewarpsmoothonthebeamwithoutgoingovertheknotsofthreads.

Feeding the Spool Rack

Next,placeaspoolorconerackaboutfiveorsixfeetbehindyourloom.Placethespoolsorconesforthefirstwarpsectionsontheconerack.

Makesureyouputeachthreadthroughthemetaleyeonthespoolracksothethreadsdonotgettangled.

Whenarrangingthespoolsonthespoolrack,itdoesn'tmatterwhetheryougotoptobottomorbottomtotop,theimportantthingistobeconsistentinverticalcolumnsandtoplacethespoolsintheorderthatthethreadsareinthewarp.

WARPING THE SECTIONAL BEAMWARPING THE SECTIONAL BEAM

Page W-4 PageW-5

Adjusting the Tension Device

Beforewindingthesectionalbeam,makesuretodisengagethetensionsystemsothatthebeamwillturncounterclockwiseswiftly.Todothis,unlockthetensionropefromthespringandcompletelyunwraptheplasticcordfromaroundthetensionbeamdrum.Also,remembertoremovetheweightfromthetensionarm.

Setting a Tracking System

Onthebackoftheloom,setatrackingsystemthatwillallowthetensionboxtotravelfromonesectiontoanother.Thetensionboxisfastenedtothetrackingsystemwithwingnuts.Thesecanbereleasedforthetensionboxtomove.Oncecenteredproperlyforaparticularsection,thetensionboxneedstobetightenedagain(foreachsection).

Tension Box

Thetensionboxisanessentialwarpingtoolwhich:

a.) Putsthreadsundertension.

b.) Spreadsthreadstotheproperwidth.

c.) Makesthread-by-threadlease.

b.) Noticetherearefourtwisttiesholdingtheheddlestogether.Sepa-ratethetoptwo.Insertthetopbar(oftheharnessthatisup)intothespacecreatedbypullingapartthetwistties.Insertthebottombar(oftheharnessthatisup)intothespacecreatedbypullingapartthebottomtwotwistties,makingcertainthattheheddlesaren’t’twisted.Nowremovethetwistties.

c.) Countofffiftyheddlesandcuttheloopatthetopbetweenthe50thandthe51stheddle.

d.) Nowputthefourtwisttiesbackonthefiftyheddlesthatwerethelasttogoontheharness.

e.) Removethesefiftyandreattachthe“heddleretainer”.

f.) Nowpushdownontheharnessthatisup,makingtheotherharnesscomeup.

g.) Removetheheddleretainer.

h.) Pullapartthetoptwotwisttiesandinsertthetopoftheharness(whichisup)intothespacecreated.Pullapartthebottomtwotwisttiesandinsertthebottomoftheharnessintothespacecre-ated.

i.) Reattachtheheddleretainer.

Threading the Tension Box

Thebestwaytothreadthetensionboxistotakeonethreadfromtheconerackandthreaditallthewaythroughallthepartsofthetensionbox,thenthenextthreadallthewaythrough.Itworksbesttousethethreadsfromtherackinaverticalorderratherthanahorizontalorder.

Nowlet’sgothroughthesequenceforthreadingthetensionbox.First,movethetwoadjustabletensionpegsupabovethestationarypegsasshowninFigure#7Worremovethemcompletely.Nowsleythethreadthroughtherear(stationary)reedsectionusingasleyhook.Sincethisreediseightdentsperinch,youwilldividetheE.P.I.intoeighttofindouthowmanyendswillbeineachdent(withsixteenE.P.I,puttwoendsinasection).IfyourE.P.I.doesnotdivideequallybyeight,youcaneithervarythenumberofendsineachdent(withtwentyE.P.I.,alternatetwoandthreeendsinthedents)orthreadthedentsalittlewiderthantwoinches(withtwentyE.P.I.,puttwoendsineachdent;withfortyends,thereedwillbesleyed21/2”wide).


Tension Box Heddle Installation Instructions

Ifthisisyourfirsttimetouseatensionbox,youneedtoinstallheddlesontheharnesses.

Yourtensionboxisdeliveredwithonebundleofonehundredheddles.Theseareheldtogetherwithtwistties.Leavetheseonfornow.RefertoFigure#7Wtofamiliarizeyourselfwiththetensionboxanditsparts.Pushdownononeoftheharnessesuntilitstops.Thiscausestheotherharnesstogoup.Youwillusethatlaterformakingathreadingcross.Rightnowwe’llneedtouseittohelpintheassemblyoftheheddlestotheharnesses.

a.) Removethe“heddleretainer”oftheharnessthatisup,usingaphillipsheadscrewdriver.

Page W-6 PageW-7

Next,bringthethreadstraightthroughthetensionpegsectionin-betweenthelargeradjustabletensionpegsandthesmallerstationarypegsorjustabovethesmallerstationarypegsifyouhaveremovedthelargerones.

Next,threadtheendthroughthetwosetsofheddles.Thefirstthreadgoesthroughthefrontsetofheddlesandthenextthreadgoesthroughtherearsetofheddles.Repeatthisalternatingheddlethreadingfortherestoftheends.Theheddlesystemwillbeusedlatertocreatethethreadingcross.

Nowthreadtheendthroughthefrontpivotingreed.Hereyouhaveachoiceofusinganeightdentortendentreed.Picktheonethatcanbesleyedevenlyandasclosetothedesiredsectionwidth.Ifyoucannotgettheexactwidthofthesection,sleyyourreedslightlywider.Thiswillmakeitjustslightlywiderthanthespacebetweenthepegs.Thesectionwillbenarroweddownbypivotingthereed.Neversleythereednarrowerthanthesectiononthebeam.Thereisnowaytoexpandit.

Afterthetensionboxiscompletelythreaded,thelargerpegsaremoveddownwardtoapplytension.Thefurtherdowntheyaremoved,themoretensionwillbeappliedtotheyarn.Thisisanadjustablesystemasdiffer-entyarnsrequiremoreorlesstension.

Withaheavywoolthepegsmayonlyneedtobemovedhalfwaydown,whereaswithafinesilk,thepegsmayneedtobemovedallthewaydownandtheyarnwrappedanextratimearoundoneofthestationarypegstogetthepropertension.Onceyouhaveadjustedthetensioncorrectly,donotchangeitduringthewindingofthebeam,aslongasyouareusingthesametypeofyarn.

Oncethetensionboxhasbeenthreaded,itisnotalwaysnecessarytorethreadit.Ifyouneedtochangespoolsorcones,simplytiethenewendsontotheoldendsjustbeforetherearstationaryreed,thengentlypullontheoldendsuntilthenewendshavecomeallthewaythroughthebox.

Winding the Warp

Beforeyoustartwindingthewarp,attachthesectionofthewarptoanextensioncord,tieanoverheadknotinthewarpthreadsfromonesectionandslipthatknotintotheopeningofthelarksheadknotyoucreatedintheextensioncord.

Pullittight.


Page W-8 PageW-9


Adjusting the Size of the Section

Lineupthetensionboxapproximatelybehindthesectionyouwillbewinding.Nowwindaboutoneyardontothebeam.Asyouwind,youwillneedtofinetunetheplacementofthetensionboxalongthetrack.Whenitiscenteredproperly,tightendownthewingnutsunderthetensionbox.Atthispoint,youcanpivotthe“pivotingreedsection”sothattheyarncomescloseto,butdoesn’tquitetouch,eitherthepegtotheleftorthepegtotheright.Nowtightenthewingnutunderthepivotingreed.Thisshouldn’tneedtobereadjusteduntilyouareusingyarnofaverydifferentsize.

NOTE:Ifyouwillbeusingaflyshuttleandareplanninganarrowwarp,youneedtooffsetthewarp4”totherightinsteadofcenteringit.(Re-member,“theright”referstotherightsideoftheloomasyouareseeingitfromtheweavingpositionattheloombench.)Thisoffsetwillensureevenselvedges.

SeeFigures8Wand9Wforroutingtheextensioncordstowardstheten-sionboxfromthebottombeampositionandthetopbeamposition.

Extracaretocorrectlycenterandadjustthewidthofeachwarpsectionwillresultinmoreperfecttensionwhileweaving.

Makesurethatthethreadsaregoingontothebeaminflatlayers.Ifyounoticethatwarppilesupatthepegs,thesectionofthewarpistoowide.Ifthewarpfallsdownatthepegs,thewarpsectionistoonarrow.

Ifanyoftheaboveishappening,gobackandpivotthefrontreedonthetensionboxagainuntilyougetperfectlyflatlayers.Thisisveryimpor-tant,otherwiseyouwillenduphavingdifferentlengththreadsinonesec-tion,sincethecircumferenceofthebeamwithinthesectionisnotgoingtogrowevenly.Therefore,youwillenduphavinglotsoftensionproblems.

Page W-10 PageW-11

Counting Turns or Yardage

Todeterminethelengthofthewarpyouareputtingonthebeam,youneedtocounteitherturns,revolutions,oryards.

Tocountturns,youcandoitinyourhead,butitismorereliabletouseadigitalormechanicalrevolutioncounter.

Countingrevolutionsevenwithadigitalcounterwillstillgivetheap-proximatewarplengthonly,becausethecircumferenceofthebeamwillincreaseslightlywitheachrotation.Thisiscalledbeambuildup.

Tocountyardswithayardagecounterwhilewarpingthesectionalbeam,youneedtoplacetheyardagecounteratthefrontofthetensionbox.Youshoulduseanextrathreadformeasuringyardage,becauseifyouuseoneofthethreadsfromyourwarpsection,thatparticularthreadwouldhaveadifferenttensiononceyoustartweaving.Theextrathreadyouuseformeasuringpurposesonlycanbereusedforeachsection.

Creating the Cross

Whenthereisaboutahalfyardlefttobewoundontothebeam,itistimetomakethethreadingcross.Simplypushontherearheddleframeofthetensionbox,makinghalfofthethreadsgoupandtheotherhalfgodown.

Nowslipinaneightinchpieceofcontrastingthread(calledamarkingthread)throughtheopening(calledashed)createdbetweenthethreadsaboveandthethreadsbelow.Locatethismarkingthreadabouthalfwaybetweenthetensionboxandtheseparationroller.

Nowpushonthefrontheddleframe,makingtheotherhalfofthethreadsgoup.Nowtakeoneendofyourmarkingthreadandbringitthroughthisshed.Thetwoendsofthemarkingthreadshouldnowbetogether.Tietheminabowknot.Windtherestofthefirstsectionon,cuttheends,andsecuretothewoundonthreadusingarubberbandoverthepegs.

Continuewindingallthesectionsinthesamemannerbymovingtheten-sionboxalongitstrack.

Sticks in the Treading Cross

Whenallthewindingiscomplete,removetherubberbands,unwindafewfeetofwarp,andsliponeleasestickthroughthepathcreatedbytheupperportionofeachmarkingtie.Nowslipanotherleasestickthroughthepathcreatedbythelowerportionofeachmarkingtie.Securetheleasestickstogether,leavingabouttwoinchesbetweenthem,usingmaskingtapeorstringthroughtheendholesoftheleasesticks.Nowbringtheleasesticks,withthewarpends,aroundtheseparationrollers.


Page W-12 PageW-13

Routing the Warp

Ifyouhaveabeamintheupperposition,thewarpwillberoutedunder theupperseparationroller.Ifyouhaveabeaminthelowerposition,thewarpwillberoutedoverthelowerseparationroller(see Figure 13W below).


Combining Sectional and Plain Warping

Ifyouarewindingaveryfinewarp,sayfortyendstotheinchormore,anddonothaveordonotwanttowindalotofspoolsorcones,itmaybemoreconvenienttowindseparatewarpsectionsonawarpingboardorreelandgofromtheredirectlytothesectionalbeam.Ifyoudecidetodothis,however,yourwarpwillbelimitedinlengthbywhatwillfitonthewarpingboardorreel.Ifyouchoosethismethod,followthesesteps:

a) Calculatenumberofthreadsforeachsectiononyoursectionalbeam.

Onthewarpingboardoronthewarpingreel,make“babywarps”foreachsectiononyourbeam(ifyouareusingawarpingboard,youwillbelimitedinlength).

Makecrossesateachend:raddlecrossononesideandthread-by-threadcrossontheother.

b) Takethewarpofftheboardorreelbytakingoffthethread-by-threadcrossfirst.

c) Putthewarpthreadsfromafirst“baby”warpintheraddle,makingsurethatthreadsarespreadevenlyandthattheyarecreatingflatlayerswhenwoundonthebeam.Puttheraddletoponorsecurewarpthreadswithrubberbands.

Insteadofaregularraddle,youcanputamini-raddleinplaceofthefrontreedonthetensionbox.Inthiscase,thetensionboxisusedonlyforguidingthreadsintothesections.Youdonotthreadthreadsinthetensionboxthroughtheharnessesnorthroughthebackreedandyoudonotadjusttensionwiththepegs.

d) Attacheachbabywarptotheextensioncordsandproceedasinregularsectionalbeamingprocedure.

e) Sinceyouarenotusingthetensionboxfortension,besuretokeepittautmanually.

f) Whenyoucomeclosetotheendofthesection,takethereedcoveroffandcontinuewindingtherestofthebabywarp.

g) Securethatsectiontothebeamandcontinuetothenextone.

Readjusting the Tension

Nowtietheleasesticksfromthetopoftheloomsothattheyareateyelevelwhenyouareinyourthreadingposition.

Tokeepthewarpfromslippingforwardduringthethreadingprocess,re-windthetensionropearoundthepulleyandtensiondrumandcliptheropeendtothespring.Remembertoreplacethetensionweightatthistime.

Page T-1

TWO OR MORE WARPS

Therewillbetimeswhenyouwillwanttousemorethanonewarp,whichcannotbeputtogetherononebeam.

Youwillhavetoputthemonseparatebeamsorusesomekindofseparatetensionsystems.

When Do You Need To Tension Your Warps Separately?

Whenweaving:

a) Verydifferentsizeyarns.

b) Yarnswithdifferentstretchingqualities.

c) Differentdensities.

d) Differentstructures.

e) Supplementarywarptechniques(becausesomewarpthreadsdonotinterlaceasoftenasothers).

f) Agroupofspecialyarnsforselvedgesandborders.

g) Loops,piles,orpuckerslikeseersucker.

h) Morethenonelayerwithdifferentsettsineachlayer.

i) Morethanonelayerwithadifferentpickcountineachlayer.

Setting Two Beams

Ifyouareconfidentinsettingonebeam,itisjustaseasytosetupaloomwithtwobeams.Itmighttaketwiceasmuchtimeandyoudoneedtobemorecarefulnottomixsequences.

a) Windeachwarponthebeamthesamewayyouwoulddoitiftherewereonlyonebeamontheloom(plainorsectional).Makeacrossandhaveapairofleasestickswithacrossineachwarp.

b) Bringthewarpwiththeleasesticksfromthetopbeamaroundandunderthetopseparationroller.

Page T-2 PageT-3

TWO OR MORE WARPS

d) Hangbothpairsofleasesticks,onealittleabovetheother,soyoucanseeeachleasefromthethreadingposition.

e) Proceedwithathreadingasifyouonlyhadonebeam/onecross,followingyourthreadinginstructionsandtakingspecialcareofwhichthreadfromwhichpairofleasestickscomesnext.

TWO OR MORE WARPS

c) Bringthewarpwiththeleasesticksfromthebottombeamaroundandabovethebottomseparationroller.

Page T-4

TWO OR MORE WARPS

More Than Two Warps, Separate Tensioning

Ifyouhavemorethantwowarpstosetandnotmorethantwobeams,youneedtoweight/tensionyouradditionalwarpsseparately(dothesameifyouonlyhaveonebeamandmorethanonewarptoset).

a) Makeyourwarpsectionsonthewarpingboardandtakethemofftheboardinachain,onakitestick,orjustinaplasticbag.

Makesurethateachbundleisnottoothick.Youwillknowwhenyouneedtodivideeachbundleifyoufeelthatallthethreadsarenotbeingtensionedevenly.

b) Theweightneedstohaveastrongloopofstringonitsothewarpbundlescanbeslipknottedintoit.Thismakesiteasytoundotheslipknotandmovetheweightwhenitclimbsuptothebackbeamandmustbeletdownagain.

c) Theweightalsoneedstobeadjustable.Plasticbottleswithhan-dlesfilledwithwaterareperfect.Youcanalsousefishingweights,washers,nuts,bolts...Theyarenotaseasilyadjustablelikewaterbottles,buttakelessspace.Thelowertotheflooryoucanhangthem,thelessoftenyouneedtorepositionthem.

PageA-1

ADDENDA

PRESSURE ROLLERS ... an important part of the Cloth Take-Up Mechanism

FollowtheseinstructionstoassembletheSideFrames,tiethemtogetherwiththecross-members,andthenyou'llbereadytoputonthePressureRollers.

ThePressureRollershavebeenclearlylabeledBackandFront(referringtothefrontoftheloom).Theyhavebeenplacedintheircrateintheirproperposition.ItiscriticalthatthePressureRollersgooninthecorrectorientationwithFrontinthefrontandBackintheback.Theywon’tfitanyotherwayandtheothergears,particularlyfortheAutomaticAdvanceandClothBeam,won’tfitiftheyareincorrectlysituated.

Special Instructions for the Automatic Advanceand Pressure Rollers.

PRESSUREROLLERSMOUNTEDONTHELOOMWITHGEARSENGAGED

PageA-2 PageA-3

ADDENDA

AUTOMATIC ADVANCE

TheAutomaticAdvanceinstructionsintheUser’sManualareaccurate(seepage24fordetail).ExceptyouhaveanAUTOMATICADVANCEmechanismonBOTHsidesoftheloom.

CONTROL BOX

AftermountingtheDobby(seepage22),youwillMounttheControlBox.ItisattachedtotheRightSideFramebyfourbolts.

ADDENDA

PHOTOS:(right)CONTROLBOXMOUNTSWITHTHEFOURCIRCLEDBOLTS(note:theFRLinthelowerleftcorner)

(below)CONTROLBOXSEENONTHELEFTSIDEOFTHELOOM

NotethattheControlBoxencompassestheFRL(asseenonpage23).Theboxcomespre-assembled,sothereshouldn’tbeanyproblemmountingit.

ContinueconnectingtheAirSystemasdescribedintheManual.

PageA-4

ADDENDA

WhenconnectingtheAutomaticAdvance,makesureyou:

1.) Checkthemechanisms(leftandright).Theyneedtobeworkingtogether,notinoppositiontooneanother.Doublecheck,it’snotaseasyasitsounds.

2.) LookattheAutomaticAdvancemechanismsbeforemountingthem.Theyhavebeenpre-assembledbyAVL,butgetorientedfirst(usethephotos).

3.) Don’tforceanything.Thegearsshouldslidetogetherreadily.Iftheydon’t,thencontactAVLimmediately.

Lower Horizontal

DIRECTION OF CLOTH

Cloth Beam

Pressure Rollers

Cloth Take-Up

PageA1-1

AIR SHUTTLE INSTATLLATION AND ADJUSTMENTS

CongratulationsonyourpurchaseoftheAVLAirShuttlesystem.Wehopetheyprovideyouyearsofproductiveweaving.

InstallationoftheAirShuttleoccursaftertheinstallationandproperadjustmentoftheBeaterastheBeaterheightadjustmentaffectstheAirShuttleadjustment.

BeforeproceedingwiththeAirShuttleinstallation,pleaseinstalltheBeaterasdescribedintheRugLoomManualprovidedwithyourloom.EnsurethattheBeaterheightisadjustedtoallowatautwarpthreadtorestlightlyupontheBeaterRace.AdjustmenttotheBeaterheightisaccom-plishedbylooseningboltsholdingtheBeaterSlideRodstotheslottedBeaterSupportBracketsasshowninFigures1and2.

INSTALLATION

1.) ThreadandfixwithtapethreewarpthreadsfromthebottomoftheWarpBeamthroughthelowestheddle,thenthroughtheReedtothetopoftheBreastBeam.Onewarpthreadshouldbelocatedinthecenterofthebeams(approximatecenterisfine).Theothertwowarpthreadsshouldbelocatedoneithersidenearthemaximumweavingwidthofthebeams(again,approximatelocationsarefine).NotewhethereachwarpthreadistouchingtheBeaterRace.

TO ADJUST THE BEATER HEIGHT

Beater

Beater Race

Beater Slide Rod (moving the rod up/down ad-justs the Beater height)

Height Adjust-ment Bolts for the Beater

FIGURE 1

FIGURE 2

Page A1-2 PageA1-3

TheAirShuttlesystemcontainsthreemajorcomponents:theleftandrightShuttleBoxes(Figures4Aand4B)andtheControlBox(Figure5).


TO INSTALL THE AIR SHUTTLE

ASSEMBLY

FIGURE 4A - Left-Side Air Shuttle Box

FIGURE 4B - Right-Side Air Shuttle Box

FIGURE 5 - Air Shuttle Control Box with front cover on

InadjustingtheBeaterheight,youwillbesettingthethreewarpthreadssothattheyarerestingupontheBeaterRace.IfthewarpthreadsareabovetheBeaterRace,theymaycatchandbreakontheShuttleduringweaving.IfthewarpthreadsarerestingtooheavilyontheBeaterRace,itmayaffectyourfabricqualityand,inextremecases,alsocatchandbreakontheShuttleduringweaving(seeFigure3).


2.) LoosenbothboltsofoneBeaterSlideRod.Then,liftorlowertheBeaterSlideRoduntilthewarpthreadonthissideoftheloomistouchingtheBeaterRace.TightenbothBeaterSlideRodbolts.Repeatontheothersideoftheloom.

3.) VerifythatthethreewarpthreadsnowrestontheBeaterRace.Iftheydonot,repeatStep2.

FIGURE 3 (Side View Illustration of Beater with Warp Threads)

Proper WarpBeater Height

Beater Too High

Beater Too Low Beater

Warp Thread

FRONT OF THE LOOM ------>

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2.) AttachthepneumatichoseswithintheControlBox.Thehoseswilleitherbecolorornumericallycodedtoguideyou.NowisagoodtimetoverifytowhichAirShuttlePickerCylindereachofthepneumatichoseswillbeattached.(ThelongersetofhoseswillattachtotheleftsideAirShuttlePickerCylinder.)RoutethehosestotheirapproximatelocationsoneithersideoftheBeater.TheleftsidewillberoutedalongtheSpringLeverSupportCrossmember.

3.) AttachtheFiringSwitchtothetop,centeroftheBeaterusingthewoodscrewsprovided(Figure7A).RoutetheFiringSwitchwiringalongthetopoftheBeaterusingthewiretiesprovided.AttachtheWiringMountingBracket(Figure7B).Continueroutingthewiringtotherear,thendowntherightVerticalmembertotherearoftheControlBoxusingthewiretiestosecurethewiretothepre-mountedwiretiemounts.RoutethewiringthroughthelowerrearaccessholdandconnectthewiringintheControlBoxusingthecolor/numericalcodedwiring.

FIGURE 7A

FIGURE 7B

Italsocontainsseveralminorcomponents,includingpneumatics,firingswitch,andbeaterlocationsensor.

1.) AttachtheAirShuttleControlBoxtotherightsideoftheloomusingtheboltsandUHMWspacersprovided(seeFigures6Aand6B).


FIGURE 6A

three mounting bolts for the Air Shuttle Control Box

FIGURE 6B

two UHMW spacers

The bolts go through the spacers into the right vertical side frame member of the loom.

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7.) WiththeBeateratthehomeposition(closesttotheharnesses),tiltandmaneuvertheAirShuttleBoxuntiltheshuttlecavityisposi-tionedslightlyaboveandatananglethatisthesameasorslightlygreaterthanthetiltoftheBeaterRace(seeFigure9A).Hint:TheBeaterRaceisslightlytiltedtowardstheHarnessestohelpkeeptheshuttleontheBeaterRaceasitfliesacross.Tightenthemount-ingboltsthatholdtheAirShuttleBoxinthisposition.

FIGURE 9A

Beater Race

Shuttle Shelf

FIGURE 9B

Straight Edge

Beater Race

Shuttle Shelf

8.) Forthenextstep,youwillneedastraightedgeofone-to-twofeetlong.Slidethestraight-edgealongthebeateruntilitreachestheShuttleShelfintheAirShuttleBox.Thereshouldbeaveryslight(1/16inchorless)heightdifferencewiththeBeaterRacebeingslightlylowercausingthestraightedgetocatchasitisslidupandontotheShuttleShelf.Thisheightadjustmentisapproximateandneednotbeexact(seeFigure9B).

4.) Attachtheleft-sideAirShuttleBoxtotheleftsideoftheloomusingthehardware(threeboltsandwashers)provided.Theboltsshouldbelefthand-tightasyouwillshortlybeadjustingtheboxes(seeFigures8Aand8B).

5.) AttachthePickerCylindertotheleftsideoftheloomusingthehardware(fourboltsandwashers)andtheUHMWspacerprovided(seeFigures8Aand8C).AttachthecolorornumericallycodedpneumatichosestothePickerCylinder.MountthepneumatichosestothewiretiemountsattachedtotheLowerHarnessSup-portCrossmemberwiththewiretiesprovided.

6.) Ifnotalreadyattached,attachthePickerArmtothePickerCylin-der,PivotPoint,andthePickerwiththehardwareprovided(seeFigure8A).


Mounting holes/bolts

FIGURE 8A

Picker Cylinder, mounting block and hardware

FIGURE 8B

FIGURE 8C

Picker (green)

Picker Arm

Picker Pivot Point

Page A1-8


PerformfineadjustmentsontheheightoftheShuttleShelfusingthestopcollarsontheoutsidesupportrodoftheAirShuttleBox(seeFigure9C).

FIGURE 9C

Collars

Support Rod

FIGURE 9D

Gap between the Straight Edge and the Beater Race

LoosenthescrewsonthetopandbottomcolletsandraiseorlowertheShuttleShelfasrequired.Whendonecorrectly,aslightgapcanbeseenbetweenthestraightedgeandtheBeaterRacewhenrestingthestraightedgeacrosstheShuttleShelf/BeaterRace(seeFigure9D).Re-tightenthecollarscrewsoncethefineadjustmentiscomplete.

9.) RepeatSteps4through8fortherightsideAirShuttleBox.

Documents

RUG LOOM USER'S MANUAL - AVL Looms :: Home Loom Manual 2010.pdfRUG LOOM USER'S MANUAL AVL Looms 2360 Park Avenue Chico, CA 95928 Sales: 800 626-9615 [email protected] August 2010 Page