Section 0.2 Switches and Signal Indicator

Section 0.2Switches and Signal Indicator

MARCH, 2007 Ver. 1.00

0.2.1 Main Power Switch 1 ......................................................... 0.2-2

0.2.2 Emergency Stop Buttons, 2T, 2L, and 2R.......................... 0.2-2

0.2.3 Operation Panels, 3L and 3R ............................................ 0.2-3

0.2.4 Function Panel 4................................................................ 0.2-7

0.2.5 Signal Indicator 5 (Signal Lamp)........................................ 0.2-8

0.2.6 Two-hand Control Switches, 6L and 6R (Option) ............. 0.2-14

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0. OPERATION

0.2 Switches and Signal Indicator0.2.1 Main Power Switch 1(1) Main power switch 1 is located at the rear side

of main control box C. Turning the switch ONenergizes the motor circuits and control cir-cuits.

(2) After a few seconds, the white lamp in signalindicator 5 will come on.(If the white lamp flashes or any other lamplights or flashes, it means that some electricalerror has occurred.)

(3) Never turn on main power switch 1 immedi-ately after turning it off. Wait at least 30 sec-onds before turning it on again; otherwise, thesystem might fail to start up correctly.

0.2.2 Emergency Stop Buttons, 2T, 2L, and 2R

(1) Three emergency stop buttons are provided atthe rear of main control box C and at the leftand right switch boxes, SL and SR.

(2) These buttons should be used to stop theweaving machine in an emergency or to lockthe machine. Do not use any of these buttonsfor ordinary stop.

(3) Pressing any of these switches automaticallylocks the machine.

(4) To release the lock, lightly press any one ofthese buttons and turn it clockwise.

NOTE: If any of these buttons is pressed, theweaving machine immediately stops its opera-tion regardless of the ordinary stop timing.In such a case, release lock and perform theoperation for recovery from weft insertionmiss. (Refer to Chapter 5 “WEFT INSERTING• MEASURING MOTION”.)

1

2R

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0.2 Switches and Signal Indicator

0.2.3 Operation Panels, 3L and 3ROperation panels, 3L and 3R, are located at the leftand right side of the weaving machine, respectively.Each of them has six switches which are arrangedthe same way.

The table below lists the switches on each opera-tion panel:

(1) INTERLOCK switch (a)INTERLOCK switch a prevents the weavingmachine from running by pressing any otheroperation-panel switch accidentally or mistak-enly.To press the operation-panel switches exceptfor STOP switch b, be sure to check the oper-ation purpose and then press INTERLOCKswitch a and the desired switch at the sametime.

3R a d e f c b

3L a d e f c b

L.H.

R.H.

Symbol Switch namea INTERLOCK switchb STOP switchc START switchd RELEASE BRAKE switche FORWARD inching switchf REVERSE inching switch

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0. OPERATION

(2) STOP switch (b)Pressing STOP switch b while the machine isin operation prevents weft insertion immedi-ately preceding machine halt and stops themachine at the preset machine stop angle.If STOP switch b is pressed immediately afterSTART switch c is pressed and before themachine starts operation, the machine imme-diately stops its operation.

(3) START switch (c)This switch should be pressed with INTER-LOCK switch a held down.Pressing START switch c automaticallyreverses the machine, stops temporarily at themachine start angle, then starts running.In any of the following cases, pressing STARTswitch c cannot start the machine operation:

1) When the emergency stop button is locked.(To prevent damages)

2) When REVERSE inching switch f should bepressed for recovery from a weft stop (that is,when the recovery is not completed).(To prevent the occurrence of fabric defectsdue to misoperation)

3) When the motor cover is removed.(For safety, the limit switch works. The FOR-WARD and REVERSE inching switches alsoare not operational when the motor cover isremoved.)

4) When the machine is in the dobby-prohibitedarea.

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(4) RELEASE BRAKE switch (d)This switch should be pressed with INTER-LOCK switch a held down.Pressing RELEASE BRAKE switch d disen-gages the brake so that the weaving machinecan be turned by hand.

(5) FORWARD inching switch (e)This switch should be pressed with INTER-LOCK switch a held down.Holding down FORWARD inching switch eruns the machine in the forward direction at alow speed; releasing it stops the machineoperation.

NOTE: During forward inching operation bythis switch, none of the weft measuringdevices and weft pool devices operate.

When you release the brake, be careful with the heald frames and slay since they may move unexpectedly depending upon the current crank angle.

Never release the brake while gripping the manual wheel handle. Your hand will drag resulting in a wrist injury.

Pressing this switch again applies the brake so as not to allow the machine to be turned by hand.

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0. OPERATION

(6) REVERSE inching switch (f)This switch should be pressed with INTER-LOCK switch a held down.Holding down REVERSE inching switch f runsthe machine in the reverse direction at a lowspeed; releasing it stops the machine opera-tion.Irrespective of the continued pressure on thisswitch, the machine will stop at the reverseinching stop angle.

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0.2.4 Function Panel 4(1) Function panel 4, which is located on left

switch box SL at the left of the front side, is atouch screen. Each display area on the panelscreen contains touch-sheet switch(es).

(2) Function panel 4 displays the various settingsstored in the memory for each mode as wellas allowing the operator to change modes orenter values just by touching the desireditems.

(3) For details, refer to Section 0.3 “DetailedDescription of Function Panel”

NOTE: To remove fly, fleece, or dust from thetouch-sheet switches on the function panel, use asoft brush or chemical duster.

• Do not use a damp cloth.

• Do not get water on the touch-sheet switches.

Handle the touch-sheet switches with care. Theyand their underlying liquid crystal plate cannot takerough handling. Touch them with your fingers only,never with a metal material.

For the function panel unit, also take care not toapply heavy load exceeding ordinary operation.Heavy load will damage or break the liquid crystalplate. Never lean against the function panel orclimb onto it.

REFERENCE: After three minutes from start up ofthe machine, the backlight of function panel 4 willautomatically go off. This will increase the servicelife of the function panel (liquid crystal display).Touching the function panel will immediately turn onthe backlight. If the machine stops, the backlightwill automatically come on.

4

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0. OPERATION

0.2.5 Signal Indicator 5 (Signal Lamp)(1) Signal indicator 5 is located at the middle of

the right front side of the machine. It signalsthat the machine has halted due to an error/failure or for prevention of further troubles,while the function panel shows the detailedreasons.

(2) Each of the 4-color and 6-color signal indica-tors has the color signal lamps arranged asshown at left.

a. Red lamp

b. Green lamp

c. White lamp

d. Yellow lamp

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(3) The table below lists the relationship betweenthe indicator state and the message shown inthe message display mode on the functionpanel.

(* Indicator colors listed below are TOYOTAstandard.)

Signal indicator Message on the function panel RemarksColor* State Control

sectionRed ON NORMAL

STOPWARP STOPWASTE-SELVAGE STOP

Main control

Flashing MACHINE TROUBLE

MAIN CONTROL: STOP SIGNAL FROM LET-OFFMAIN CONTROL: FAILURE TO LET-OFF FOR PATTERN CHANGEMAIN CONTROL: FAILURE TO LET-OFF FOR PATTERN SETTINGMAIN CONTROL: FAILURE TO LET-OFF FOR END OF OPERATIONMAIN CONTROL: FAILURE TO LET-OFF FOR FELL-FWD SIGNALMAIN CONTROL: FAILURE TO LET-OFF FOR BEAM PREPARE MODEMAIN CONTROL: FAILURE TO TAKE-UP FOR FELL-FWD SIGNAL

Main control

TAKE-UP: SERVO AMPLIFIER ERRORTAKE-UP: SERVO AMPLIFIER OVERSHOOTTAKE-UP: RESOLVER FEEDBACK ERRORTAKE-UP: SERVO AMP. TENTATIVELY OVERLOADEDTAKE-UP: SERVOMOTOR OVERHEAT (SOFTWARE-DETECTED)TAKE-UP: SERVO AMP., SPEED CONTROL AMP. SATURATEDTAKE-UP: SERVO AMP. OVERCURRENT (SOFTWARE-DETECTED)TAKE-UP: SERVO AMP., MAIN CIRCUIT CONTACTOR ERRORTAKE-UP: RESOLVER CABLE BROKENTAKE-UP: DROPPED MAIN AC POWER SUPPLY VOLTAGE TO SERVO AMP.TAKE-UP: OVERVOLTAGE SUPPLIED TO SERVO AMP.TAKE-UP: SERVO AMP., IPM ERRORTAKE-UP: SERVOCOUNTER OVERFLOWTAKE-UP: SERVO AMP. RELEASE ERRORTAKE-UP: ABNORMAL SIGNAL FROM ENCORDERTAKE-UP: COMMUNICATION, TIME-OUT ERRORTAKE-UP: COMMUNICATION, SERVO_AMP RECEIVE ERRORTAKE-UP: COMMUNICATION, SERVO_AMP RESPONSE ERRORTAKE-UP: COMMUNICATION, DIRECTION SIGNAL FAILURE

Take-up control

WARNING WASTE-SELVAGE ROLLER TANGLEDWARP DETECTOR OFFWASTE SELVAGE SENSOR OFFWARP DETECTOR DISCONNECTEDMAIN CONTROL: EMERGENCY STOP SIGNAL FROM LET-OFFMAIN CONTROL: EMERGENCY STOP SIGNAL FROM LH TAKE-UPDECLARE (M/C TROUBLE)

Main control

STATE SURFACE ROLLER IN FORWARD ROTATIONSURFACE ROLLER IN REVERSE ROTATIONTAKE-UP: SERVO AMP. EMERGENCY-STOP BEING RELEASED

Take-up control

Green ON NORMAL STOP

WEFT STOP BY WF1 (COLOR 1)WEFT STOP BY WF1 (COLOR 2)WEFT STOP BY WF1 (COLOR 3)WEFT SUPPLY STOP BY LH FEELER (COLOR 1)WEFT SUPPLY STOP BY LH FEELER (COLOR 2)WEFT SUPPLY STOP BY LH FEELER (COLOR 3)

Main control

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0. OPERATION

Green Flashing WARNING WF1 IS OFF SETTINGWF1 SENSOR OFFWF1 FAILUREDECLARE (MENDING)BOBBIN SENSOR AND TAIL END SENSOR ARE OFF

Main control

White ON NORMAL STOP

[ STOP ] SWITCH PRESSEDREMOTE CONTROL STOP

Main control

Flashing NORMAL STOP

CLOTH BEAM FULLCLOTH BEAM TO BE DOFFEDEMERGENCY STOP BUTTON PRESSED

Main control

WARNING MACHINE TO BE POWER-OFFBRAKE RELEASEDINCHING WEFT INSERSION IS ON SETTINGDOBBY IS LEVELLING ON SETTINGDOBBY: INVERSION PROHIBITED FM FWD TO REVERSEDOBBY: INVERSION PROHIBITED FM REVERSE TO FWDDECLARE (CLOTH DOFFING)

Main control

LOCK HANDLE COVER NOT INSTALLEDSTARTING INTERLOCK BY LEVELINGDOBBY: INCHING IN UNINVERTIBLE-ANGLE RANGE(FM FWD TO REVERSE)DOBBY: INCHING IN UNINVERTIBLE-ANGLE RANGE(FM REVERSE TO FWD)REMOTE CONTROL LOCKREPLACE THE EMPTY BOBBIN

Main control

CAUTION CLOTH BEAM DOFFING SIGNALLED Main control

Yellow ON NORMAL STOP

FULL-LENO SELVAGE STOP, RIGHT-HANDFULL-LENO SELVAGE STOP, LEFT-HAND

Main control

Flashing FAILURE [ START ] SWITCH DEFECTIVE[ STOP ] SWITCH DEFECTIVE[ REVERSE ] SWITCH DEFECTIVE[ FORWARD ] SWITCH DEFECTIVE[ INTERLOCK ] SWITCH DEFECTIVETWO-HAND CONTROL SWITCH DEFECTIVE[ RELEASE BRAKE ] SWITCH DEFECTIVEDOBBY: NO.01 SOLENOID BREAKDOBBY: NO.02 SOLENOID BREAKDOBBY: NO.03 SOLENOID BREAKDOBBY: NO.04 SOLENOID BREAKDOBBY: NO.05 SOLENOID BREAKDOBBY: NO.06 SOLENOID BREAKDOBBY: NO.07 SOLENOID BREAKDOBBY: NO.08 SOLENOID BREAKDOBBY: NO.09 SOLENOID BREAKDOBBY: NO.10 SOLENOID BREAKDOBBY: NO.11 SOLENOID BREAKDOBBY: NO.12 SOLENOID BREAKDOBBY: NO.13 SOLENOID BREAKDOBBY: NO.14 SOLENOID BREAKDOBBY: NO.15 SOLENOID BREAKDOBBY: NO.16 SOLENOID BREAKDOBBY: NO.17 SOLENOID BREAKDOBBY: NO.18 SOLENOID BREAKDOBBY: NO.19 SOLENOID BREAKDOBBY: NO.20 SOLENOID BREAK

Main control


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Yellow Flashing FAILURE YARN TAIL END SENSOR 1 IS ABNORMAL (WIRE BREAK)YARN TAIL END SENSOR 2 IS ABNORMAL (WIRE BREAK)YARN TAIL END SENSOR 3 IS ABNORMAL (WIRE BREAK)YARN TAIL END SENSOR 4 IS ABNORMAL (WIRE BREAK)

Main control

MACHINE TROUBLE

AUTO LEVELING : ABNORMAL CONDITIONAUTO LEVELING : NO SIGNAL OF NORMAL POSITIONAUTO LEVELING : INTERRUPTED BY STOP PBOILING SENSOR STOP (SHEDDING MACHINE)OILING FAILED (PRESSURE IS LOW )OILING FAILED (PRESSURE IS HIGH )AUTO LEVELING : ILLEGAL INPUT FROM SENSORFULL-LENO SELVAGE SENSOR OFFSTROBO SCOPE ONBRAKE VOLTAGE FAILUREMAIN MOTOR OVERLOAD140 VDC FAILURE24 VDC1 FAILURE24 VDC2 FAILURE24 VDC3 FAILURE48 VDC FAILURE15 VDC FAILUREP15 VDC FAILUREM15 VDC FAILURE12 VDC FAILURE5 VDC FAILUREENCODER, Z-PHASE ERRORENCODER, A- OR B-PHASE ERRORBLOWER MOTOR OVERLOADINVERTER FAILURE OR INCHING OVERLOADLACK OF BRAKE TORQUENO INPUT FROM ENCODER Z-PHASE (IN OPERATION)ENCODER FWD-REV. PULSE COUNT ERROR (IN OPERATION)MAIN CONTROL: WATCH DOG RESETMAIN CONTROL: COMMUNICATIONS ERROR, WITH SC INVERTERDOBBY: ABNORMAL SIGNALLING FM PROXIMITY SWITCHESFAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 1FAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 2FAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 3FAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 4FAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 5FAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 6FAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 7FAILED TO EXHAUST REMAINED YARN AROUND BOBBIN 8SIGNAL ARRIVAL FROM THE YARN TAIL END SENSOR IS TIME OUTNO SIGNAL FROM BOBBIN SENSORSC INVERTER:OVERHEATSC INVERTER:OVERCURRENTSC INVERTER:OVERVOLTAGESC INVERTER:LOW VOLTAGESC INVERTER:MAIN MOTOR REVOLUTION ERROR

Main control


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0. OPERATION

Yellow Flashing WARNING MAIN CONTROL:SETTING VALUES INITIALIZEDINVERTER IS OFF SETTINGWINDING SENSOR OFFBLOWER MOTOR THERMAL SENSOR OFFMAIN CONTROL:LOW BATTERY VOLTAGEWINDING SENSOR FAILUREWINDING SENSOR SIGNALS MORE THAN NO. OF ACTUAL TURNS (COLOR 1)WINDING SENSOR SIGNALS MORE THAN NO. OF ACTUAL TURNS (COLOR 2)WINDING SENSOR SIGNALS MORE THAN NO. OF ACTUAL TURNS (COLOR 3)WINDING SENSOR SIGNALS LESS THAN NO. OF ACTUAL TURNS (COLOR 1)WINDING SENSOR SIGNALS LESS THAN NO. OF ACTUAL TURNS (COLOR 2)WINDING SENSOR SIGNALS LESS THAN NO. OF ACTUAL TURNS (COLOR 3)MAIN CONTROL: EMERGENCY STOP SIGNAL FROM SC INVERTERDECLARE (WARP OUT)DECLARE (FOREMAN CALL ON)YARN RUN OUT AROUND BOBBIN 1YARN RUN OUT AROUND BOBBIN 2YARN RUN OUT AROUND BOBBIN 3YARN RUN OUT AROUND BOBBIN 4YARN RUN OUT AROUND BOBBIN 5YARN RUN OUT AROUND BOBBIN 6YARN RUN OUT AROUND BOBBIN 7YARN RUN OUT AROUND BOBBIN 8YARN TAIL END SENSOR 1 DETECTS SIGNALYARN TAIL END SENSOR 2 DETECTS SIGNALYARN TAIL END SENSOR 3 DETECTS SIGNALYARN TAIL END SENSOR 4 DETECTS SIGNAL

Main control

CAUTION OPERATE YARN TAIL HANDLING MANUALLYCHECK WHETHER YARN TAIL EXISTING

Main control

STATE SC INVERTER:EMERGENCY STOP SIGNAL FM MAIN CONTROL SCI control

Red, yellow,

and white

Flashing STATE (EMERGENCY STOP BUTTON PRESSED) Main control

All colors

Flashing STATE MACHINE DOES NOT RUN, WHILE AUTOMATIC YARN TAIL HANDLER IS OPERATING

Main control

OFF MACHINE TROUBLE

REVERSE-REV. PULSE FROM ENCODER (IN OPERATION)MAIN CONTROL: CPU ERRORMAIN CONTROL: ACCESS-POINT OVERRIDEMAIN CONTROL: SEND TIME-OUT, WITH LET-OFFMAIN CONTROL: SEND ERROR, WITH LET-OFFMAIN CONTROL: NEGATIVE RESPONSE FROM LET-OFFMAIN CONTROL: TIME-OUT ERROR, WITH LET-OFF

Main control

WARNING INCHING WEFT INSERSION IS ON SETTINGDEMO STOPMAIN CONTROL: PATTERN 1ST PICK INITIALED

Main control

LOCK MACHINE TO BE REVERSED Main control


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OFF STATE OILING NOWOILING FINISHEDOILING NOW (VALVE RESTORING )REPLACE THE LH-CUTTERSUPPLY THE OIL MANUALLYSUPPLY THE GEAR-BOX OIL MANUALLYSUPPLY THE LETOFF-OIL MANUALLYSUPPLY THE SHEDDING-BOX OIL MANUALLYBEAM PREPARE MODEMAIN CONTROL: CLOCK ABNORMALMONITORING STOP NOW

Main control

SC INVERTER:SETTING NOT ALLOWED SCI control


section

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0. OPERATION

0.2.6 Two-hand Control Switches, 6L and 6R (Option)

(1) Two-hand control switches, 6L and 6R, areoptionally provided at the left side of switchbox SL and at the right side of switch box SR,respectively.

(2) Use either of these two-hand control switchestogether with the following switches. Themachine will not run without pressing any ofthese two-hand control switches.

• RELEASE BRAKE switch

• FORWARD inching switch

• REVERSE inching switch

• START switch

(3) When the machine has optional two-handswitches, the INTERLOCK switch is not oper-ational since each of those two-hand switches6L and 6R works as an interlock switchinstead.

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Documents

Section 0.2 Switches and Signal Indicator