MEMMINGER-IRO MRA 2 Manual de usuario

Operating Instructions

english

027-920-000-01

27.05.09

MRA 2

Introduction

Congratulations and thank you for choosing a quality product from MEMMINGER IRO. To ensure that you get top

performance from this product you should be fully familiar with all its features and functions.

This is why we ask you to read this instruction manual carefully before starting to use the product. The manual contains

precautions, operating instructions and other useful information about how to make the best use of this product. Keep

this manual where it will be readily available for reference.

Introduction / Contents

Table of contents

Introduction................................................................................................................................................................ 1

Contents ..................................................................................................................................................................... 1

Safety.......................................................................................................................................................................... 2

Permitted uses.............................................................................................................................................................2

Safety precautions.......................................................................................................................................................2

Warranty ...................................................................................................................................................................... 2

Disposal.......................................................................................................................................................................2

Symbols used in this manual.......................................................................................................................................2

Description................................................................................................................................................................. 3

Unit components..........................................................................................................................................................3

Function.......................................................................................................................................................................3

Components ................................................................................................................................................................3

Installation options.................................................................................................................................................... 4

Single motor on one diameter ring with one toothed belt ............................................................................................ 4

Single motors on two different diameter rings with two toothed belts.......................................................................... 4

Single motors on two same diameter rings with two toothed belts.............................................................................. 4

Twin motor on one diameter ring with two toothed belts ............................................................................................. 5

Twin motors on two different diameter rings with four toothed belts............................................................................ 5

Single motor and twin motors on three different diameter rings with ve toothed belts .............................................. 5

Preparing for installation..........................................................................................................................................6

Setting the hollow shaft encoder ratio ......................................................................................................................... 6

Setting the toothed belt length.....................................................................................................................................6

Removing the toothed belts, the tensioning devices and the quality adjustment pulleys............................................ 6

Assembly.................................................................................................................................................................... 7

Fitting the hollow shaft encoder...................................................................................................................................7

Fitting the control unit .................................................................................................................................................. 8

Fitting the capacitor batteries (optional) ...................................................................................................................... 8

Connecting up the step-down transformer (optional) .................................................................................................. 8

Fitting the MRA 2 motors ............................................................................................................................................. 9

Fitting the tensioning device...................................................................................................................................... 10

Fitting the toothed belts ............................................................................................................................................. 10

Fitting the GT 3 console ............................................................................................................................................ 10

Terminal connection diagram................................................................................................................................. 11

Control unit ................................................................................................................................................................ 11

Electrical connections................................................................................................................................................ 11

Operation.................................................................................................................................................................. 12

Layout of GT3 console display .................................................................................................................................. 12

Access level menu.....................................................................................................................................................12

Conguration menu ................................................................................................................................................... 13

Setting the hollow shaft encoder for the set yarn feed rate ....................................................................................... 15

Fabric press-off rectication ...................................................................................................................................... 16

Device information menu...........................................................................................................................................16

Fault and status message menu ............................................................................................................................... 17

Console menu ...........................................................................................................................................................17

Technical data.......................................................................................................................................................... 18

Troubleshooting ...................................................................................................................................................... 18

Dimensions .............................................................................................................................................................. 19

MRA 2 motor..............................................................................................................................................................19

Control unit ................................................................................................................................................................20

GT3 console ..............................................................................................................................................................21

Hollow shaft encoder................................................................................................................................................. 21

Declaration of Manufacturer................................................................................................................................... 22

Safety

Permitted uses

The MRA 2 system is designed solely for feeding yarn to textile machines. All other uses are not permitted. The manu-

facturer will not accept any liability for damages resulting from non-permitted uses. The user is liable for damages

resulting from non-permitted uses.

Safety precautions

No special training is required to operate an MRA 2 system.

The operator is responsible for ensuring that all instructions regarding the electrical installation, tting, operation and

maintenance of the MRA 2 are implemented.

The MRA 2 must only be installed and serviced by qualied electricians working in accordance with current electrical

engineering practices and regulations.

The MRA 2 has electronic components which are sensitive to interference from electrostatic charges. Before

you open the equipment housing, you should take precautions to prevent electrostatic charges. You can

discharge any electrostatic charges beforehand by touching an earthed object such as the machine or the

earth contact of a socket.

The MRA 2 system is designed for operation with a 3 x 400 V AC power supply. The power supply for the MRA 2 must

be taken from the circular knitting machine. The power supply to the MRA 2 must be switched on and off from the

main switch of the circular knitting machine. This means that the MRA 2 can only be powered up when the machine

is powered up. When the machine is turned with the hand lever, the unit must be ready for operation.

Before you start any adjustments, even small ones, you must power down the knitting machine. Power up the equip-

ment only after you have completed these adjustments.

In the interests of your own safety, please enter all the necessary data on the GT3 console.

Before you start any adjustment of the unsprung tensioner device, power down the circular knitting machine.

Only use original spare parts and accessories.

Warranty

Failure to follow the instructions in this manual will void your warranty. The manufacturer will not accept any liability

for damages or operating faults resulting from failure to follow the instructions in this manual.

Disposal

You should dispose of MRA 2 components in compliance with the regulations for the disposal of electrical and elec-

tronic components.

Symbols used in this manual

CAUTION!

This symbol marks important instructions where failure to follow the instructions can cause personal

injury or damage to the equipment.

INFORMATION!

This symbol marks useful information which will help you to get the best from the equipment.

Description

Function

The hollow shaft encoder detects and measures machine

movements and rotation, translates this measurement

into a signal and then sends the signal to the control unit

where it is used to control the MRA 2 motor. The GT3

console is used to precision set the yarn feed rate for

each individual belt. The yarn feed rate for fabric press-off

rectication can be reduced by programming. The MRA

2 motors can run in both directions. This means that the

feeder for S and Z yarns can be run with left-handed or

right-handed direction of rotation.

In the event of a mains power failure, capacitor batteries

will continue to power the system until the machine has

come to a complete standstill. If a fault occurs during an

operating cycle, the machine will be powered down; it will

not be possible to restart the machine.

MRA 2 motors can be exchanged when required without

the need for any reprogramming.

Components

MRA 2 motor: The MRA 2 motors receive control signals

from the control unit and drive the toothed belts at the

speed for the set yarn feed rate. In order to handle speed

changes, manual operation and starting and stopping,

the motor incorporates advanced control technology. The

MRA 2 motor incorporates a frequency converter which

converts line current into three-phase alternating current

with variable frequency. No additional electrical cabinet is

required because the converter is already incorporated

in the motor.

GT3 console: The GT3 console is used to enter all the

parameters needed to install and operate the system.

Control unit: The control unit is powered from the mains

power supply at 3 x 400 V AC. It can power up to six MRA

2 motors. It stores operating parameters and distributes

information from the GT3 console and the hollow shaft

encoder. The GT3 console is used to enter the yarn

feed rate and displays the information about machine

movements received from the hollow shaft encoder. This

information is processed by the control unit and then

transmitted to the MRA 2 motors.

Hollow shaft encoder: The hollow shaft encoder is

installed on the drive shaft and is connected via a gear

box to the machine cylinder. The hollow shaft encoder

detects cylinder movements, translates these into pulses

and transmits the pulses to the control unit.

Capacitor batteries: Inthe eventof a mainspowerfailure,

the batteries ensure that the system continues running

until the machine has come to a complete standstill; this

prevents yarn breakage.

Unit components

1 - MRA 2 motors

2 - GT3 console

3 - Control unit

4 - Hollow shaft encoder

5 - Capacitor batteries

Installation options

Single motors on two different diameter rings with two toothed belts

Single motor on one diameter ring with one toothed belt

Single motors on two same diameter rings with two toothed belts

Installation options

Twin motors on two different diameter rings with four toothed belts

Twin motor on one diameter ring with two toothed belts

Single motor and twin motors on three different diameter rings with ve

toothed belts

Preparing for installation

Setting the hollow shaft encoder ratio

Before you t the MRA 2 system you must set the ratio

between the one machine revolution and the revolutions

of the knitting machine drive shaft.

Rotate the machine through one revolution and count

the number of revolutions of the quality adjustment

pulley.

The last revolution of the quality adjustment pulley

must coincide with the end of the single machine

revolution and should be counted at this point (e.g. 1

machine revolution = 10.8 quality adjustment pulley

revolutions)

Measure the yarn feed rate per machine revolution.

You will need to know the yarn feed rate in order to

ne adjust the hollow shaft encoder ratio (see the

section Setting the hollow shaft encoder for the set

yarn feed rate).

Example:

10.8

Setting the toothed belt length

MPF unit on the feeder ring:

Toothed belt length = (ring outer diameter + 200 mm) x

3.14 + 500 mm

MER unit on the feeder ring:

Toothed belt length = (ring outer diameter + 150 mm) x

3.14 + 500 mm

Continuous toothed belts are available in sizes from 2 to

16 metres in steps of 200 mm. Measure the belt length

required (for example 7100 mm) and then use the next

belt length up (7200 mm in this example).

Removing the toothed belts, the

tensioning devices and the quality

adjustment pulleys.

Before you t the MRA 2 you must rst remove the toothed

belts, the tensioning devices and the quality adjustment

pulleys.

You can also remove any unnecessary drive shafts and

housings.

Assembly

Fitting the hollow shaft encoder

Fix the adapter (2) and the torque bracket (5) to the

hollow shaft encoder (4).

Fit the encoder support (6) to the torque bracket

(5).

Slide the hollow shaft encoder (4) onto the drive shaft

(8).

Screw the screw (1) of the adapter (2) into the keyway

on the drive shaft (8).

Attach theencodersupport(6)to thedrivebar/column

(9) of the knitting machine.

CAUTION!

Only the rotor (3) of the hollow shaft encoder

(4) should rotate with the drive shaft (8).

The torque support (5) should not be bent or

kinked.

Fit the hollow shaft encoder (4) to the drive shaft (8) and

then the quality adjustment pulley (7).

Assembly

Fitting the control unit

Fit the control unit to the drive bar or column or to the

machine foot (see the section Device Components).

Connect the MRA 2 motors to the control unit using the

motor cables (1.8 or 3.0 metre lengths).

CAUTION!

The MRA 2 must only be installed and

serviced by qualied electricians working

in accordance with current electrical engineering

practices and regulations.

Before you connect or disconnect a motor cable,

you must power down the knitting machine. Wait two

minutes before unplugging the motor cable.

Power supply

3 x 400 V AC

PE L1 L2 L3

PE: yellow/green

L1: black

L2: black

L3: black

Connecting up the step-down trans-

former (optional)

The MRA 2 system operates a rated voltage of 400 VAC.

At input voltages greater than 400 V AC and up to 585

V AC, you must t a step-down transformer between the

knitting machine and the control unit.

Fit the step-down transformer in the electrical cabinet

or on the machine foot.

585 V

530 V

485 V

440 V

585 V

530 V

485 V

440 V

585 V

530 V

485 V

440 V

Power supply from knitting machine

3 x 440 - 585 V, 50/60 Hz

Power supply for the control unit

3 x 400 V, 50/60 Hz

Fitting the capacitor batteries (optional)

In the event of a mains power failure, knitting machines

continue to run on for some time. In the event of a power

failure, a MRA 2 system without capacitor batteries will

stop the yarn feed immediately and this could cause yarn

breakage.

OnanMRA2systemwithcapacitorbatteries,thecapacitor

batteries will continue to power the MRA 2 system until

the knitting machine has come to a complete standstill.

The number of capacitor batteries required depends

on a variety of factors and can only be decided on site.

The factors inuencing the number of batteries required

includes: machine speeds; rotating mass (open wide knit-

ting machines); general condition of the knitting machine;

number of MRA 2 motors tted; motor power required;

yarn sensitivity.

Fit the capacitor batteries to the machine foot and

connect them to the control unit (see the control unit

terminal connection diagram).

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