TT-5852 MASCOTT PLUS 25-30 CROSSLAPPER AND MONO_1AB_27-3000 NEEDLE LOOM

REFERENCE NUMBER: TT-5852 MASCOTT PLUS 25-30 CROSSLAPPER AND MONO_1AB_27-3000 NEEDLE LOOM ITEM 001 MASCOTT PLUS 25-30 CROSSLAPPER LEADER IN ABRASIVE FELTS BUT THEY ARE GOOD FOR ALL FIBERS. IT BECOME ABRASIVE FELT PASSING INTO THE OVEN. GENERAL DESCRIPTION IN THE PRODUCTION CHAIN OF NONWOVEN FABRIC, THE FOLDER'S FUNCTION IS TO COLLECT THE CARDED WEB (WHETHER MADE OF NEW OR REGENERATED FIBERS) AND LAYER IT ONTO A DEDICATED CONVEYOR. THE WEB IS FED INTO THE FOLDER BY AN EXTENSION OF THE LOWER FEED BELT, WHICH ALLOWS THE COLLECTION OF THE WEB WITHOUT ADDITIONAL STEPS OR DRAWING, DIRECTLY FEEDING THE TWO MAIN CARRIAGES. THESE CARRIAGES, WITH ALTERNATING TRANSVERSE MOTION, LAYER THE WEB ONTO A CONVEYOR MOVING PERPENDICULARLY TO THE MACHINE AXIS. THE CONVEYOR BELTS ARE INDEPENDENT AND INDIVIDUALLY ADJUSTABLE. THE MACHINE'S SUPPORTING STRUCTURE IS COMPOSED OF TWO MODULAR SIDE PANELS MADE FROM HIGH-QUALITY STEEL PLATES, WHICH ARE LASER-CUT, WELDED, SANDBLASTED, NUMERICALLY CONTROLLED, AND PAINTED. THIS STRUCTURE GIVES THE MACHINE PARTICULAR STURDINESS, QUIET OPERATION, AND VIBRATION-FREE PERFORMANCE. THE FEED BELT IS AN EXTENSION OF THE TRANSPORT BELT, DESIGNED TO COLLECT THE CARDED WEB WITHOUT DRAWING. DURING CARDING MAINTENANCE, THIS BELT RETRACTS INTO THE FOLDER STRUCTURE. THE MATERIAL’S OUTPUT BELT IS CONTAINED WITHIN THE MACHINE’S ENVELOPE. THE FEED BELT MUST BE MOUNTED AT THE CARDING MACHINE’S OUTPUT SIDE, INCLINED APPROPRIATELY TO THE HEIGHT OF THE CARDING MACHINE’S WEB STRIPPING COMB. IF TWO STRIPPING COMBS ARE PRESENT, THE FOLDER CAN BE EQUIPPED UPON REQUEST WITH TWO OPTIONAL FEED BELTS, INDEPENDENTLY ADJUSTABLE. THE LOWER CONVEYOR TRANSPORTS THE WEB INTO THE RECOVERY CARRIAGE, WHICH TEMPORARILY STORES THE MATERIAL BASED ON THE DISTRIBUTOR CARRIAGE’S MOVEMENT DIRECTION, BEFORE RELEASING IT ONTO THE DISCHARGE BELT. THE FOLDER DOES NOT USE DISTRIBUTOR ROLLERS, WHICH CAN DAMAGE THE WEB AND CREATE AIR TURBULENCE DURING DEPOSITION. THANKS TO ITS SPECIAL BELT ARRANGEMENT, IT HAS ACHIEVED A SINGLE-RETURN TEXTILE CIRCUIT, USING THE DEPOSITION BELTS AS FOLDING CYLINDERS. THEREFORE, THE OUTPUT BELT’S HEIGHT MUST BE ADJUSTED TO ACHIEVE THE CORRECT PRESSURE BETWEEN THE FOLD AND THE DEPOSITION BELTS. THIS HEIGHT ADJUSTMENT IS CONTROLLED BY TWO ELECTRIC ACTUATORS, AND EACH MUST BE PERFORMED INDIVIDUALLY THROUGH DEDICATED SELECTORS BASED ON THE FINISHED PRODUCT. THE ALTERNATING MOTION OF THE CARRIAGES IS ACHIEVED THROUGH A SYSTEM FULLY DECOUPLED FROM EACH SIDE PANEL AND EACH CARRIAGE. THIS MOVEMENT IS DRIVEN BY PLANETARY REDUCERS COUPLED TO BRUSHLESS MOTORS THAT ACT DIRECTLY ON THE PULLEYS, DRIVING THE CARRIAGES’ TRANSMISSION BELTS. THIS SYSTEM OPTIMIZES INERTIA DURING FOLDER OPERATION. THE DEPOSITION BELTS ARE DRIVEN BY GEARMOTORS, DIRECTLY FLANGED TO ONE OR MORE CONTROL CYLINDERS. ANOTHER GEARMOTOR DRIVES THE DISCHARGE BELT. THE DEPOSITION BELT TENSION IS CONTROLLED PNEUMATICALLY, WHILE THE DISCHARGE BELT TENSION IS ADJUSTED MECHANICALLY. THE ALIGNMENT OF THE DEPOSITION BELTS IS CONTROLLED BY PROPORTIONAL PNEUMATIC REGULATION. PROS: THE MACHINE IS HIGHLY SPECIALIZED FOR NONWOVEN PRODUCTION, ENSURING A STREAMLINED PROCESS WITH MINIMAL HANDLING, REDUCING CONTAMINATION AND DEFECTS. THE MODULAR AND ROBUST DESIGN ENSURES LONG-TERM DURABILITY AND QUIET OPERATION. AUTOMATED FEATURES LIKE BELT HEIGHT ADJUSTMENT AND DECOUPLED CARRIAGE MOVEMENT OPTIMIZE PERFORMANCE AND PRODUCTION EFFICIENCY. CONS: THE COMPLEXITY OF THE MACHINE LIMITS ITS USE TO WELL-TRAINED PERSONNEL, WHICH MIGHT INCREASE LABOR COSTS FOR TRAINING AND QUALIFICATION. DUE TO ITS SPECIFIC DESIGN, THE MACHINE IS UNSUITABLE FOR PROCESSING MATERIALS OTHER THAN FIBER-BASED NONWOVEN WEBS, LIMITING ITS VERSATILITY. PACKAGING AND TRANSPORT: DECLARES THAT THE MACHINES ARE DELIVERED IN PERFECT CONDITION, EX-WORKS FROM OUR FACTORY, AND ONLY AFTER HAVING PASSED RIGOROUS TESTING. THESE CONDITIONS MUST BE VERIFIED BY THE CUSTOMER UPON DELIVERY OF THE GOODS, INCLUDING ANY ACCESSORIES MENTIONED IN THE CONTRACT. THE CUSTOMER IS ALSO REQUIRED TO NOTIFY OF ANY DAMAGES OR MISSING PARTS OF THE MACHINERY. WARNING NOT LIABLE FOR DAMAGES CAUSED BY CARELESSNESS, INCORRECT HANDLING, OR IMPROPER LIFTING METHODS. IT IS THEREFORE MANDATORY TO FOLLOW THE INSTRUCTIONS PROVIDED BY OUR TECHNICIANS. INSTALLATION AND PRELIMINARY OPERATIONS LIFTING OF THE PACKAGES MUST BE DONE ACCORDING TO THE MARKINGS PROVIDED TO ENSURE BALANCE AND OPERATOR SAFETY. GIVEN THE LENGTH OF THE PACKAGES, IT IS NECESSARY TO USE A LIFTING BEAM AND STRAPS OR CHAINS WITH A CAPACITY OF 5,000 KG. THE BEAM HOOKS MUST BE POSITIONED ON THE EYEBOLTS MARKED BY THE MANUFACTURER. WARNING WILL VOID THE WARRANTY CONDITIONS IF THE PACKAGES CONTAINING COMPONENTS AND OTHER PARTS OF THE MACHINE ARE OPENED WITHOUT THE PRESENCE OF OUR TECHNICIANS. FOR SAFETY IN THE MACHINE'S ENTRY AREA, REFER TO CHAPTER (NUMBER NOT SPECIFIED). THE CONTENTS OF THE PACKAGES MUST BE CAREFULLY CLEANED BY REMOVING THE PACKAGING AND ANY OIL LAYER WITHOUT USING SOLVENTS. THE WELDED STEEL STRUCTURE OF THE MACHINE DOES NOT REQUIRE GROUND ANCHORING AND MUST BE PLACED ON A FLAT SURFACE CAPABLE OF BEARING A LOAD OF 1,500 KG PER SUPPORT POINT. THE MACHINE'S FRAME CONSISTS OF TWO LATERAL SIDES, WHICH CONTAIN MOST OF THE MECHANICAL PARTS AND THE ELECTRICAL COMPONENTS ON THE MACHINE. POSITION THE STRUCTURES AS THEY EXIT THE CARDING MACHINE, AS SHOWN IN FIGURE D, ALIGNING WITH THE WORK ON THE SIDES TO DETERMINE THE CORRECT DIRECTION. THE SUPPORT BRACKETS MUST THEN BE MOUNTED ON THE SLOTS OF THE FOUR SIDES AS SHOWN IN FIGURE E. SUBSEQUENTLY, THE SIDES SHOULD BE SEPARATED BY REMOVING THE TRANSPORT CROSSBARS AND THEN POSITIONED AT A DISTANCE EQUAL TO THE LENGTH OF THE CONNECTING CROSSBARS, WITH A TOLERANCE OF 20mm. PERFORM THE DIAGONAL CHECKS USING POINT 2 OF FIGURE C ON THE FOUR SIDES. AT THIS POINT, ASSEMBLE THE CROSSBARS. TRACE THE CENTERLINE OF THE CARDING MACHINE AND POSITION THE STRUCTURE CENTERED ON THE EXTENSION OF THIS AXIS. ON THE CONNECTION CROSSBARS, THE CENTER POINTS OF THE MACHINE ARE MARKED. AFTER INSERTING THE ANTI-VIBRATION SUPPORTS AND REMOVING THE TEMPORARY SUPPORTS, THESE POINTS MUST BE ALIGNED WITH THE PREVIOUSLY DESCRIBED CENTERLINE. AT THIS POINT, THE CYLINDERS CAN BE INSERTED. A PARTICULAR FEATURE IS THAT THE BELTS ARE PROVIDED ALREADY CLOSED IN A LOOP. IN THIS CASE, THE OUTER CYLINDERS MUST FIRST BE MOUNTED ONTO THE BELTS, FOLLOWED BY THE INNER CYLINDERS, STARTING WITH THE DRIVE DRUMS OF THE TWO BELTS. SINCE THESE ARE HEAVY, THEY CAN BE SAFELY INSERTED USING LIFTING EQUIPMENT. ALSO, CHECK THAT THE CYLINDERS EQUIPPED WITH EXTERNAL SUPPORTS AND BELTS ARE MOUNTED EQUIDISTANT FROM THE INNER SIDES. FOLLOW THIS WITH THE INSTALLATION OF THE CENTERING AND TENSIONING GROUPS, FASTENING THE RESPECTIVE SUPPORTS AND RAILS FOR THE MOVEMENT OF THE CARRIAGES ON THE SIDES. AT THIS POINT, APPLY TENSION TO THE BELTS AFTER CONNECTING THE PNEUMATIC SYSTEM. THE INSTALLATION OF THE ELECTRICAL PANEL AND THE MACHINE'S ONBOARD COMPONENTS MUST COMPLY WITH CURRENT REGULATIONS. ALMOST ALL CONNECTIONS ARE MADE USING MULTIPOLAR CONNECTORS. THEREFORE, USE THE ELECTRICAL DIAGRAM TO GUIDE YOU WITH THE VARIOUS TERMINALS. WE ALSO RECOMMEND INSTALLING THE ELECTRICAL PANEL NEAR THE MACHINE AND USING APPROPRIATELY SIZED AND SHIELDED POWER AND SIGNAL CABLES. CABLE DUCTING FOR ELECTRICAL CABLES THE ELECTRICAL PANEL MUST NOT BE LOCATED MORE THAN 30 METERS FROM THE MACHINE, ENSURING THAT THE DUCTS DO NOT PASS THROUGH LOAD-BEARING MASONRY STRUCTURES. THE PANEL MUST BE INSTALLED IN A DRY ENVIRONMENT AWAY FROM HEAT SOURCES AND, IF POSSIBLE, NEAR A WALL. OVERHEAD DUCTS MUST BE DIVIDED INTO TWO TYPES: SIGNAL AND POWER, ALWAYS USING SHIELDED CABLES. WITHIN THE MACHINE, THESE LINES ARE SEPARATED AND MUST REMAIN SO UNTIL THEY REACH THE PANEL, WHETHER USING OVERHEAD OR UNDERGROUND DUCTS (METAL CONDUITS). FOR UNDERGROUND DUCTS, TRENCHES MUST BE DUG TO A DEPTH OF NO LESS THAN 50 CM WITH APPROPRIATE JUNCTION BOXES AT EACH CORNER OF THE LINE, AND THE PIPE TUBE MUST BE USED. FOR OVERHEAD DUCTS, USE METAL RACEWAYS OF APPROPRIATE SECTION AND HEIGHT FROM THE GROUND, IN ACCORDANCE WITH CURRENT REGULATIONS. IF METAL MATERIALS ARE USED FOR THE DUCTING, THEY MUST ALWAYS BE CONNECTED TO THE GROUNDING SYSTEM. WE RECOMMEND USING CONNECTION CABLES PROVIDED, DIVIDED INTO THE FOLLOWING TYPES: PRE-ASSEMBLED CABLES MOTOR CABLES OUR PRE-ASSEMBLED CONNECTION CABLES MAKE THE ENTIRE AUTOMATION PROCESS PLUG & PLAY. RESOLVER/ENCODER CABLES THE CABLES USED HEAVILY INFLUENCE THE PERFORMANCE OF A CLOSED-LOOP SERVO SYSTEM. THE MOST COMMON ISSUES ENCOUNTERED ARE: CROSS-TALK BETWEEN INDIVIDUAL PAIRS OF RESOLVER CABLES CAN CAUSE IRREGULAR MOTOR OPERATION. EXCESSIVE CAPACITANCE BETWEEN CONDUCTORS CAUSES SIGNIFICANT LEAKAGE CURRENTS, LEADING TO UNNECESSARY LOAD ON THE CONVERTER. POOR SHIELDING CONNECTIONS CAN CAUSE MALFUNCTIONS IN OTHER ELECTRONIC DEVICES AND LEAD TO DISTURBANCES IN CONVERTER OPERATION. BY USING OUR CABLES, THESE ISSUES ARE ELIMINATED. ALL CONSENT CONNECTION CABLES ARE PRE-ASSEMBLED, BASED ON THE BUYER'S SPECIFICATIONS, WITH MULTIPOLAR CONNECTORS TO OPTIMIZE INSTALLATION AND OPERATION OF THE MACHINE. WARNING THE USER IS FREE TO CHOOSE THE TYPE OF DUCTING (UNDERGROUND OR OVERHEAD) ACCORDING TO THEIR NEEDS AND THE LAYOUT OF THE ENTIRE SYSTEM BUT MUST ALWAYS ENSURE THE SEPARATION OF SIGNAL AND POWER CABLES. OTHERWISE, THE GENERAL WARRANTY CONDITIONS WILL BE VOIDED. PARTS SUBJECT TO ADJUSTMENT: TENSION AND CENTERING WARNING ALL ADJUSTMENT, MAINTENANCE, AND CLEANING OPERATIONS MUST BE CARRIED OUT WITH THE MACHINE TURNED OFF AND ONLY AFTER THE POWER SUPPLY HAS BEEN DISCONNECTED VIA THE MAIN SWITCH. THE DISTRIBUTION BELTS ARE SUBJECT TO TWO TYPES OF ADJUSTMENTS: TENSION AND CENTERING. THEREFORE, THE BELTS MUST ALWAYS BE MONITORED BY ADJUSTING THESE PARAMETERS TO IMPROVE THEIR PERFORMANCE AND LONGEVITY. TENSION: AFTER INSTALLATION, OUR PERSONNEL WILL APPLY A PRE-TENSION AND INPUT ADJUSTMENT PARAMETERS. HOWEVER, ONCE THE MACHINE ENTERS PRODUCTION, THESE CAN BE ADJUSTED TO SUIT THE TYPE OF MATERIAL BEING PROCESSED, WORKING SPEEDS, AND THE NATURAL WEAR OF THE COMPONENTS. THIS TENSIONING SYSTEM INCLUDES A BALANCING MECHANISM BETWEEN THE TWO SIDES. ENSURE THAT THE POSITION OF THE TWO TENSIONING CARRIAGES IS EQUIDISTANT, AND ADJUST THE SLOTS ON THE RACKS IF NECESSARY TO COMPENSATE FOR ANY LATERAL DISPLACEMENT OF THE BELT. THE TENSIONING OF THE DISTRIBUTION BELTS IS INDEPENDENT AND CAN BE ADJUSTED BY ACTING ON THE APPROPRIATE PRESSURE SWITCHES. CENTERING: THE AUTOMATIC BELT CENTERING SYSTEM OPERATES WITH PROPORTIONAL CONTROL AND PNEUMATIC ACTUATION, STRUCTURED AS FOLLOWS: ANGULAR SENSOR FOR BELT POSITION DETECTION PRESSURE SWITCH FOR ADJUSTING CONTROL PRESSURE PNEUMATIC CYLINDERS FOR MOVING THE CARRIAGES OUR TECHNICIANS WILL CARRY OUT ALL NECESSARY ADJUSTMENTS BASED ON WORKING HEIGHTS AND THE TYPE OF MATERIAL BEING PROCESSED. ALSO, ENSURE THAT THE CARRIAGES ON WHICH THE EXTERNAL SUPPORTS OF THE CYLINDERS ARE MOUNTED CAN MOVE FREELY ALONG THEIR RAILS. THE TENSION OF THE OUTPUT CONVEYOR BELT IS MECHANICAL. ONCE THE BELT IS CLOSED, ADJUST THE TENSION EQUIDISTANTLY FROM ONE SIDE TO THE OTHER. THE VULCANIZED GUIDE STRIPS ON THE BELT WILL KEEP THE BELT ALIGNED THROUGH PULLEYS MOUNTED ON THE SIDES OF THE CYLINDERS. WARNING ENSURE THAT THE DOWNSTREAM PNEUMATIC SYSTEM DOES NOT HAVE ANY LEAKS DURING MACHINE DOWNTIME (WHEN THE MACHINE IS OFF), WHICH COULD CAUSE THE DISTRIBUTION BELTS TO LOOSEN AND LEAD TO AN INCORRECT POSITION OF THE ANGULAR TRANSDUCER. DURING MAINTENANCE, WHENEVER THE TENSION IS REMOVED FROM THE FEED BELTS, IT IS MANDATORY TO LOCK THE SENSOR’S CONTACT BLADE TO PREVENT IT FROM RUBBING AGAINST THE BELT WHEN PRESSURE IS RESTORED. REMEMBER TO UNLOCK THE BLADE BEFORE STARTING THE WORK CYCLE. TRANSMISSION BELTS THE TRANSMISSION BELTS DRIVE THE CARRIAGES, WHICH EXPERIENCE SIGNIFICANT ACCELERATION DUE TO THEIR ALTERNATING MOTION. THEREFORE, IT'S NECESSARY TO NOT ONLY MONITOR THEIR TENSION BUT ALSO THEIR WEAR. THE FOLDING MACHINE'S TRANSPORT SYSTEM IS A CLOSED LOOP BETWEEN CONVEYOR BELTS AND BELTS. BY ADJUSTING THE PRESSURE SWITCH OF THE LOWER CONVEYOR BELT, YOU ALSO REGULATE THE TENSION OF THE OUTERMOST BELT. SIMILARLY, BY ADJUSTING THE PRESSURE SWITCH OF THE UPPER BELT, THE TENSION OF THE OTHER BELTS IS REGULATED. ADDITIONALLY, ENSURE THE PROPER POSITIONING OF THE BELTS, ESPECIALLY WHEN RELEASING PRESSURE DURING MAINTENANCE, AND THEN RESTORING IT. VERTICAL ADJUSTMENT OF THE OUTPUT CONVEYOR THE HEIGHT OF THE OUTPUT CONVEYOR REFERS TO THE DISTANCE BETWEEN THE FOLDED MATERIAL ON THE OUTPUT CONVEYOR AND THE CONVEYOR BELTS. THIS DISTANCE SHOULD ALWAYS BE MINIMIZED, ALTHOUGH FACTORS LIKE PRODUCTION SPEED, MATERIAL NATURE, THE NUMBER OF LAYERS IN THE FOLD, AMBIENT VENTILATION, ETC., MAY REQUIRE MORE PRECISE ADJUSTMENT. THESE ADJUSTMENTS SHOULD BE MADE WITH DIRECT VISUAL CONTROL BY STAFF TO AVOID ACCIDENTAL CONTACT BETWEEN THE CONVEYOR BELTS AND THE OUTPUT CONVEYOR. TO ACHIEVE THIS, ADJUST THE SELECTORS THAT CONTROL THE RAISING OR LOWERING OF THE OUTPUT CONVEYOR. THERE ARE TWO SELECTORS, ONE FOR EACH SIDE OF THE MACHINE. DURING MAINTENANCE, THESE SELECTORS CAN BE USED TO FULLY LOWER THE OUTPUT CONVEYOR, PROVIDING EASY ACCESS FOR CLEANING OR ANY OTHER INSPECTION OPERATIONS. WARNING ALL ADJUSTMENT, MAINTENANCE, AND CLEANING OPERATIONS MUST BE CARRIED OUT WITH THE MACHINE STOPPED AND ONLY AFTER DISCONNECTING THE POWER SUPPLY USING THE MAIN SWITCH. COMMAND PANEL DESCRIPTION THE MACHINE IS EQUIPPED WITH AN ELECTRICAL CABINET THAT HOUSES THE ENTIRE ELECTRICAL SYSTEM AND THE MAIN SWITCH. THE CABINET IS CONNECTED VIA MULTI-POLE PLUGS TO A CONTROL PANEL, DESCRIBED IN THIS SECTION. TOUCH SCREEN ELECTRONIC PANEL (RTV) EMERGENCY STOP BUTTON INDICATOR LIGHTS FOR 230V AUXILIARY POWER PRESENCE INDICATOR LIGHTS FOR 24V AUXILIARY POWER PRESENCE AUTOMATION DESCRIPTION TO UNDERSTAND THE OPERATING LOGIC OF THE FOLDING MACHINE, A BRIEF DESCRIPTION OF THE AUTOMATION WILL BE PROVIDED. THE OPERATING PROGRAMS OF THE FOLDING MACHINE REFER TO THE SIGNAL EMITTED BY THE MASTER ENCODER INSTALLED AT THE CARDING MACHINE'S OUTPUT. THIS SIGNAL IS READ BY THE MOTION CONTROLLER AND SENT VIA CAN-BUS TO THE SERIES OF DRIVERS. THE FOLDING MACHINE AUTOMATION IS DIVIDED INTO FOUR SECTIONS: SPEED CONTROL OF THE CARDING MACHINE OUTPUT. MOVEMENT OF THE CONVEYOR BELTS. MOVEMENT OF THE CARRIAGES. OPERATOR-MACHINE INTERFACE WITH AN RTV TOUCH SCREEN PANEL FOR MANAGING RECIPES AND PRODUCTION-REQUIRED PARAMETERS. COMMUNICATION BETWEEN THE VARIOUS BLOCKS OCCURS VIA CAN-BUS, WITH SERIAL CONNECTION (MODBUS) BETWEEN THE RTV AND THE MOTION CONTROLLER. THE RTV IS RESPONSIBLE FOR INTERFACING THE MACHINE WITH THE OPERATOR, WHO, THROUGH SIMPLE DATA ENTRY BUTTONS, CONFIGURES THE PRODUCT BEING WORKED ON AND MONITORS ALL THE PROCESSING PHASES. TECHNICAL DATA FOR DRIVES AND RTV PRIMO MOTION CONTROL 16+ MOTION CONTROL: STANDALONE FOR UP TO 16 AXES LINKING OF 17 TO 700 AXES PRIMO-MOTION CONTROL SYSTEMS HAVE BEEN DEVELOPED ESPECIALLY FOR COMPLEX MOTIONS IN ALL PROBLEM SCENARIOS WITHIN THE PACKAGING INDUSTRY. BASED ON THE IEC 61131-3 PROGRAMMING STANDARD AND TOOLS FOR CAM DESIGN AND DIAGNOSTICS, EVEN COMPLEX MULTI-AXIS APPLICATIONS CAN BE REALIZED EASILY AND, ABOVE ALL, VERY QUICKLY. UPON CUSTOMER REQUEST, THE MOST COMMON SERVO DRIVES CAN BE CONTROLLED BY DIGITAL DEMAND SIGNALS. SERVOSTAR™ 600 DESIGNED FOR USE IN ALL APPLICATIONS, THE SERVOSTAR™ 600 OFFERS ALL THE BENEFITS OF DIGITAL TECHNOLOGY. HIGH FLEXIBILITY MEANS EASE OF USE AND A WIDE RANGE OF FUNCTIONS AVAILABLE AS STANDARD. WITH OUR SERVOMOTORS AND AVAILABLE ACCESSORIES, THE SERVOSTAR™ 600 BECOMES A SOLUTION TO HELP YOU MEET ALL YOUR MOTION CONTROL NEEDS. MAIN FEATURES: DIRECT NETWORK POWER SUPPLY, 230V-10% ... 480V+10%, 50 Hz 208V-10% ... 480V+10%, 60 Hz UP TO 20A WITH INTEGRATED EMC FILTERS ALL SHIELDS CONNECTED DIRECTLY TO THE CONVERTER POSSIBILITY TO CONNECT THE DC-BUS IN PARALLEL WITH PATENTED RECOVERY RESISTOR TECHNOLOGY FULLY PROGRAMMABLE VIA RS232 SERIAL LINE GRAPHICAL PROGRAMMING TOOL IN WINDOWS™ 95/98/NT ENVIRONMENT BASIC PROGRAMMING VIA 2 BUTTONS ON THE CONVERTER STATUS INDICATION VIA LED DISPLAY UP TO 20A USABLE IN CABINETS WITH A USEFUL DEPTH OF 300mm RTV 820 DESIGNED SPECIFICALLY FOR ON-BOARD MACHINE AUTOMATION AND THE HIGH PERFORMANCE OF THE RTPOWER PLATFORM, THE INDUSTRIAL TERMINALS OF THE RTVISION LINE OFFER REMARKABLE FEATURES WITH A VERY AGILE ECONOMIC SETUP. AVAILABLE IN 8.4" AND 12" FORMATS, WITH A TOUCHSCREEN OR AN ALPHANUMERIC AND FUNCTIONAL KEYBOARD, THEY SUPPORT HMI APPLICATIONS MANAGEABLE BOTH LOCALLY AND VIA THE WEB, WHICH ARE EASY TO IMPLEMENT USING THE WEBFDS PACKAGE. THANKS TO A 500 MHZ ENGINE POWERED BY AN ADVANCED REAL-TIME LINUX OPERATING SYSTEM, THEY SERVE AS THE HEART AND INTELLIGENCE OF RTPOWER, A POWERFUL REAL-TIME MACHINE AUTOMATION SYSTEM BASED ON I/O FIELDBUS, ISAGRAF SOFTLOGIC, OR PROGRAMS IN "C". FOR FURTHER TECHNICAL SPECIFICATIONS, IT IS RECOMMENDED TO CONSULT THE MANUALS OF THE INDIVIDUAL COMPONENTS, PROVIDED BY THE MANUFACTURER ALONG WITH THIS FOLDING MACHINE’S OPERATION AND MAINTENANCE MANUAL. ALARM AND EMERGENCY MANAGEMENT THE MANAGEMENT OF ALARMS AND EMERGENCIES FOR THE FOLDING MACHINE IS BASED ON THE SEQUENCE OF DIGITAL INPUTS WIRED TO THE MOTION CONTROLLER. SPECIFICALLY, THE EMERGENCY STOP INPUT, BEING CONNECTED IN CASCADE WITH OTHER COMPONENTS, WILL TRIGGER AN IMMEDIATE STOP OF THE MACHINE IN CASE OF A FAULT. THIS WILL CUT THE POWER DIRECTLY TO THE DRIVERS WHILE KEEPING THE LOGIC POWERED, ALLOWING THE RTV TO DISPLAY AN ALARM MESSAGE IDENTIFYING THE FAULT’S CAUSE. FOR ALARM CODES AND THEIR RESPECTIVE SOLUTIONS, REFER TO THE "ALARMS AND RECOVERY PROCEDURES" CHAPTER. RTV PROGRAM TO FACILITATE QUICK AND EASY USE OF THE FOLDING MACHINE, AN INTUITIVE INTERFACE PROGRAM HAS BEEN DESIGNED, MINIMIZING THE PARAMETERS THE OPERATOR NEEDS TO INPUT TO START THE MACHINE. A DETAILED DESCRIPTION OF THIS PROGRAM FOLLOWS. ITS UNDERSTANDING IS ESSENTIAL FOR PROPER USE OF THE MACHINE AND MUST BE ACQUIRED BEFORE ANY OPERATION ON THE FOLDER IS CARRIED OUT. THE RTV PANEL IS A TOUCHSCREEN, MEANING THAT TO SELECT A PAGE, ACTIVATE OR DEACTIVATE BUTTONS, OR ENTER DATA, A LIGHT TOUCH ON THE DESIRED AREA IS SUFFICIENT. WHEN ENTERING DATA, A NUMERIC KEYPAD WILL APPEAR ON THE SCREEN, WHERE VALUES MUST BE ENTERED AND CONFIRMED BY PRESSING ENTER. THE RTV PROGRAM CONSISTS OF SEVERAL PAGES, EACH DEDICATED TO A SPECIFIC FUNCTION, AND THESE PAGES ARE COMPOSED OF VARIOUS BUTTONS. THERE ARE 4 TYPES OF BUTTONS: PAGE BUTTONS DATA ENTRY BUTTONS ON/OFF BUTTONS PARAMETER READING BUTTONS SYSTEM BUTTONS PAGE BUTTONS LOCATED AT THE TOP OF THE MONITOR OR IN THE CENTER OF THE FIRST PAGE, THESE YELLOW BUTTONS CORRESPOND TO A MACHINE STATE (WORK CYCLE). FOR EXAMPLE, PRESSING MANUAL WILL AUTOMATICALLY SWITCH TO THE MACHINE’S MANUAL CYCLE. AVAILABLE CYCLES INCLUDE: RECIPES: THIS PAGE ALLOWS THE DOWNLOAD OR SAVING OF ALL PRODUCTION PARAMETERS FOR DIFFERENT PRODUCTS. CARRIAGE ALIGNMENT: THIS PAGE HANDLES THE PROCEDURE FOR ALIGNING THE CARRIAGE MOTORS. MANUAL: THIS PAGE IS USED TO ENTER SPEED DATA FOR THE MANUAL STATE OF THE FOLDER. AUTOMATIC: IN THIS PAGE, ALL AUTOMATION SYNCHRONIZES WITH THE MASTER ENCODER MOUNTED ON THE CARDER, AND PARAMETERS FOR DETERMINING THE OUTPUT FOLD FORMAT AND STRETCHER ADJUSTMENTS ARE ENTERED. OPEN/CLOSE HOOD: THIS PAGE ALLOWS THE AUTOMATIC OPENING OF THE MACHINE’S SIDE PANELS. PROFILE: IN THIS PAGE, PARAMETERS FOR DETERMINING THE TRANSVERSE PROFILE OF THE OUTPUT FOLD ARE ENTERED. ACTIVE ALARMS: THIS PAGE DISPLAYS ALL ACTIVE ALARMS. ALARM HISTORY: THIS PAGE SHOWS THE HISTORY OF ALL PREVIOUSLY ACTIVATED ALARMS. SYSTEM PARAMETERS: THIS PAGE IS PASSWORD-PROTECTED AND RESERVED FOR THE MANUFACTURER. EXIT CYCLE: THIS BUTTON ALLOWS YOU TO EXIT THE CURRENT MACHINE STATE. DATA ENTRY BUTTONS THESE BLUE BUTTONS ALLOW REAL-TIME VIEWING AND MODIFICATION OF WORK PARAMETERS. USING THE GRAPHICAL INTERFACE, IT IS EASY TO INTUITIVELY IDENTIFY THE ACTION POINT WITHIN THE WORK PROCESS. AFTER PRESSING THE ASSOCIATED BUTTON AND ENTERING THE VALUE, PRESS ENTER TO CONFIRM THE DATA OR THE DELETE KEY (THE UPWARD ARROW LOCATED BELOW THE NUMERIC KEYPAD) FOR CORRECTIONS. THEY ARE EQUIPPED WITH A WORK RANGE (PRE-SET), WHICH PREVENTS ENTERING INCORRECT VALUES THAT COULD CAUSE ABNORMAL OPERATION OF THE FOLDER. IN THE MANUAL PAGE, THESE BUTTONS ARE: INPUT/CARRIAGE/OUTPUT SPEED: SETS THE SPEED IN M/MIN FOR THE SELECTED AXIS. LEFT STROKE: LOCATED ON THE FAR LEFT OF THE OUTPUT BELT, REPRESENTS IN CM THE LEFT STROKE RELATIVE TO THE CENTERLINE. VALUES ARE POSITIVE. RIGHT STROKE: LOCATED ON THE FAR RIGHT OF THE OUTPUT BELT, REPRESENTS IN CM THE RIGHT STROKE RELATIVE TO THE CENTERLINE. VALUES ARE NEGATIVE. IT SHOULD BE NOTED THAT INCREASING THE CARD AND CARRIAGE STRETCH INCREASES THE TRANSVERSE SHRINKAGE OF THE OUTPUT FOLD, THUS DECREASING THE HEIGHT OF THE FOLDED PRODUCT. ADJUST THESE PARAMETERS (RIGHT AND LEFT STROKE) ACCORDINGLY AND CHECK THE RESULTING PRODUCT. THE SUM OF THE LEFT AND RIGHT STROKE REPRESENTS THE HEIGHT OF THE FOLDED PRODUCT UPON EXIT. IN THE AUTOMATIC PAGE, THESE BUTTONS ARE: CARD STRETCH: LOCATED AT THE FOLDER’S ENTRANCE, INDICATES THE PERCENTAGE DIFFERENCE IN THE SPEED OF THE DEPOSIT BELTS RELATIVE TO THE CARD’S OUTPUT SPEED. EACH CHANGE IN THIS VALUE CASCADES DOWN TO THE CARRIAGE AND OUTPUT SPEEDS. CARRIAGE STRETCH: LOCATED AT THE TOP LEFT ABOVE THE FOLDER, REPRESENTS THE PERCENTAGE DIFFERENCE BETWEEN THE DISTRIBUTOR CARRIAGE SPEED AND THE INPUT SPEED. ANY CHANGE IN THIS VALUE CASCADES DOWN TO THE OUTPUT SPEED. LEFT STROKE: LOCATED ON THE FAR LEFT OF THE OUTPUT BELT, REPRESENTS IN CM THE LEFT STROKE RELATIVE TO THE CENTERLINE. VALUES ARE POSITIVE. RIGHT STROKE: LOCATED ON THE FAR RIGHT OF THE OUTPUT BELT, REPRESENTS IN CM THE RIGHT STROKE RELATIVE TO THE CENTERLINE. VALUES ARE NEGATIVE. NUMBER OF FOLDS: LOCATED AT THE CENTER OF THE OUTPUT BELT, REPRESENTS THE NUMBER OF FOLDS (PLEATS) MAKING UP THE FINAL PRODUCT. IT AUTOMATICALLY SYNCHRONIZES THE OUTPUT CONVEYOR’S SPEED AND, TOGETHER WITH THE WEB COVERAGE PARAMETER, ENSURES THE PROPER LAYERING OF WEBS IN THE FOLD. PROGRAM PAGE DESCRIPTION THE INTERFACE PROGRAM IS LOCATED ON THE RTV TERMINAL INSTALLED ON THE CONTROL PANEL. UPON STARTUP, THE INITIAL SCREEN WILL DISPLAY THE WORK CYCLES PAGE. IN THE RECIPES PAGE, RECIPES ARE DISPLAYED AND MANAGED. A RECIPE REFERS TO THE SET OF PRODUCTION PARAMETERS FOR THE FOLDER. AFTER PRESSING THE RECIPES BUTTON, YOU WILL ENTER THE MANAGEMENT PAGE, DISPLAYING THE LIST OF AVAILABLE RECIPES CATEGORIZED BY PRODUCT TYPE. SCROLL WITH THE ARROW KEYS UNTIL THE CURSOR ON THE LEFT HIGHLIGHTS THE DESIRED RECIPE. PRESS ENTER TO ACCESS THE RECIPE. NOTE: AT LEAST ONE RECIPE MUST ALWAYS RESIDE IN MEMORY. IMPORTANT: THE FIRST RECIPE IN THE LIST IS THE ONE THAT THE PANEL SENDS TO THE PLC AT STARTUP. AT THIS POINT, A LIST OF AVAILABLE VARIABLES WILL BE DISPLAYED, CORRESPONDING TO THE DATA INPUT BUTTONS DESCRIBED IN THE PREVIOUS PAGES. TO MODIFY THESE VALUES, SCROLL WITH THE ARROW KEYS UNTIL THE CURSOR ON THE LEFT HIGHLIGHTS THE DESIRED PARAMETER, PRESS F1 TO START EDITING THE VALUE, ENTER TO CONFIRM, AND F2 TO FINALIZE THE MODIFICATION. THEN, PRESS F5 TO SAVE THE RECIPE, AND F3 TO SEND THE RECIPE TO THE DRIVES. PRESS THE EXIT BUTTON TO RETURN TO THE PREVIOUS PAGES. ATTENTION: BEFORE ACCESSING THIS PAGE, ENSURE THAT ALL AXES ARE STOPPED, THAT NO OPERATOR IS NEAR THE FOLDER, AND THAT ALL COVERS, INCLUDING INSPECTION COVERS, ARE CLOSED. IN THE CART ALIGNMENT PAGE, THE MOTORS OF THE CARRIAGES AND THE COMPENSATOR ARE REALIGNED. THE PROCEDURE IS AS FOLLOWS: A) PRESS THE ERROR RESET BUTTON IF THERE ARE ANY ACTIVE ALARMS DISPLAYED BY THE SYSTEM BUTTON AT THE BOTTOM RIGHT. B) HOLD DOWN THE ALIGNMENT RESET BUTTON UNTIL THE MESSAGE "MACHINE READY" APPEARS. THIS BUTTON OPERATES THE MACHINE HOMOGENEOUSLY, MEANING THE CARRIAGES MOVE SLOWLY (INDICATED BY ROTATING GEARS) ONLY WHILE THE BUTTON IS PRESSED. THE CARRIAGES WILL STOP UPON RELEASE OR AUTOMATICALLY UPON REACHING THE STARTING POSITION. TO EXIT THE CYCLE, PRESS THE EXIT CYCLE BUTTON. ATTENTION: BEFORE ACCESSING THIS PAGE, ENSURE THAT ALL AXES ARE STOPPED, NO OPERATOR IS NEAR THE FOLDER, AND ALL COVERS, INCLUDING INSPECTION COVERS, ARE CLOSED. IN THE AUTOMATIC PAGE, THE REFERENCE SIGNAL IS TAKEN FROM THE MASTER ENCODER MOUNTED AT THE CARDING MACHINE OUTPUT. IN THIS PAGE, THE OPERATOR CAN MODIFY PARAMETERS AND SETTINGS ONLINE AS EXPLAINED IN THE PREVIOUS PARAGRAPHS. TO EXIT, PRESS THE EXIT CYCLE BUTTON. NOTE: ONLY ENTER THE CYCLE WHEN THE SYSTEM IS STOPPED. IMPORTANT: IF THE AXES ARE MOVING AND THE EXIT CYCLE BUTTON IS PRESSED, ALL AXES WILL STOP GRADUALLY. THEREFORE, EXIT THE CYCLE ONLY WHEN THE SYSTEM IS STOPPED. IN THE PROFILE PAGE, THE PROFILE OF THE OUTPUT WEB IS PARAMETERIZED. FOR THE FUNCTIONS, REFER TO THE PREVIOUS PARAGRAPHS. IN THE ALARM HISTORY PAGE, THE HISTORY OF ALARMS THAT HAVE OCCURRED IS DISPLAYED UNTIL THE AVAILABLE MEMORY IS EXHAUSTED, AFTER WHICH OLDER ALARMS WILL BE DELETED TO MAKE ROOM FOR NEW ONES. PRESS THE EXIT BUTTON TO RETURN TO THE PREVIOUS PAGES. IN THE OPEN/CLOSE COVERS PAGE, THE COMMAND TO OPEN AND CLOSE THE SIDE PANELS IS GIVEN. UPON ENTERING THIS PAGE, ALL MACHINE AXES REMAIN STATIONARY. DURING OPENING, AN ACOUSTIC SIGNAL WARNS THE OPERATOR THAT THE PANELS ARE SLOWLY OPENING. IT IS NECESSARY TO MAINTAIN A SAFE DISTANCE FROM THE MACHINE DURING THE OPENING/CLOSING PHASES. ONCE INSPECTION OPERATIONS ARE COMPLETE, CLOSE THE PANELS TO EXIT THE PAGE. FOR MAINTENANCE OPERATIONS, TURN OFF THE POWER FROM THE ELECTRICAL PANEL. ATTENTION: ALL ADJUSTMENT, MAINTENANCE, AND CLEANING OPERATIONS MUST BE CARRIED OUT WITH THE MACHINE STOPPED AND ONLY AFTER THE POWER HAS BEEN DISCONNECTED USING THE MAIN SWITCH. SUCH OPERATIONS SHOULD ALSO BE PERFORMED BY OUR TECHNICIANS OR ADEQUATELY TRAINED PERSONNEL FROM THE BUYER. WHEN RESTARTING, ALARMS FOR OPEN SIDE PANELS WILL APPEAR. EXIT THE ALARM PAGE, CLOSE THE PANELS, AND PERFORM ALIGNMENT. FIRST STARTUP ATTENTION: BEFORE PROCEEDING WITH ANY OPERATION, ENSURE THAT ALL ELECTRICAL CONNECTIONS HAVE BEEN MADE CORRECTLY, THE CENTERING PINS HAVE BEEN REMOVED FROM THE MACHINE STOPS, NO OPERATOR IS NEAR THE FOLDER, AND ALL COVERS, INCLUDING INSPECTION COVERS, ARE CLOSED. ALSO, CHECK THAT THE CORRECT AIR PRESSURE HAS BEEN APPLIED TO THE BELT TENSION, THE CORRECT POSITIONING OF THE CARRIAGE TRANSMISSION BELTS, THE CORRECT POSITIONING OF THE END-OF-STROKE BELTS' MICRO LIMIT SWITCHES, AND THE CORRECT POSITIONING OF THE BELT POSITION SENSORS. POWER THE PANEL BY SETTING THE MAIN SWITCH TO POSITION 1. WAIT ABOUT 40 SECONDS, THE TIME REQUIRED FOR THE DEBUG PROGRAM TO COMPLETE THE PRIMARY OPERATIONS. PRESS THE CART ALIGNMENT BUTTON AND PERFORM THE PROCEDURE AS DESCRIBED IN THE PREVIOUS CHAPTERS. THEN, EXIT THE CYCLE AND RETURN TO THE INITIAL PAGE. PRESS THE MANUAL BUTTON AND MOVE ONE AXIS AT A TIME, AS PER THE PROCEDURES DESCRIBED IN THE PREVIOUS CHAPTER UNDER MANUAL, GRADUALLY INCREASING THE SPEEDS AND ENSURING THE CORRECT POSITIONING OF THE BELTS AND THE CORRECT MOVEMENT OF THE CARRIAGES. ONCE THIS CHECK IS COMPLETE, EXIT THE CYCLE. AT THIS POINT, THE FOLDER IS OPERATIONAL. GO TO THE RECIPES PAGE AND DOWNLOAD THE ONE RELATED TO THE PRODUCT TO BE PROCESSED. PRESS THE AUTOMATIC BUTTON TO ACTIVATE SYNCHRONIZATION WITH THE CARDING MACHINE, AND THE EXIT CYCLE BUTTON TO DEACTIVATE IT. MANUAL START AND STOP ATTENTION: ENSURE THAT ALL AXES ARE STOPPED, NO OPERATOR IS NEAR THE FOLDER, AND ALL COVERS, INCLUDING INSPECTION COVERS, ARE CLOSED BEFORE ACCESSING THIS PAGE. POWER THE PANEL BY SETTING THE MAIN SWITCH TO POSITION 1. WAIT ABOUT 40 SECONDS, THE TIME NECESSARY FOR THE DEBUG PROGRAM TO COMPLETE THE PRIMARY OPERATIONS. PRESS THE MANUAL BUTTON AND MOVE THE AXES, AS DESCRIBED IN THE PREVIOUS CHAPTER UNDER MANUAL. EXIT THE CYCLE. ATTENTION: THE MACHINE'S MANUAL MODE OPERATION IS INTENDED EXCLUSIVELY FOR MAINTENANCE AND CLEANING OPERATIONS. THEREFORE, THE OPERATING SPEEDS OF THE AXES MUST BE LIMITED. THE INCREASE IN SPEED, THROUGH THE INPUT OF VALUES ON THE RTV BUTTONS, SHOULD BE GRADUAL (E.G., 10 M/MIN AT A TIME). AUTOMATIC START AND STOP ATTENTION: ENSURE THAT ALL AXES ARE STOPPED, NO OPERATOR IS NEAR THE FOLDER, AND ALL COVERS, INCLUDING INSPECTION COVERS, ARE CLOSED BEFORE ACCESSING THIS PAGE. ENSURE THE CARDING MACHINE IS STOPPED BEFORE ACCESSING THIS CYCLE. POWER THE PANEL BY SETTING THE MAIN SWITCH TO POSITION 1. WAIT ABOUT 40 SECONDS, THE TIME REQUIRED FOR THE DEBUG PROGRAM TO COMPLETE THE PRIMARY OPERATIONS. PRESS THE RECIPES BUTTON, SELECT THE DESIRED RECIPE FROM THE LIST, AND SEND IT TO THE DRIVES AS DESCRIBED IN THE PREVIOUS CHAPTER UNDER RECIPES. PRESS THE AUTOMATIC BUTTON, AS DESCRIBED IN THE PREVIOUS CHAPTER UNDER AUTOMATIC. START THE CARDING MACHINE. STOP THE CARDING MACHINE. EXIT THE CYCLE. ALARMS AND RECOVERY PROCEDURES IN THE EVENT OF ANY IRREGULARITY, THE FOLDER WILL COME TO A COMPLETE STOP, AS DESCRIBED IN CHAPTER 14. EACH ALARM IS ASSOCIATED WITH A MESSAGE ON THE RTV, CODED ACCORDING TO THE FOLLOWING TABLE: ALARM DESCRIPTION: COMMENT GENERIC ALARM: GENERAL ALARM DATA INPUT ERROR: A PARAMETER INCOMPATIBLE WITH THE PRE-SET CAMS WAS ENTERED PANEL STARTUP ERROR: THE PANEL'S DEFAULT RECIPE WAS NOT LOADED CORRECTLY PLC STARTUP ERROR: AN ERROR OCCURRED DURING THE PLC OR DRIVE STARTUP PROCEDURE COMPENSATION OVERTRAVEL: LIMIT SWITCH ACTIVATION CARRIAGE FORWARD OVERTRAVEL: LIMIT SWITCH ACTIVATION CARRIAGE BACKWARD OVERTRAVEL: LIMIT SWITCH ACTIVATION PRESSWEB CYLINDER END OF STROKE: LIMIT SWITCH ACTIVATION BELT SWAY END OF STROKE: LIMIT SWITCH ACTIVATION BELT TENSION PISTONS AT END OF STROKE: MAGNETIC RELAY LIMIT SWITCH ACTIVATION EMERGENCY STOP / INTERLOCKED COVER OPENING: * INSUFFICIENT PNEUMATIC SYSTEM PRESSURE: * ENTRY SPEED LIMIT: MAXIMUM SPEED LIMIT OF THE FOLDER EXCEEDED. PLC MAYER ATTEMPT TO DIVIDE BY ZERO: A VALUE THAT CAUSES A DIVISION BY ZERO WAS ENTERED INTO THE PROGRAM. PLC MAYER ERROR CAN: CANNOT ACTIVATE SERVO CONTROLLER ON CAN BAS: DURING MACHINE STARTUP, ONE OF THE DRIVES FAILED TO REPORT ITS PRESENCE TO THE PLC ON THE CAN NETWORK. PLC MAYER ERROR CAN-BAS: NODE GUARDING ERROR, NODE %D! TEMPORARY LOSS OF COMMUNICATION WITH ONE OF THE DRIVES ON THE CAN NETWORK. PLC MAYER ERROR FROM SERVO CONTROLLER: ONE OF THE DRIVES IS MALFUNCTIONING. PLC MAYER TOO MANY PLC TASKS ACTIVE: TOO MANY FUNCTIONS WERE ACTIVATED SIMULTANEOUSLY IN THE PLC, WHICH MAY HAVE CAUSED SOME FUNCTIONS TO NOT EXECUTE. SERVOSTAR NO. NO CLUTCHING WITHOUT SOFTWARE CLUTCH AND MOVING MASTER: A COMMAND WAS GIVEN TO ENGAGE THE MASTER ENCODER CARD WHILE IT WAS IN MOTION. SERVOSTAR NO. ERROR: HEAT SINK TEMPERATURE TOO HIGH: THE COOLING FINS OF THE DRIVE HAVE REACHED A DANGEROUSLY HIGH TEMPERATURE. SERVOSTAR NO. ERROR: OVERVOLTAGE: THERE HAS BEEN A PROLONGED VOLTAGE SPIKE IN THE DRIVES. SERVOSTAR NO. ERROR: FEEDBACK (CABLE BREAK, SHORT CIRCUIT, SHORT TO GROUND): ISSUES WITH THE RESOLVER CABLE. SERVOSTAR NO. ERROR: UNDERVOLTAGE: THE VOLTAGE IS TOO LOW TO OPERATE THE DRIVE CORRECTLY. SERVOSTAR NO. ERROR: MOTOR TEMPERATURE: THE MOTOR TEMPERATURE IS ABOVE THE PERMISSIBLE LIMITS. SERVOSTAR NO. ERROR: INTERNAL AUX VOLTAGE NOT OK: ISSUES WITH THE DC POWER SUPPLY OF THE DRIVE BOARD. SERVOSTAR NO. ERROR: OVERSPEED: THE MAXIMUM ALLOWED SPEED FOR THIS MOTOR HAS BEEN EXCEEDED. SERVOSTAR NO. ERROR: EEPROM CHECKSUM ERROR: THE DATA LOADED DURING STARTUP DOES NOT MATCH WHAT WAS SAVED IN THE EEPROM OF THE DRIVE. SERVOSTAR NO. ERROR: FLASH-EPROM CHECKSUM ERROR: THE DATA LOADED DURING STARTUP DOES NOT MATCH WHAT WAS SAVED IN THE FLASH-EPROM OF THE DRIVE. SERVOSTAR NO. ERROR: BRAKE (CABLE BREAK, SHORT CIRCUIT, SHORT TO GROUND): ISSUES WITH THE BRAKE CABLE. SERVOSTAR NO. ERROR: MOTOR PHASE MISSING: ONE OF THE PHASES IS NOT CONNECTED IN THE MOTOR POWER CABLE. SERVOSTAR NO. ERROR: INTERNAL TEMPERATURE TOO HIGH: THE INTERNAL TEMPERATURE OF THE DRIVE IS TOO HIGH. SERVOSTAR NO. ERROR: OUTPUT STAGE NOT OK: ISSUES WITH THE POWER OUTPUT STAGE OF THE DRIVE. SERVOSTAR NO. ERROR: I2T MAX VALUE EXCEEDED: THE MAXIMUM I2T VALUE HAS BEEN EXCEEDED (THE MOTOR IS DRAWING TOO MUCH TORQUE). SERVOSTAR NO. ERROR: SUPPLY POWER - BTB/RTO: POWER IS MISSING FROM THE DRIVE, AND THEREFORE, IT CANNOT BE ENABLED. SERVOSTAR NO. ERROR: A/D CONVERTER DEFECTIVE: ISSUES WITH THE DRIVE'S ANALOG-TO-DIGITAL CONVERTER. SERVOSTAR NO. ERROR: REGEN CIRCUIT FAULTY: ISSUES WITH THE MOTOR BRAKING CIRCUIT (TOO MUCH ENERGY WAS ACCUMULATED DURING MOTOR BRAKING). SERVOSTAR NO. ERROR: SUPPLY PHASE MISSING: ONE OF THE POWER SUPPLY PHASES IS MISSING FOR THE DRIVE. SERVOSTAR NO. ERROR: SYSTEM ERROR (SYSTEM SOFTWARE): SYSTEM ERROR (THE DRIVE SOFTWARE HAS CRASHED). COM: ERROR OR UNRELIABLE: THERE IS NO COMMUNICATION BETWEEN THE RTV PANEL AND THE MOTION CONTROLLER. CHECK THE CONNECTION CABLE. THE AXES ARE CODED AS FOLLOWS: - SERVOSTAR 1 => MOTOR FOR CART 1. - SERVOSTAR 2 => MOTOR FOR CART 2. - SERVOSTAR 3 => MOTOR FOR LOWER DEPOSIT BELT. - SERVOSTAR 4 => MOTOR FOR UPPER DEPOSIT BELT. - SERVOSTAR 5 => COMPENSATION MOTOR. - SERVOSTAR 6 => DISCHARGE BELT MOTOR. RESTORATION PROCEDURE (THIS PROCEDURE SHOULD BE FOLLOWED AFTER EVERY FAULT): - IDENTIFY AND REMOVE THE CAUSE OF THE FAULT. - CARRY OUT THE TROLLEY ALIGNMENT PROCEDURE AS DESCRIBED IN PREVIOUS CHAPTERS. MAINTENANCE PROGRAM WARNING: ALL ADJUSTMENT, MAINTENANCE, AND CLEANING OPERATIONS MUST BE PERFORMED WHILE THE MACHINE IS STOPPED AND ONLY AFTER DISCONNECTING THE POWER SUPPLY USING THE MAIN SWITCH. THE TECHNICIAN MUST LOCK THE SWITCH TO PREVENT ACCIDENTAL START-UP. THESE OPERATIONS MUST BE PERFORMED BY OUR TECHNICIANS OR ADEQUATELY TRAINED PERSONNEL OF THE BUYER. TO PRESERVE THE INTEGRITY OF THE MACHINERY, PERFORM THE FOLLOWING: DAILY: - PERFORM A COMPLETE CLEANING OF THE MACHINE BY BLOWING COMPRESSED AIR ON THE CONVEYOR BELTS AND ALL MOVING PARTS INSIDE THE FOLDER. - REMOVE ANY FIBER BUILD-UP FROM THE BELTS, CARRIAGE SLIDING WHEELS, CYLINDER SHAFTS, CENTERING AND TENSIONING CARRIAGES, END-OF-TRAVEL MICRO-SWITCHES, AND BELT POSITION TRANSDUCER RODS. - CHECK THE BELT PRESSURE. - CHECK THE CORRECT POSITIONING OF THE ANGULAR TRANSDUCER. MONTHLY: - GREASE ALL BEARINGS AND SUPPORTS. - CHECK THE INTEGRITY OF THE BEARINGS INSIDE THE CARRIAGE CYLINDERS. IF ANOMALIES ARE FOUND, REPLACE THEM. - TIGHTEN THE BOLTS OF THE MAIN MECHANICAL AND STRUCTURAL TRANSMISSION COMPONENTS. - CHECK THE OIL AND GREASE LEVELS IN THE VARIOUS SPEED REDUCERS. ANNUALLY: - PERFORM A GENERAL OVERHAUL OF THE MACHINE, REPLACING ALL DEFECTIVE COMPONENTS (IT IS RECOMMENDED THAT OUR TECHNICIANS BE PRESENT). ITEM 002 TEXNOLOGY MONO_1AB_27-3000 NEEDLE LOOM MAKE: TEXNOLOGY (ITALY) LEADER IN ABRASIVE FELTS BUT THEY ARE GOOD FOR ALL FIBERS. IT BECOME ABRASIVE FELT PASSING INTO THE OVEN. SAFETY INFORMATION THE MACHINE IS EQUIPPED WITH PROTECTIVE COVERS, AND THE DOORS AND PANELS ARE ELECTRICALLY MONITORED WITH INTERLOCKING SWITCHES. THE OPERATOR MUST REGULARLY CHECK THE COMPLIANCE WITH LOCAL SAFETY REGULATIONS IN THE WORKPLACE. CAUTION! FIBER DUST CAN BE HARMFUL TO HEALTH! FOR THIS REASON, THE NECESSARY MEASURES MUST BE TAKEN TO COMPLY WITH LEGISLATIVE LIMIT VALUES. ATTENTION! IN CERTAIN STROKE SPEED RANGES, SPECIFIC TYPES OF FIBERS, NEEDLE TYPES, AND PUNCHING PARAMETERS MAY CAUSE STRONG VIBRATIONS AND NOISE IN THE MACHINE. THESE "CRITICAL" STROKE SPEEDS MUST BE AVOIDED BY SLIGHTLY INCREASING OR DECREASING THE SPEED; OTHERWISE, DAMAGE TO THE MACHINE MAY OCCUR! ATTENTION! SPECIAL CARE MUST BE TAKEN DURING VISUAL INSPECTIONS OF THE MACHINE, ESPECIALLY FOR THE PRESENCE OF DUST AND FIBER DEPOSITS. THESE MUST BE REMOVED PERIODICALLY AND THOROUGHLY TO PREVENT ANY FIRE HAZARDS. IN THE EVENT OF MALFUNCTIONS, THE MACHINE MUST BE IMMEDIATELY TAKEN OUT OF SERVICE AND ADEQUATELY PROTECTED. MALFUNCTIONS SHOULD BE RESOLVED IMMEDIATELY. TECHNICAL DESCRIPTION THE NEEDLE-PUNCHING MACHINE, MODEL MONO_1AB_27-3000: MOUNTED ON VIBRATION DAMPERS, WITHOUT THE NEED FOR FOUNDATIONS TOP NEEDLE PUNCHING WITH TWO NEEDLE BOARDS DESIGNED FOR GENERAL NEEDLE-PUNCHING FUNCTIONS AND MEDIUM SURFACE WEIGHTS MAXIMUM WORKING WIDTH: 2700 MM MAXIMUM STROKE FREQUENCY: 800 RPM THE PRACTICAL STROKE FREQUENCY DURING CONTINUOUS OPERATION DEPENDS ON THE FIBER PARAMETERS AND SURFACE WEIGHT. NEEDLE BAR STROKE: 70mm NUMBER OF NEEDLES: APPROX. 2 X 3000 / 1 METER OF WORKING WIDTH NEEDLE BOARD WIDTH: 300mm NEEDLE BAR: SPECIAL ALUMINUM PROFILE WITH HIGH BENDING AND TORSIONAL CAPACITY, EQUIPPED WITH SIDE GUIDES, STOP, AND PNEUMATIC PIN INDICATOR FOR PRECISE AND FAST POSITIONING OF THE NEEDLE BOARDS, WITH QUICK-LOCKING SYSTEM FOR FAST NEEDLE BOARD CHANGES. NEEDLE BAR GUIDE: ROLLING LEVER SYSTEM WITH MINIMAL FRICTION AND MAINTENANCE, HERMETICALLY SEALED TO PREVENT OIL AND DUST INFILTRATION. NEEDLE BOARDS: MADE OF ALUMINUM WITH POLYURETHANE SUPPORT, FOR SECURING NEEDLES TO PREVENT THEIR MOVEMENT AND FALLING, WITHOUT NEEDLES. DRILLING PATTERN: 7000_GTX-3 NUMBER OF NEEDLE BOARDS: 2 SETS = 12 NEEDLE BOARDS (WITHOUT NEEDLES) NEEDLE PENETRATION PLATE: ELECTRICALLY ADJUSTABLE DURING OPERATION AND WHEN THE MACHINE IS STOPPED TO CONTROL THE NEEDLE PENETRATION DEPTH. GUIDES ARE LOCKED AND FREE OF PLAY. NEEDLE STRIPPER PLATE: ELECTRICALLY ADJUSTABLE DURING OPERATION AND WHEN THE MACHINE IS STOPPED TO CONTROL THE DISTANCE FROM THE PRESSER. GUIDES ARE LOCKED AND FREE OF PLAY. MATERIAL FEEDING: CONTINUOUS FEEDING THROUGH A PAIR OF FEEDER ROLLERS MOUNTED IN A FREE-STANDING FRAME, SMOOTH DRIVE ROLLER AND COMPRESSION ROLLER, PNEUMATICALLY ADJUSTABLE FOR EASY MATERIAL THREADING. THE CYLINDER GAP IS MICRO-ADJUSTABLE PNEUMATICALLY WITH PRESSURE CYLINDERS, MANUAL CONTROL SLIDER FOR ROLLER ACTIVATION, AIR CONNECTION WITH PRESSURE REDUCER, AND MANOMETER. MOBILE DESIGN. MAXIMUM WORKING WIDTH: 2700mm MACHINE STOP: WITH THE MACHINE STOP FUNCTION, THE MACHINE IS GRADUALLY BROUGHT TO A STOP BY REDUCING THE SPEED OF THE MAIN DRIVES WHILE THE NEEDLE BARS ARE MOVED TO THE TOP DEAD CENTER POSITION. MACHINE STOP OCCURS IN THE FOLLOWING CASES: ACTIVATION OF THE MOTOR PROTECTION SWITCH ACTIVATION OF THERMAL PROTECTION / MAIN DRIVE ACTIVATION OF ONE OF THE SAFETY SWITCHES (PROTECTIVE DEVICES, ETC.) THE MACHINE CAN ONLY BE RESTARTED AFTER THE AFOREMENTIONED MALFUNCTIONS HAVE BEEN RESOLVED. EMERGENCY STOP THE MACHINE IS DEACTIVATED IN AN EMERGENCY STOP STATE BY IMMEDIATELY STOPPING ALL DRIVES. EMERGENCY STOP OCCURS IN THE FOLLOWING CASES: ACTIVATION OF ONE OF THE EMERGENCY STOP BUTTONS OR AN EMERGENCY PULL ROPE THE MACHINE CAN ONLY BE RESTARTED AFTER THE DANGEROUS SITUATION HAS BEEN REMEDIED BY RESETTING THE RESPECTIVE EMERGENCY STOP BUTTON OR PULL SWITCH AND CONFIRMING THE ERROR ON THE CONTROL PANEL. PACKAGING AND TRANSPORT PACKAGING THE MACHINE IS PACKAGED IN A MANNER TO ENSURE SAFE TRANSPORTATION AND PROTECTION FROM ENVIRONMENTAL FACTORS. THE PACKAGING MATERIALS SHOULD BE REMOVED CAREFULLY UPON DELIVERY TO AVOID ANY DAMAGE TO THE MACHINE. TRANSPORT THE MACHINE SHOULD BE TRANSPORTED WITH CARE. ENSURE THAT THE TRANSPORT VEHICLE IS SUITABLE FOR THE WEIGHT AND DIMENSIONS OF THE MACHINE. THE MACHINE SHOULD BE SECURED PROPERLY TO PREVENT MOVEMENT DURING TRANSIT. USE APPROPRIATE LIFTING EQUIPMENT AND FOLLOW SAFETY PROCEDURES TO AVOID ACCIDENTS. INSTALLATION AND PRELIMINARY OPERATIONS INSTALLATION ENSURE THAT THE INSTALLATION SITE MEETS THE REQUIREMENTS SPECIFIED IN THE MACHINE'S TECHNICAL DOCUMENTATION. UNPACK THE MACHINE AND INSPECT IT FOR ANY DAMAGE THAT MAY HAVE OCCURRED DURING TRANSPORT. POSITION THE MACHINE ON A FLAT, STABLE SURFACE USING THE PROVIDED MOUNTING POINTS OR VIBRATION DAMPERS AS REQUIRED. CONNECT THE MACHINE TO THE POWER SUPPLY ACCORDING TO THE SPECIFICATIONS PROVIDED. CONNECT ANY ADDITIONAL EQUIPMENT OR ACCESSORIES AS INDICATED IN THE INSTALLATION INSTRUCTIONS. PRELIMINARY OPERATIONS CHECK ALL CONNECTIONS TO ENSURE THEY ARE SECURE AND CORRECTLY INSTALLED. VERIFY THAT ALL SAFETY DEVICES ARE IN PLACE AND FUNCTIONING PROPERLY. PERFORM A TEST RUN WITHOUT ANY MATERIAL TO ENSURE THAT THE MACHINE OPERATES CORRECTLY AND ALL COMPONENTS FUNCTION AS EXPECTED. MAKE ANY NECESSARY ADJUSTMENTS AS PER THE MANUFACTURER'S INSTRUCTIONS. ELECTRICAL CABLE ROUTING CABLE ROUTING ENSURE THAT ALL ELECTRICAL CABLES ARE ROUTED ACCORDING TO THE SPECIFICATIONS TO AVOID INTERFERENCE WITH MOVING PARTS OR POTENTIAL HAZARDS. USE CABLE TRAYS OR CONDUITS TO PROTECT CABLES FROM DAMAGE AND TO MAINTAIN A NEAT AND ORGANIZED INSTALLATION. VERIFY THAT ALL CABLE CONNECTIONS ARE SECURE AND PROPERLY INSULATED. NEEDLE BOARD REPLACEMENT REPLACING NEEDLE BOARDS FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR REMOVING AND REPLACING NEEDLE BOARDS. ENSURE THE MACHINE IS TURNED OFF AND PROPERLY SECURED BEFORE BEGINNING ANY MAINTENANCE WORK. REMOVE THE OLD NEEDLE BOARDS AND INSTALL THE NEW ONES, ENSURING THEY ARE CORRECTLY ALIGNED AND SECURELY FASTENED. PERFORM A TEST RUN TO CONFIRM THAT THE NEW NEEDLE BOARDS ARE FUNCTIONING CORRECTLY. CONTROL PANEL DESCRIPTION CONTROL PANEL THE CONTROL PANEL PROVIDES ACCESS TO THE MACHINE'S OPERATIONAL SETTINGS AND CONTROLS. FAMILIARIZE YOURSELF WITH THE LOCATION AND FUNCTION OF EACH CONTROL, INCLUDING START/STOP BUTTONS, SPEED ADJUSTMENTS, AND EMERGENCY STOP FEATURES. REFER TO THE CONTROL PANEL DIAGRAM FOR DETAILED INFORMATION ON EACH COMPONENT. AUTOMATION DESCRIPTION AUTOMATION THE MACHINE INCLUDES AUTOMATED FEATURES TO ENHANCE EFFICIENCY AND EASE OF USE. AUTOMATED FUNCTIONS MAY INCLUDE PROGRAMMABLE SETTINGS FOR NEEDLE DEPTH, SPEED, AND OTHER PARAMETERS. REFER TO THE AUTOMATION SECTION OF THE MANUAL FOR INSTRUCTIONS ON CONFIGURING AND USING THESE FEATURES. TECHNICAL DATA FOR DRIVES TECHNICAL DATA THE TECHNICAL SPECIFICATIONS FOR THE MACHINE'S DRIVES, INCLUDING MOTOR POWER, SPEED RANGES, AND OTHER RELEVANT DATA, ARE DETAILED IN THIS SECTION. ENSURE THAT THE DRIVES ARE OPERATED WITHIN THE SPECIFIED PARAMETERS TO MAINTAIN OPTIMAL PERFORMANCE AND AVOID DAMAGE. ALARM AND EMERGENCY MANAGEMENT ALARM MANAGEMENT THE MACHINE IS EQUIPPED WITH ALARM SYSTEMS TO ALERT OPERATORS TO ANY ISSUES OR MALFUNCTIONS. FOLLOW THE INSTRUCTIONS PROVIDED FOR RESPONDING TO ALARMS AND MANAGING EMERGENCY SITUATIONS. RTV PROGRAM THIS SECTION DETAILS THE RTV (ROUTINE TESTING AND VERIFICATION) PROGRAM, INCLUDING PROCEDURES AND SCHEDULES FOR REGULAR MAINTENANCE AND TESTING. ADHERE TO THE RTV PROGRAM TO ENSURE THE MACHINE REMAINS IN GOOD WORKING CONDITION. MAINTENANCE PROGRAM THE MAINTENANCE PROGRAM OUTLINES THE PROCEDURES AND INTERVALS FOR ROUTINE MAINTENANCE TASKS. FOLLOW THE PROGRAM TO PERFORM REGULAR CHECKS AND SERVICING TO PREVENT POTENTIAL ISSUES AND EXTEND THE MACHINE'S LIFESPAN. LUBRICATION SPECIFICATIONS DETAILED INSTRUCTIONS FOR LUBRICATING THE MACHINE'S COMPONENTS ARE PROVIDED IN THIS SECTION. USE THE SPECIFIED LUBRICANTS AND FOLLOW THE RECOMMENDED APPLICATION METHODS TO ENSURE PROPER FUNCTIONING. SAFETY STANDARDS AND RESIDUAL RISKS THIS SECTION COVERS THE SAFETY STANDARDS APPLICABLE TO THE MACHINE AND ANY RESIDUAL RISKS ASSOCIATED WITH ITS OPERATION. FOLLOW ALL SAFETY GUIDELINES TO MINIMIZE RISKS AND ENSURE SAFE OPERATION. PACKAGING AND TRANSPORT DECLARES THAT THE MACHINES ARE DELIVERED IN PERFECT CONDITION, AS CERTIFIED BY OUR FACILITY, AND ONLY AFTER UNDERGOING STRICT TESTING. THESE CONDITIONS MUST BE VERIFIED BY THE CUSTOMER AT THE TIME OF DELIVERY, INCLUDING ANY ACCESSORIES SPECIFIED IN THE CONTRACT. THE CUSTOMER IS ALSO REQUIRED TO REPORT ANY DAMAGES OR MISSING PARTS OF THE MACHINERY. ATTENTION RESPONSIBLE FOR DAMAGES CAUSED BY IMPROPER HANDLING, INCORRECT MANEUVERS, OR IMPROPER LIFTING METHODS. IT IS THEREFORE MANDATORY TO FOLLOW THE INSTRUCTIONS PROVIDED BY OUR TECHNICIANS. FOR TRANSPORTING THE STRUCTURES, TWO SHAFTS SHOULD BE PASSED THROUGH THE RESPECTIVE HOLES. THE MACHINE SHOULD BE SUSPENDED BY THE PROTRUDING ENDS OF THE SHAFTS. ATTENTION! NO OTHER TYPE OF FIXATION IS PERMITTED! LIFT AS SHOWN IN THE ATTACHED PHOTOS. INFORMATION/WARNING WEIGHT: UPPER STRUCTURE: 11,000 KG LOWER STRUCTURE: 13,000 KG STORAGE BEFORE OR AFTER INSTALLATION IF THE MACHINE IS NOT IMMEDIATELY PUT INTO OPERATION, IT MUST STILL BE PROTECTED AGAINST WEATHER CONDITIONS. NEVER LEAVE THE MACHINE OUTDOORS. LEAVE THE MACHINE IN ITS PACKAGED STATE. STORE THE MACHINE IN DRY LOCATIONS NOT EXPOSED TO DUST. COVER THE MACHINE APPROPRIATELY TO PREVENT CONTAMINATION AND MOISTURE INGRESS. SAFETY INFORMATION DANGER! IT IS RECOMMENDED TO USE LIFTING DEVICES THAT ARE ADEQUATELY SIZED FOR THE WEIGHT OF THE MACHINE. ONLY USE THE DESIGNATED LIFTING POINTS PROVIDED. TRANSPORT SHOULD ONLY BE CARRIED OUT BY TRAINED AND AUTHORIZED PERSONNEL. DURING TRANSPORTATION USING A FORKLIFT OR OTHER SUITABLE LIFTING DEVICES, THE MACHINE MUST BE ADEQUATELY PROTECTED AGAINST TIPPING. NEVER STAND UNDER SUSPENDED LOADS. DANGER! RISK OF DEATH DUE TO ACCIDENTAL CONTACT WITH LIVE ELECTRICAL COMPONENTS. THE ELECTRICAL EQUIPMENT OF THE MACHINE AND ALL COMPONENTS MUST BE CONFIGURED ACCORDING TO STANDARD EN 60204-1. ANY WORK ON ELECTRICAL EQUIPMENT MUST BE PERFORMED EXCLUSIVELY BY SPECIALIZED AND QUALIFIED ELECTRICIANS. DO NOT PERFORM ANY WORK ON LIVE ELECTRICAL COMPONENTS. DURING MAINTENANCE ON ELECTRICAL EQUIPMENT, ENSURE THE MACHINE IS TURNED OFF AND OUT OF SERVICE. PERFORM THE WORK ONLY AFTER DISCONNECTING THE POWER THROUGH THE MAIN SWITCH AND APPLYING A LOCKOUT TO PREVENT ACCIDENTAL REACTIVATION. CONTROL CABINETS MUST ALWAYS REMAIN CLOSED. IMMEDIATELY ADDRESS ANY LOOSE CONNECTIONS AND REPLACE DAMAGED, BURNED, OR MELTED CABLES. CABLES MUST NOT BE JAMMED OR CRUSHED. CABLES SHOULD BE LAID OUT IN SUCH A WAY AS TO AVOID TRIPPING HAZARDS OR DAMAGE. DANGER! BEFORE STARTING THE MACHINE, ENSURE THAT NO ONE REMAINS IN THE DANGER ZONE. INSPECTION OF CONSTRUCTION UNITS CHECK COMPONENTS FOR VISIBLE EXTERNAL DAMAGE SUCH AS: PAINT DAMAGE DENTS ON SHEET METAL COMPONENTS AND COVERINGS. REPORT ANY DAMAGE TO THE MANUFACTURER IMMEDIATELY ON THE SAME DAY IT IS NOTICED. INSTALLATION AND PRELIMINARY OPERATIONS THE LIFTING OF THE PACKAGES MUST BE CARRIED OUT ACCORDING TO THE REFERENCES TO ENSURE BALANCE AND OPERATOR SAFETY. GIVEN THE LENGTH OF THE PACKAGES, A HOIST AND STRAPS OR CHAINS WITH A CAPACITY OF 25,000 KG ARE NECESSARY. THE HOIST HOOKS SHOULD BE POSITIONED ON THE TUBES MARKED BY THE MANUFACTURER. ATTENTION WILL VOID THE WARRANTY IF THE PACKAGES CONTAINING COMPONENTS AND OTHER PARTS ARE OPENED IN THE ABSENCE OF OUR TECHNICIANS. FOR SAFETY IN THE MACHINE’S ENTRY AREA, SEE CHAPTER 15. THE CONTENTS OF THE PACKAGES SHOULD BE CLEANED CAREFULLY, REMOVING THE PACKAGING AND ANY OIL LAYER WITHOUT USING SOLVENTS. MACHINE ASSEMBLY DELIVERY, ASSEMBLY, AND COMMISSIONING OF THE MACHINE ARE CARRIED OUT EXCLUSIVELY BY SPECIALIZED PERSONNEL AND THROUGH A SO-CALLED SUPERVISORY ASSEMBLY. ELECTRICAL CABLE ROUTING CONTROL PANEL THE ELECTRICAL PANEL SHOULD NOT BE PLACED MORE THAN 30 METERS FROM THE BUNDLE, ENSURING THAT THE CABLES DO NOT PASS THROUGH LOAD-BEARING MASONRY STRUCTURES. THE PANEL SHOULD BE LOCATED IN A DRY ENVIRONMENT AWAY FROM HEAT SOURCES, PREFERABLY CLOSE TO A WALL. OVERHEAD CABLE ROUTING SHOULD BE DIVIDED INTO TWO TYPES: SIGNAL AND POWER, ALWAYS USING SHIELDED CABLES. INSIDE THE MACHINE, THESE LINES ARE SEPARATE AND SHOULD REMAIN SO UNTIL REACHING THE PANEL, WHETHER USING OVERHEAD OR BURIED ROUTING (METALLIC SHEATHS). FOR BURIED ROUTING, EXCAVATE TO A DEPTH OF AT LEAST 50 CM WITH RELATED JUNCTION BOXES AT EVERY CORNER OF THE LINE AND PASS THE PIPE TUBE. FOR OVERHEAD ROUTING, USE METAL BLIND BARS OF APPROPRIATE SECTION AND HEIGHT FROM THE GROUND ACCORDING TO CURRENT STANDARDS. IF METALLIC ROUTING IS USED, ENSURE IT IS ALWAYS CONNECTED TO EQUIPOTENTIAL GROUNDING. IT IS RECOMMENDED TO USE CONNECTION CABLES PROVIDED, CATEGORIZED AS FOLLOWS: PRE-ASSEMBLED CABLES MOTOR CABLES OUR PRE-ASSEMBLED CONNECTION CABLES MAKE THE ENTIRE AUTOMATION PLUG & PLAY. RESOLVER/ENCODER CABLES THE CABLES USED SIGNIFICANTLY AFFECT THE PERFORMANCE OF A CLOSED-LOOP SERVO SYSTEM. COMMON ISSUES INCLUDE: CROSS-TALK BETWEEN RESOLVER CABLE PAIRS CAUSING IRREGULAR MOTOR OPERATION. EXCESSIVE CAPACITANCE BETWEEN CONDUCTORS LEADING TO HIGH LEAKAGE CURRENTS, WHICH CAUSE UNNECESSARY LOAD ON THE CONVERTER. POOR SHIELD CONNECTIONS CAUSING MALFUNCTIONS IN OTHER ELECTRONIC DEVICES AND INTERFERENCE IN THE CONVERTER’S OPERATION. ALL THESE ISSUES ARE AVOIDED BY USING OUR CABLES. ALL CONNECTION CABLES ARE SUPPLIED IN THE CORRECT LENGTHS AND PRE-ASSEMBLED, ACCORDING TO THE BUYER'S SPECIFICATIONS, WITH MULTI-POLE CONNECTORS TO OPTIMIZE THE ASSEMBLY AND OPERATION OF THE BUNDLE. MULTI-POLE CONSENT CABLES ATTENTION THE USER IS FREE TO CHOOSE THE TYPE OF ROUTING (BURIED OR OVERHEAD) ACCORDING TO THEIR NEEDS AND THE LAYOUT OF THE ENTIRE SYSTEM, BUT MUST ENSURE THAT SIGNAL CABLES ARE ALWAYS KEPT SEPARATE FROM POWER CABLES. FAILURE TO DO SO WILL VOID THE GENERAL WARRANTY CONDITIONS. NEEDLE BOARD REPLACEMENT MACHINE MAINTENANCE WITH THE MACHINE STOPPED, PRESS THE MAINTENANCE BUTTON, TURN THE KEY SELECTOR TO ON AND SELECT TABLE EXTRACTION (THE MACHINE WILL AUTOMATICALLY POSITION ITSELF CORRECTLY AND PNEUMATICALLY RELEASE THE NEEDLE BOARDS). OPEN THE MACHINE DOOR ON THE EXCHANGE SIDE. DANGER! THE NEEDLES MUST NO LONGER BE IN THE GRIPPING POSITION. IF NECESSARY, MOVE THE NEEDLE BAR TO THE TOP DEAD CENTER BY PRESSING GO TO TOP DEAD CENTER. THE DISPLAY WILL SHOW NEEDLES OPEN AND CENTERING TABLE SUP OFF. ATTENTION! IF THE MACHINE DOES NOT PERFORM THIS OPERATION DURING THE SELF-DIAGNOSIS, THE MISSING CONDITION WILL BE REQUESTED TO COMPLETE THE OPERATION. IF NECESSARY, MOVE THE NEEDLE BAR WITH THE KEY BY PRESSING BRAKE LOCKED. DANGER! REMOVE THE NEEDLE PLATES FROM THE MACHINE LATERALLY. USE THE HANDLES AND TRANSPORT GRIPS FOR THIS PURPOSE. INSERT THE NEW NEEDLE PLATES (FOLLOWING THE NUMBERING) INTO THE NEEDLE BAR UNTIL THEY ARE IN THE FINAL STOP POSITION. CLOSE THE OPEN DOOR, THEN PRESS RESET ERRORS AND SUBSEQUENTLY TABLE EXTRACTION. DANGER! BEFORE STARTING THE MACHINE, ENSURE THAT NO ONE REMAINS IN THE DANGER ZONE. BEFORE SWITCHING ON, CHECK THAT ALL SAFETY DEVICES ARE MOUNTED. SET THE MAINTENANCE KEY SELECTOR TO OFF. THE MACHINE IS OPERATIONAL. CONTROL PANEL DESCRIPTION THE MACHINE IS EQUIPPED WITH AN ELECTRICAL CABINET THAT CONTAINS THE ENTIRE ELECTRICAL SYSTEM AND THE MAIN SWITCH. THE CABINET IS CONNECTED VIA MULTI-POLE PLUGS TO A CONTROL PANEL, WHICH IS DESCRIBED IN THIS SECTION. 1 TOUCH SCREEN ELECTRONIC PANEL (RTV) 2 EMERGENCY STOP BUTTON 3 INDICATOR LIGHTS FOR 230 V AUXILIARY POWER 4 INDICATOR LIGHTS FOR 24 V AUXILIARY POWER AUTOMATION DESCRIPTION TO UNDERSTAND THE MACHINE'S OPERATING LOGIC, A BRIEF DESCRIPTION OF THE AUTOMATION WILL BE GIVEN. THE OPERATING PROGRAMS OF THE NEEDLE MACHINE REFER TO THE SIGNAL EMITTED BY THE PREVIOUS MACHINE. THIS SIGNAL IS READ BY THE MOTION CONTROLLER AND SENT VIA CAN-BUS TO THE SERIES OF DRIVERS. COMMUNICATION BETWEEN VARIOUS BLOCKS OCCURS THROUGH CAN-BUS, WITH SERIAL CONNECTION (MODBUS) BETWEEN RTV AND MOTION CONTROLLER. THE RTV'S ROLE IS TO INTERFACE THE MACHINE WITH THE OPERATOR, WHO, USING SIMPLE DATA INPUT BUTTONS, SETS PARAMETERS FOR THE PROCESSED PRODUCT AND MONITORS ALL PROCESSING STAGES. TECHNICAL DATA FOR DRIVES AND RTV PRIMO MOTION CONTROL 16+ MOTION CONTROL: STANDALONE UP TO 16 AXES LINKING OF 17 TO 700 AXES PRIMO MOTION CONTROL SYSTEMS HAVE BEEN DEVELOPED ESPECIALLY FOR COMPLEX MOTIONS IN ALL PROBLEM DEFINITIONS OF THE PACKAGING INDUSTRY. BASED ON THE IEC 61131-3 PROGRAMMING STANDARD AND TOOLS FOR CAM DESIGN AND DIAGNOSTICS, COMPLEX MULTI-AXIS APPLICATIONS CAN BE REALIZED EASILY AND VERY QUICKLY. AT THE CUSTOMER'S REQUEST, THE MOST COMMON SERVO DRIVES CAN BE CONTROLLED BY DIGITAL DEMAND SIGNALS. SERVOSTAR™ 600 DESIGNED FOR USE IN ALL APPLICATIONS, THE SERVOSTAR™ 600 OFFERS ALL THE BENEFITS OF DIGITAL TECHNOLOGY. HIGH FLEXIBILITY MEANS EASE OF USE AND A LARGE NUMBER OF STANDARD FUNCTIONS. WITH OUR SERVOMOTORS AND AVAILABLE ACCESSORIES, THE SERVOSTAR™ 600 BECOMES A SOLUTION TO MEET ALL YOUR "MOTION" NEEDS. MAIN FEATURES: DIRECT NETWORK POWER SUPPLY 230V-10% ... 480V+10%, 50 Hz 208V-10% ... 480V+10%, 60 Hz UP TO 20A WITH INTEGRATED EMC FILTERS ALL SCREENS DIRECTLY CONNECTED TO THE CONVERTER PARALLEL CONNECTION OF DC-BUS WITH PATENTED REGENERATIVE RESISTOR TECHNIQUE FULLY PROGRAMMABLE VIA RS232 SERIAL LINE GRAPHICAL PROGRAMMING TOOL IN WINDOWS™ 95/98/NT ENVIRONMENT BASIC PROGRAMMING THROUGH 2 BUTTONS ON THE CONVERTER STATUS INDICATION VIA LED DISPLAY UP TO 20A USABLE IN CABINETS WITH A USEFUL DEPTH OF 300MM RTV 820 FOR FURTHER TECHNICAL SPECIFICATIONS, REFER TO THE MANUALS DELIVERED BY THE MANUFACTURER WITH THIS MACHINE. DESIGNED SPECIFICALLY FOR MACHINE AUTOMATION AND HIGH-PERFORMANCE RTPOWER PLATFORMS, THE RTVISION LINE INDUSTRIAL TERMINALS OFFER FORMIDABLE FEATURES IN A VERY AGILE ECONOMIC PACKAGE. AVAILABLE IN 8.4” AND 12” SIZES, WITH TOUCHSCREEN OR ALPHANUMERIC KEYBOARD AND FUNCTIONAL, THEY SUPPORT HMI APPLICATIONS MANAGEABLE BOTH LOCALLY AND VIA WEB, EASILY CREATED WITH THE WEBFDS PACKAGE. WITH A 500 MHZ PROCESSOR GOVERNED BY AN ADVANCED REAL-TIME LINUX OPERATING SYSTEM, THEY ARE THE CORE AND INTELLIGENCE OF RTPOWER, A POWERFUL REAL-TIME MACHINE AUTOMATION SYSTEM BASED ON I/O FIELDBUS, ISAGRAF SOFTLOGIC, OR “C” PROGRAMS. ALARM AND EMERGENCY MANAGEMENT THE MANAGEMENT OF ALARMS AND EMERGENCIES FOR THE MACHINE IS BASED ON THE CASCADING CONNECTION OF DIGITAL INPUTS TO THE MOTION CONTROLLER. SPECIFICALLY, THE EMERGENCY STOP INPUT, BEING CONNECTED IN SERIES WITH OTHER COMPONENTS, WILL CAUSE THE MACHINE TO STOP IMMEDIATELY IN CASE OF A FAULT (FOULT), BY CUTTING OFF THE POWER DIRECTLY TO THE DRIVERS WHILE KEEPING THE LOGIC POWERED, ALLOWING THE RTV TO DISPLAY AN ALARM MESSAGE IDENTIFYING THE CAUSE OF THE FAULT. FOR ALARM CODING AND RELATED SOLUTIONS, REFER TO THE "ALARMS AND RECOVERY PROCEDURES" CHAPTER. RTV PROGRAM TO ENABLE QUICK AND EASY USE OF THE NEEDLE MACHINE, AN INTUITIVE INTERFACE PROGRAM HAS BEEN DESIGNED, MINIMIZING THE PARAMETERS THE USER MUST SET TO OPERATE THE MACHINE. THE RTV PANEL IS A TOUCH SCREEN; TO SELECT A PAGE, ACTIVATE OR DEACTIVATE BUTTONS, OR ENTER DATA, A LIGHT PRESS DIRECTLY ON THE RELEVANT AREA IS SUFFICIENT. IN THE CASE OF DATA ENTRY, PRESSING WILL BE FOLLOWED BY THE APPEARANCE OF A NUMERIC KEYPAD WHERE THE DATA MUST BE ENTERED AND THEN CONFIRMED WITH THE ENTER KEY. THE RTV PROGRAM CONSISTS OF A SERIES OF PAGES, EACH DEDICATED TO A SPECIFIC FUNCTION. THESE PAGES CONTAIN VARIOUS TYPES OF BUTTONS: PAGE BUTTONS DATA ENTRY BUTTONS ON/OFF BUTTONS PARAMETER READING BUTTONS SYSTEM BUTTONS PAGE BUTTONS LOCATED AT THE TOP OF THE MONITOR OR IN THE CENTRAL PART OF THE FIRST PAGE AND ARE YELLOW. EACH BUTTON CORRESPONDS TO A MACHINE STATE (WORK CYCLE). FOR EXAMPLE, PRESSING MANUAL AUTOMATICALLY ENTERS THE MACHINE INTO MANUAL MODE. AVAILABLE CYCLES ARE: RECIPES: THIS PAGE IS FOR DOWNLOADING OR SAVING PRODUCTION PARAMETERS FOR VARIOUS PRODUCTS. MANUAL: THIS PAGE IS FOR ENTERING SPEED DATA FOR THE MANUAL STATE OF THE NEEDLE MACHINE. AUTOMATIC: THIS PAGE SYNCHRONIZES ALL AUTOMATION WITH THE PREVIOUS MACHINE AND INPUTS PARAMETERS FOR DETERMINING THE PRODUCT FORMAT. MAINTENANCE: THIS PAGE ALLOWS ACTIVATION OF ALL FUNCTIONS FOR MACHINE MAINTENANCE. RESET MACHINE: THIS PAGE RESETS ALL ACTIVE ALARMS. ACTIVE ALARMS: THIS PAGE DISPLAYS ALL ACTIVE ALARMS. ALARM HISTORY: THIS PAGE SHOWS THE HISTORY OF ALL PREVIOUSLY ACTIVATED ALARMS. EVENT HISTORY: THIS PAGE SHOWS THE HISTORY OF ALL PREVIOUSLY ACTIVATED INTERNAL SERVO DRIVE ALARMS. SYSTEM PARAMETERS: A PAGE RESERVED FOR THE MANUFACTURER AND PROTECTED BY A PASSWORD. EXIT CYCLE: THIS BUTTON ALLOWS EXITING THE CURRENT MACHINE STATE. DATA ENTRY BUTTONS THESE BUTTONS ARE BLUE AND ALLOW YOU TO VIEW AND CHANGE WORK PARAMETERS ONLINE. THROUGH THE GRAPHICAL INTERFACE, YOU CAN INTUITIVELY LOCATE THE POINT OF ACTION IN THE PROCESSING SEQUENCE. AFTER PRESSING THE ASSOCIATED BUTTON AND ENTERING THE VALUE, PRESS ENTER TO CONFIRM THE DATA OR THE DELATE KEY (THE ARROW ^ LOCATED BELOW THE NUMERIC KEYPAD) FOR ANY CORRECTIONS. THEY ARE EQUIPPED WITH A PRE-SET WORKING RANGE THAT PREVENTS THE ENTRY OF INCORRECT VALUES WHICH COULD CAUSE ABNORMAL MACHINE OPERATION. THE BUTTONS ON THE MANUAL PAGE ARE: EXIT CYCLE: RETURNS TO THE INITIAL SCREEN, STOPPING THE MACHINERY. ENTRY/EXIT SPEED: SETS THE VALUE IN M/MIN FOR THE SELECTED AXIS SPEED. VEL RPM BAR: SETS THE RPM OF THE NEEDLE BAR. GAP: SETS THE DISTANCE IN MM BETWEEN THE PENETRATION SHEET AND THE NEEDLE STRIPPING SHEET. PENETRATION: SETS THE PENETRATION DEPTH IN MM OF THE NEEDLE INTO THE SHEET. TEMPERATURE: DISPLAYS THE TEMPERATURE IN THE BEARINGS. GREASING: DISPLAYS THE LUBRICATION STATUS OF THE MACHINE. NOTE: NEVER CHANGE THE GREASING VALUES; THIS OPERATION SHOULD ONLY BE PERFORMED BY A TECHNICIAN. IN THE AUTOMATIC PAGE, THE BUTTONS ARE: ACTIVE ALARMS: SHOWS ALL ACTIVE ALARMS. STOP AUTOMATIC: EXITS THE AUTOMATIC CYCLE, RETURNING TO THE INITIAL SCREEN AND STOPPING THE MACHINE AND LINE. ENTRY STRETCH: CORRECTS THE SPEED DIFFERENCE BETWEEN THE INPUT CYLINDERS AND THE PREVIOUS MACHINE. EXIT STRETCH: CORRECTS THE SPEED DIFFERENCE BETWEEN THE INPUT CYLINDERS AND THE EXTRACTION CYLINDERS. SHOCK DENSITY: ADJUSTS THE NUMBER OF STROKES/MIN, CHANGING THE NUMBER OF PENETRATIONS PER CM². GAP: SETS THE DISTANCE IN MM BETWEEN THE PENETRATION SHEET AND THE NEEDLE STRIPPING SHEET. PENETRATION: SETS THE PENETRATION DEPTH IN MM OF THE NEEDLE INTO THE SHEET. TEMPERATURE: DISPLAYS THE TEMPERATURE IN THE BEARINGS. GREASING: DISPLAYS THE LUBRICATION STATUS OF THE MACHINE. NOTE: NEVER CHANGE THE GREASING VALUES; THIS OPERATION SHOULD ONLY BE PERFORMED BY A TECHNICIAN. IN THE MAINTENANCE PAGE, THE BUTTONS ARE: LEFT/RIGHT CLOSED: OPENS THE PNEUMATIC DOORS ON THE SIDES FIXED TO THE STRUCTURE. RESET BENCHES: IF THE GAP AND PENETRATION SETTINGS DO NOT MATCH THE ACTUAL VALUES, THE MACHINE WILL PERFORM AUTO-TUNING. GO TO TOP DEAD CENTER: MOVES THE NEEDLE BAR TO THE TOP DEAD CENTER. BRAKE LOCKED: ALLOWS LOCKING/UNLOCKING OF THE BRAKE FOR MANUAL MOVEMENT OF THE NEEDLE BAR. TABLE EXTRACTION: AUTOMATICALLY UNLOCKS THE NEEDLE HOLDING TABLES, PREPARING THEM FOR MANUAL EXTRACTION. SIDE DOORS: UNLOCKS THE GATES FIXED TO THE GROUND, ALLOWING ACCESS TO THE MACHINE IN THE MATERIAL INTRODUCTION/EXTRACTION AREA. IN THE RECIPES PAGE, RECIPES ARE DISPLAYED AND IMPLEMENTED. A RECIPE REFERS TO THE SET OF PRODUCTION PARAMETERS FOR THE MACHINE. AFTER PRESSING THE RECIPES BUTTON, YOU ENTER THE MANAGEMENT PAGE, FIRST VIEWING THE LIST OF AVAILABLE RECIPES SORTED BY PRODUCT TYPE. SCROLL USING THE CURSOR KEYS UNTIL THE DESIRED RECIPE IS HIGHLIGHTED. PRESS ENTER TO ACCESS THE RECIPE. NOTE: AT LEAST ONE RECIPE MUST ALWAYS BE STORED IN MEMORY. NOTE: THE FIRST RECIPE IN THE LIST IS THE ONE THE PANEL SENDS TO THE PLC AT STARTUP. AT THIS POINT, THE LIST OF AVAILABLE VARIABLES WILL BE DISPLAYED, CORRESPONDING TO THE DATA ENTRY BUTTONS DESCRIBED IN PREVIOUS PAGES. TO MODIFY THESE VALUES, SCROLL WITH THE CURSOR KEYS UNTIL THE DESIRED PARAMETER IS HIGHLIGHTED, PRESS F1 TO START EDITING THE VALUE, ENTER TO CONFIRM, AND F2 TO FINALIZE THE MODIFICATION. THEN PRESS F5 TO SAVE THE RECIPE AND F3 TO SEND THE RECIPE TO THE DRIVES. PRESS THE EXIT BUTTON TO RETURN TO PREVIOUS PAGES. MAINTENANCE PROGRAM WARNING ALL ADJUSTMENT, MAINTENANCE, AND CLEANING OPERATIONS SHOULD BE CARRIED OUT WITH THE MACHINE STOPPED AND ONLY AFTER DISCONNECTING THE POWER SUPPLY VIA THE MAIN SWITCH. THESE OPERATIONS SHOULD ALSO BE PERFORMED BY OUR TECHNICIANS OR ADEQUATELY TRAINED PERSONNEL. TO PRESERVE THE INTEGRITY OF THE MACHINE, PERFORM THE FOLLOWING: DAILY: PERFORM A THOROUGH CLEANING OF THE MACHINE USING COMPRESSED AIR. REMOVE ANY FIBER ACCUMULATIONS. MONTHLY: GREASE ALL BEARINGS AND SUPPORTS. CHECK THE CONDITION OF INTERNAL BEARINGS AND REPLACE IF FAULTY. CHECK THE TIGHTENING OF BOLTS ON MAJOR TRANSMISSION, MECHANICAL, AND STRUCTURAL COMPONENTS. VERIFY THE OIL LEVEL IN VARIOUS SPEED REDUCERS. CHECK THE GREASE LEVEL IN THE GENERAL TANK. ANNUALLY: PERFORM A GENERAL OVERHAUL OF THE MACHINE, REPLACING ALL DEFECTIVE COMPONENTS (PRESENCE OF OUR TECHNICIANS IS RECOMMENDED). ELASTIC SHOCK ABSORBERS NO SPECIAL MAINTENANCE IS REQUIRED FOR THE SHOCK-ABSORBING ELEMENTS OF THE STRUCTURE, BUT PERIODICALLY CHECK THE SURFACE PROTECTION AND IMPROVE IT IF NECESSARY. THE CONDITION OF PROTECTIVE SLEEVES SHOULD ALSO BE CHECKED PERIODICALLY. DAMAGED SLEEVES SHOULD BE REPLACED. LUBRICATION SPECIFICATIONS FOR OPTIMAL OPERATION OF THE GENERAL DISTRIBUTOR, CHECK THE OIL LEVEL AND, IF NECESSARY, ADD OIL AND CLEAN THE RADIATOR COOLING FAN. FIRST OIL CHANGE AFTER 400 HOURS OF OPERATION. SUBSEQUENT OIL CHANGES EVERY 4000 HOURS OF OPERATION. INFORMATION/WARNING WITH THE MACHINE STOPPED, THE OIL SHOULD BE AT THE MIDDLE OF THE SIGHT GLASS. DURING OPERATION, REGULARLY CHECK THE OIL LEVEL AND GEAR TEMPERATURES (OIL TEMPERATURES UP TO 90°C ARE NOT PROBLEMATIC). FOR GREASE LUBRICATION OF ALL BEARINGS KLUBER LUBRICATION CENTOPLEX 2 EP FOR OIL LUBRICATION OF ALL REDUCERS KLUBER LUBRICATION KLUBEROIL GEM 1-150 N SAFETY REGULATIONS AND RESIDUAL RISKS REGULATIONS TO BE OBSERVED THIS MACHINE MUST BE USED ONLY FOR THE PURPOSE IT WAS EXPLICITLY DESIGNED FOR. THE MANUFACTURER CANNOT BE HELD RESPONSIBLE FOR ANY DAMAGE TO PERSONS, ANIMALS, OR PROPERTY RESULTING FROM IMPROPER, ERRONEOUS, OR UNREASONABLE USE OF THE MACHINE. BEFORE PERFORMING ANY CLEANING OR MAINTENANCE OPERATIONS, DEACTIVATE THE MACHINE USING THE MAIN SWITCH AND LEAVE IT IN THE "OFF" POSITION. DO NOT DISMANTLE ANY SAFETY DEVICES INSTALLED ON THE MACHINE. NEVER OPERATE THE MACHINE IF FIXED AND/OR MOVABLE SAFETY DEVICES ARE REMOVED. IT IS POSSIBLE TO STOP THE MACHINE'S OPERATION AT ANY TIME BY PRESSING THE RED EMERGENCY STOP BUTTON. IN CASE OF MALFUNCTION OR POOR PERFORMANCE OF THE MACHINE, DEACTIVATE IT, DO NOT INTERVENE DIRECTLY, AND CONTACT AN AUTHORIZED SERVICE CENTER USING ONLY ORIGINAL SPARE PARTS. MAKE ELECTRICAL CONNECTIONS ACCORDING TO THE INSTALLATION CHAPTER. STRICTLY FOLLOW THE MAINTENANCE PROGRAM. THIS MANUAL MUST ALWAYS ACCOMPANY THE MACHINE IN ANY TRANSFER. DESCRIPTION OF SAFETY DEVICES EMERGENCY STOP BUTTON THE MACHINE IS EQUIPPED WITH AN "EMERGENCY STOP" BUTTON (RED MUSHROOM WITH MECHANICAL LOCK) ON EACH CORNER OF THE MACHINE AND ONE ON THE CONTROL PANEL. ACTIVATING IT CAUSES AN IMMEDIATE HALT TO ALL MACHINE FUNCTIONS. SAFETY MICRO-SWITCHES ON THE FRONT OF THE MACHINE, THE PROTECTIVE PANELS ARE CONNECTED TO SAFETY SWITCHES THAT STOP THE MACHINE’S OPERATION WHEN REMOVED. MOVING TRANSMISSION AND WORKING PARTS ALL MOVING TRANSMISSION PARTS ARE PROTECTED BY FIXED GUARDS THAT CAN ONLY BE REMOVED WITH TOOLS AND BY TRANSPARENT COVERS. CONNECTION POINTS BETWEEN NEEDLE PUNCHING MACHINES THIS CRITICAL SAFETY POINT MUST BE PROTECTED BY A GATE EQUIPPED WITH AN INTERLOCKING DEVICE. CANNOT ARRANGE THIS PROTECTION AS IT DEPENDS ON THE SPECIFIC CHARACTERISTICS OF THE INSTALLATION. THEREFORE, THE OVERALL PLANT MANAGER MUST ENSURE ITS INSTALLATION. RESIDUAL RISKS CARE MUST BE TAKEN, ESPECIALLY DURING MAINTENANCE PHASES, NOT TO REASSEMBLE THE GUARDS BEFORE ENSURING NO OTHER PERSONNEL ARE INSIDE THE MACHINE. SIMILARLY, TOOLS AND OTHER OBJECTS SHOULD NOT BE LEFT INSIDE. CONNECTION POINTS BETWEEN THE NEEDLE PUNCHING MACHINE AND OTHER MACHINES IN THE PLANT ARE POTENTIALLY DANGEROUS. THE PLANT MANAGER MUST ENSURE THAT PROTECTIONS ARE ADEQUATE IN THESE AREAS. THE SIDE HEIGHTS AND TRANSPARENT GUARDS PREVENT ACCESS FROM ABOVE THE MACHINE. HOWEVER, ALWAYS KEEP IN MIND THAT THE UPPER AREA OF THE MACHINE IS NOT PROTECTED (PARTICULARLY IF SCAFFOLDING, LADDERS, TRANSPORT SYSTEMS, ETC., ARE PRESENT).