337A_Instruction_manual_eng - CARDA.pdf
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Felt Carder Code 337A
Eng Ita
Operating instructions & maintenance
Felt Carder
Le informazion informazionii contenute contenute nel seguente seguente manuale manuale sono sono soggette soggette a modifiche modifiche senza preavviso preavviso.. © Copyright 2001 Mesdan S.p.A. Tutti i diritti riservati. Stampato in Italia Prima Edizio Edizione ne Revisione Revis ione 2003
Ottobre Ottob re 2001
Summary General Information .................................................... 7 I NTRODUCTION NTRODUCTION ....................................................................................... 7 G ENERAL TION ........................................................................... 8 INFORMATION ENERAL INFORMA W ARRANTY ARRANTY RULES ARRANTY RULES ................................................................................. .................................................................................9 D EFINITIONS EFINITIONS ...................................................................................... 10
Technical Data ....................................................... 11 M ANUF ANUF ACTURER ' S 'S D AT A AND EC MARKS .................................................... ....................................................11 O PERA PERATION PERATION ....................................................................................... .......................................................................................12 T ECHNICAL ECHNICAL D AT A ................................................................................. 14 O VERALL VERALL DIMENSIONS AND WEIGHTS ......................................................... .........................................................15
Safety and accident prevention.............................. 16 D ESCRIPTION ESCRIPTION OF THE MACHINE ................................................................ 16 M ACHINE ACHINE SAFETY DEVICES ..................................................................... .....................................................................17 FOR USE .............................................................................. G ENERAL INSTRUCTIONS FOR FOR USE ENERAL INSTRUCTIONS ACCESS TO WORKING AREAS AND CONTROL .................................................................. CCESS TO TO WORKING WORKING AREAS AREAS AND AND CONTROL .................................................................. T YPES PROTECTION AND SAFETY DEVICES .................................................................. YPES OF OF PROTECTION AND SAFETY SAFETY DEVICES YPES OF .................................................................. OF PROTECTIONS AND SAFETY DEVICES .................................................................. LIST IST OF OF PROTECTIONS PROTECTIONS AND AND SAFETY SAFETY DEVICES .................................................................. D ANGEROUS ANGEROUS AREAS ANGEROUS AREAS .............................................................................................. S ECONDARY ECONDARY RISKS ECONDARY RISKS ...............................................................................................
17 18 19 19 20 21
AN AL ALY ALY SIS SIS OF RISKS .............................................................................. 22 T ECHNICAL ECHNICAL ST AND AND ARDS ARDS APPLIED .............................................................. 23 S HIPMENT AND ST AR MOUNTING AND AND ST HIPMENT , HANDLING , MOUNTING AR TING TING ........................................... 24 ADJUSTMENTS ................................................................................... ...................................................................................25 F ISHING YWHEEL AND SUB - FLYWHEEL FLYWHEEL ISHING ADJUSTMENT OF FL -FL FLYWHEEL .................................. 26 ADJUSTMENT OF COMBER FISHING ............................................................ ............................................................27 ATION OF THE WEB DET ACHING COMB ...................... 28 ADJUSTMENT OF THE OSCILL OSCILLA ADJUSTMENT OF THE CONVEYING BEL T TENSION ............................................ 29 BELT
Starting ................................................................. 31 Malfunctions .......................................................... 32 F LOODING ......................................................................................... 32 P OSSIBLE AND REMEDIES ...................................................... 33 OSSIBLE BREAKDOWNS BREAKDOWNS AND AND REMEDIES OSSIBLE BREAKDOWNS LUBRIFICA TION .................................................................................... UBRIFICATION ....................................................................................33
Maintenance ............................................................ 34 R UNNING UNNING - I N ....................................................................................... -IN .......................................................................................34 M AINTENANCE AINTENANCE .................................................................................... 34 C LEANING CYLINDER GASKETS ............................................................. LEANING OF OF CYLINDER CYLINDER GASKETS LEANING OF .............................................................35
Spare parts ............................................................ 36 Electrical diagram .................................................. 39
General Information
General
Information
I N TRODUCTION The present manual is to be considered a part of the machine and must be carefully read before starting the machine.
The machine is not prepared to operate along with other machines.
Felt Carder
- Mesdan Lab 7
General Information
G E N E R A L INFORMATION This manual contains the instructions for the use and maintenance of the FELT CARDER. For a proper operation of the machine, read carefully the instructions given in this manual containing all the information required by the EC 89/392 standard of 14/ 06/89 known as “MACHINE DIRECTIVE” and further updating.
The present manual is to be considered a part of the machine and one of its copy must be kept available to the personnel using, carrying out the maintenance and controlling the machine.
The producer reserves the right to apply all those modifications required for the proper operation of the machine without previous notice.
Moreover, the producer is not responsible for: - the wrong interpretation of the present manual - the improper use of the machine - the use of the machine by unqualified or not duly trained personnel
All electric connections must be carried out according to the attached wiring diagram. The machine must be placed on a floor or a ceiling able to support its weight.
Please, apply to the producer immediately for any damages detected during transport.
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General Information
W A R R A NTY RULES All the mechanical and electrical components of the machine are covered by warranty for one year, starting from the date of the machine testing for all those damages caused by material defects or wrong manufacture. For those parts that are not manufactured by the producer, the warranty of each part manufacturer will be valid. Warranty is valid for one year provided that: - the machine is still a property of the first purchaser. - the machine has been tested by our personnel - the machine has been used according to the instructions and to all the use and maintenance rules contained in this manual. - any worn out part has been replaced with original spare parts. - the failure is not caused by a wrong use. - the failure does not depend on modifications that have not been authorized by our company. In all cases, the producer will replace the part free of charge only after a careful check at its factory. In the case of part replacements, always use original spare parts only. Spare parts that are not authorized by the producer may have different construction features thus causing damages, even serious, during operation.
Felt Carder
- Mesdan Lab 9
General Information
D EFINITIONS As the terms contained in this manual are widely used, there follows a clear explication of their meaning.
Operator The person in charge of running and adjusting the machine as well as of its ordinary maintenance and cleaning.
Servicing engineer A skilled technician, duly trained and entitled to carry out the ordinary maintenance as well as repairs and adjustments requiring a deep knowledge of the machine, its operation and safety devices.
E xposed people A person who stays entirely or partially in a dangerous area.
Dangerous area All those areas inside or near the machine in which the presence of a person is a risk to the safety of that person. Moreover, this manual contains symbols referring to these concepts.
Attention It refers to accident prevention rules that the operator must respect or rules which non-compliance is not allowed.
Warning It refers to possible damages to the machine or its components.
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Technical Data
Technical Data M A NUFA C TUR E R ' S
DATA A ND
E C MA R K S
The machine “FELT CARDER” has been manufactured by MESDAN according to the directions of the EEC 89/392 standard known as “MACHINERY DIRECTION” and its successive updating.
The EC mark certifies the machine safety according to the communitarian standards.
The picture shows the EC plate applied on the machine.
Felt Carder - Mesdan Lab 11
Technical Data
O PERATION The FELT CARDER has been conceived to line up and make fibres parallel giving origin to a thin web to be especially used for sampling. Every machine is provided with the following operating components.
F eeding component Component where fibres are placed manually on the feeding belt conveying them under the cylinders feeding the big drum
Carding component The carding operation starts as soon as the fibres conveyed by the big drum meet the first of the three carding components, (composed of a worker and a doffer), drawn and put again on the big drum to repeat the operation to the next carding unit.
Outlet component Machine component composed of two cylinders called flywheel and subflywheel, a combing drum the web detaching unit is connected to. The web detaching unit detaches the web from the combing drum with an oscillating motion and places it on the collecting cylinder.
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Technical Data
CONVEYING BELT
PUSH-BUTTON CONTROL PANEL
CONVEYING BELT TENSION DEVICE
ELECTRIC BOARD
WORKER CYLINDER
DOFFER CYLINDER
BIG DRUM
FLYWHEEL CYLINDER
SUB-FLYWHEEL CYLINDER
ROLLER SUPPORTING SHOULDER
MAIN MOTOR
TRANSMISSION PULLEY
FEEDING CYLINDERS
WEB DETACHING COMB
COMBING DRUM
WEB COLLECTING CYLINDER
CARD SUPPORT
Felt Carder - Mesdan Lab 13
Technical Data
T E CHNICAL DATA TYPE OF MACHINE MACHINE DIMENSIONS NUMBER OF CARDING UNITS WORKING HEIGHT MACHINE WEIGHT PROCESSABLE MATERIALS PRODUCTION OUTPUT POWER INSTALLED SUPPLY VOLTAGE NOISE VIBRATIONS HARMFUL EMISSIONS
FELT CARD 1820x760xH = 1500 THREE 495 mm 580 kg TEXTILE FIBRES 3 kg/hour approx. 1.5 KW 380V 50HZ < 70 dBA NONE NONE
Using the machine to process other materials or changing its components to increase the production output is considered improper, therefore the manufacterer declines any responsability for damages to people or things.
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Technical Data
OV E R A L L
DIMENSIONS A ND WEIGHTS
Height 1500
Width 800
Length 1900
Overall weight of the machine: 580 KG
The handling and lifting operations must be carried out by skilled and trained personnel wearing all accident prevention protections. It is forbidden to everybody to pass under the loading and handling area. Personnel in charge of signalling machine loading, handling and unloading are required.
Felt Carder - Mesdan Lab 15
Safety and accident prevention
Safety
and accident prevention
D ESCRIPTION OF TH E MA C HINE Conditions for use The felt carder cannot operate under the following conditions: -
Very wet environments Temperature over 40° and below 5° In the presence of chemical agents In environments at fire or explosion risks The use of the machine under conditions different from the above-ment ioned ones, causes the immediate forfeiture of warrenty, the user must create the suitable conditions for the working enviroment
Lighting The machine can operate in environments having a lighting degree which is suitable for industrial processing in the presence of skilled personnel.
Noise The machine does not emit any noise or acoustic radiation pressure exceeding the thresholds provided for by the rules in force > 70dBA. Cleaning and lubrication of the moving organs allow to keep the above threshold.
Vibrations The machine does not emit any vibrations that may cause damages to the users
E mission of residuals abd environmental pollution As the result of processing, the machine produces residual matters deriving from processing. Residual dusts can be sucked by means of an exhaust fan and then collected in special boxes to be disposed.
For cleaning operations, the user must wear a dustpr oof mask and gloves. The user must train his personnel for a correct disposal of residual matters in compliance with the rules in force.
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Safety and accident prevention
M A C HINE S A FE TY D E V I C E S G ENERAL
INSTRUCTIONS FOR US E
The machine has been conceived considering all the risks it might give rise to. The customer must inform the personnel about the existence of secondary risks, the measures and the standards to be adopted about accident prevention. The operator must have full knowledge of the information contained in this handbook as well as know the concept of responsibility and competence. The operator must wear the protective equipment supplied with the machine.
The operator is not allowed to wear watches, bracelets, jewels and clothes which could get caught in the machine.
The operator must fully respect the instructions, the warning messages and the general rules contained in this handbook. Non-authorised tampering or replacement of one or more pieces of t he machine as well as the use of accessories, tools, expandable materials other than the ones recommended by the manufacturer imply a risk of accident. The clothes of the personnel in charge of the machine maintenance must comply with the basic standards in force in that country, as shown by the EEC directive no. 89/656 and no. 89/868 concerning the use of personal protec tion devices.
Felt Carder - Mesdan Lab 17
Safety and accident prevention
A C C E S S
TO WORKING A R E A S A ND CONTROL
The machine has been manufactured so as to allow an easy control of the driving functions.
Area “A” Load/Unload Control
Area “B” Control
Area B
Area A
Area A
Area B
It is forbidden to enter all the areas surronding the machine by the operator when all protections are open and the machine is under maintenanc e.
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Safety and accident prevention
T Y P E S
OF PROTECTION A ND S A FE TY D E V I C E S
The machine is provided with movable, fixed and electric protections and safety devices to prevent work accidents in compliance with the rules in force.
L IS T OF PROTECTIONS A ND S A FE TY D E V I C E S 1 Right lateral fixed protection cover with screws 2 Left lateral fixed protection cover with screws 3 Fixed protection cover with screws over the conveying belt 4 Fixed protection cover with screws over the flywheel cylinder 5 Fixed protection cover with screws over the web detaching comb 6 Fixed protection cover with screws over the fixed roller driving belt 7 Movable upper protection cover with electric block 8 Mushroom-head stop push button 9 Upper protection micro-cover
The fixed protection covers with screws can be removed by using suitable wrenches only
The purchaser is fully responsible for all risks which might rise or derive from any trouble due to the protection cover removal or any other type of protection. The machine start is forbidden as long as all protection covers have not been secured by means of their special screws.
Felt Carder - Mesdan Lab 19
Safety and accident prevention
D A NG E R OUS A R E A S Even though the machine is provided with all necessary protections and safety devices, in the case of their removal or tampering, the machine may have dangerous areas for the operator.
1 Area exposed to electric energy risks 2 Areas exposed to risks deriving from automatisms, that is getting entangled, dragging, impact and cut. 3 Areas exposed to static electricity noise, dust emission.
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Safety and accident prevention
S E C O N D A R Y R I S K S Even though the loading area is well protected, if the material is not introduced into the area and properly placed, to arrange it, first of all the machine must be stop; in the case of cleaning after removing the protection covers, the machine must be stopped to blow or suck dusts. On starting the machine, in the exit area when the felt is removed form the web detaching comb, stop the machine, collect the web with your hands and place it on the collecting cylinder, then start again the machine. When the machine is running, no further operations are required except placing the material on the conveying belt.
The non respect of the above instructions may cause possible injuries to the upper limbs due to squashing and/or rubbing.
Moreover, we recommend to read with care the adhesive plates in those places where the best attention is required.
BECAREFUL TO YOUR HANDS
DO NOT LUBRICATE AND CLEAN DURING MOTION
Don not remove the warning plates acting as safety tools . In the case they are removed, warranty decays and the purchase wil l be fully responsible for that.
Felt Carder - Mesdan Lab 21
Safety and accident prevention
A NALYSIS
OF R I S K S For a proper analysis of the existing risks, we referred to a series of specific standards included in PR:1050/1993 – you can see the existing types of risks in the table here below:
Type of risk Risks due to electric energy Risks due to noise
Standards applied
EN 60 204/1 80/1127/CEE 82/605/CEE 82/605/CEE 83/477/CEE 86/188/CEE Risks due to surfaces, corners, DPR N. 547/1955 art. 27 entangling dragging angles
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Precautions See page See references at pages 9 and 13
Reference at page 13
Safety and accident prevention
T E CHNICAL S TA NDA R DS A PPLIE D On designing the machine, the following European Standards in force at present were applied:
They are related to: Machine Directive 89/392 – 91/368 – 93/44 – 93/68 EC EN292/1 standards Safety of the equipment. Basic concepts, general designing principles EN292/2 standards Safety of the equipment. Basic concepts, general designing principles. Specifications of technical principles EN294 standards Safety of the equipment. Safety distance to prevent dangerous areas from being reached from upper limbs. EN418 standards Safety of the equipment. Emergency stop device. Functional aspects. Design principles. PrEN842 standards Safety of the equipment. Danger visual signals. General requirements. CEI-EN standards Safety of the equipment. Electrical equipment of machines. General requirements. PrEN953 standards Safety of the equipment. Design and protection construction requirements. Fixed and movable protections. PrEN1037 standards Safety of the equipment. Insulation and energy dissipation. Prevention against sudden starting. PrEN1088 standards Safety of the equipment. Interlocking devices with or without protection block system.
Felt Carder - Mesdan Lab 23
Installation and adjustments
S HIPMENT , HANDLING , MOUNTING A ND S TA R TING Shipment The machine is normally shipped in a cardboard package; if transport must be carried out with containers it is shipped in boxes.
H andling To handle the machine inside the workshop, refer to the pictures here below.
Mounting The machine can be mounted by the personnel authorized by the purchaser; lay the machine on a flat and not slippery floor, rest the four feet as uniform as possible by using the adjusting screw, refer to the figure here below.
Starting The machine can be started by the personnel authorized by the purchaser, carrying out the following: 1 make sure that all screws are properly tightened 2 make sure that the machine runs without rubbing by means of a 13 fixed wrench, see picture below 3 make sure that all fixed and movable protection covers are installed 4 connect the machine to the electric system 5 first, kick over the machine, then start it in continuous mode. Introduce the 13 mm wrench here
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Installation and adjustments
A DJUSTMENTS Adjustment of worker and doffer fishing. To obtain a correct carding action with respect of the fibre to be processed, it is necessary to adjust the distance of workers and doffers from the big drum. To adjust workers release screw A, adjust the distance from the big drum by using screws B and C connected to support D (that may vary from 0.2 mm to 0.4 mm), check parallelism by means of screws E and F. To adjust doffers carry out the same operation, moreover make sure that the distance between workers and doffers is 0.2 mm to 0.4 mm by means of screws E and F.
During adjustment, cylinders must be free from belts and chains. Moreover they must be longitudinally checked and rotated manually to avoid that any higher point rubs against the other cylinders.
Felt Carder - Mesdan Lab 25
Installation and adjustments
F I SHING A DJ US TME NT OF FLYWHEEL A ND S UB FLYWHEEL To carry out the flywheel fishing adjustment make a strip 30/40 mm high on the gasket of the big drum by using a white chalk, move the chalk strip under the flywheel by rotating the flywheel itself; rotate the flywheel by keeping the big drum standstill – for a correct adjustment, the flywheel must remove a chalk strip 10/15 mm high. The gasket distance can be changed according to the processed fibre requirements by using screws A and B of lateral support C. The fibres remaining on the flywheel are removed from the sub-flywheel and placed again on the big drum, it is therefore necessary to position the sub-flywheel at a 0.2/0.4 mm distance from the flywheel and the big drum by using screws D and E of lateral support F.
During adjustment, cylinders must be free from belts and chains. Moreover they must be longitudinally checked and rotated manually to avoid that any higher point rubs against the other cylinders.
26 Felt Carder - Mesdan Lab
Installation and adjustments
A DJUSTMENT OF COMBER
FISHING
To obtain a correct detachment of the fibre, the distance of the comber from the big drum must be adjusted.
Place the comber at a 0.1/0.3 mm distance from the big drum by using screws A and B of support C.
The distance between the comber and the big drum must be adjusted as soon as the detaching action of the fibre is not regular any more. Cylinders must be longitudinally checked and rotated manually to avoid that any higher point rubs against the other cylinders.
Felt Carder - Mesdan Lab 27
Installation and adjustments
A DJUSTMENT OF THE OSCILLATION OF TH E WE B DETACHING COMB To obtain a correct detachment of the web, it is necessary to adjust the travel and the distance of the web detaching comb from the comber.
The distance of the web detaching comb A from the comber varies from 0.2 mm up to a measure that allows a uniform detachment. This operation must be carried out by using screws B and C connected to support D.
The oscillation amplitude is achieved by using screw E, increasing or decreasing the distance between the big end of the connecting rod F and pin G.
The web detaching comb must be longitudinally checked to avoid that any higher point rubs against the comber.
28 Felt Carder - Mesdan Lab
Installation and adjustments
A DJUSTMENT OF TH E CONVEYING
B E L T TENSION
To get the right tension of the conveying belt, proceed as follows: release screw A of the belt tension support B, use screws C and D until when the belt i s lowered by 10 mm approx. by pressing it with your hand.
Then, let the machine rotate and, if the belt tends to move towards the edges, carry out the above-mentioned operations on the belt tension support even several times up to obtain a right matching of the belt.
Felt Carder - Mesdan Lab 29
Installation and adjustments
Check periodically the tension of the belts and the chains, this operation allows a uniform rotation of the cylinders and a better processing. Adjust the belts and the chains when they appear to be slackened by means of the special tension device without exaggerating to prevent mechanical troubles.
During checks, the belts must be free from cracks and kerfs, otherwise replace them immediately. Replace immediately also chains appearing too much lengthened.
These operations permit to protect the mechanical component s against wears and failures, they also assure a correct processing of material.
BELT TENSION DEVICE CHAIN TENSION DEVICE
30 Felt Carder - Mesdan Lab
Starting
Starting Make sure that all the protection covers are installed and properly closed with their screws. Check the rotation direction, see the picture below. 1. Turn the switch to the ON position, see page 17 to energize the machine. 2. Load the conveying belt manually making sure to prepare a fibre layer 2.5/3 cm high. 3. Start the machine by pressing the green push-button seated on the push-button panel, see page 7. 4. Wait for the web to come out from the outlet seated under the web detaching comb (see A, page 23). Stop the machine, collect the web and place it on the web collecting cylinder (page 7) near the green cloth. 5. Start again the machine by pressing the green push-button. 6. Carry out carding of the material.
As soon as the material is over, before to load some more, clean the machine with care to avoid pollution and to improve quality along with the mechanical life of the machine
Wear the suitable protective equipment during the machine cleaning along with the protective gloves to use the hook and the brush, use the dustproof mask when using compressed air
Felt Carder - Mesdan Lab 31
Malfunctions
Malfunctions F L OODING When one or more cylinders are wrapped with too much material, they may jam the machine, in this case proceed as follows:
1. Stop the machine, turn off the power by turning the switch to the OFF position (see page 35). 2. Remove the movable upper protection cover by unloosening the two knobs. 3. Remove the exceeding material by using a hook making sure not to damage the cylinder gasket. 4. Install again the protection cover and repeat the operation until when the machine starts operating in a continuous and uniform manner.
Use a hook and wear gloves when removing the exceeding material
32 Felt Carder - Mesdan Lab
Malfunctions
P O S S I B L E B R E A K D O W N S A ND
REMEDIES
The machine does not start 1. Make sure the power is ON 2. Make sure that the microswitch – see page 12 item 9 – is pressed 3. Make sure that the stop red mushroom-head push-button is reset
The machine operates discontinuosly 1. Make sure the cylinders are free from windings 2. Make sure that no material is entangled between the cylinders and the shoulder of the machine 3. Check the right position of belts and chains 4. Make sure that no material crumbs are entangled in the belts or chains If problems persist, apply to the manufacturer
L UBRIFICATION Periodically lubricate (every 30 days) chains and gears by applying a very thin layer of grease making sure not to foul the other organs.
Points to be greased
Felt Carder - Mesdan Lab 33
Maintenance
Maintenance R UNNING -IN The machine does not need any running-in
M A IN TE NA NC E 1. Extraordinary maintenance – to be carried out after 40 working hours approx. of the machine and consists in checking that all screws are tightened, adjusting the chains, the belts and the conveying belt, if necessary.
2. Daily maintenance – to be carried out when cleaning the machine, changing material and once a day at least
3. Monthly maintenance – general and careful cleaning, control of chains, belts and conveying belt and adjusting as described at pages 25/26/27/28/29/30, if necessary.
34 Felt Carder - Mesdan Lab
Maintenance
C LEANING
OF CYLINDER G A S K E T S Gaskets must be cleaned and adjusted by skilled personnel only by means of special tools.
Manual cleaning must be carried out by means of a hard bristle brush once the machine has been stopped and the protection covers have been removed; any possible residual matter got entangled between cylinders and machine shoulders must be removed by means of a hook.
The above operations must be carried out by servicing techni cal personnel wearing accident prevention protections, gloves, dust proof mask and with the main switch on position “OFF”, that is switched off.
Off position
Manual cleaning of gasket
Felt Carder - Mesdan Lab 35
Spare parts
Spare parts
36 Felt Carder - Mesdan Lab
Maintenance
Felt Carder - Mesdan Lab 37
Maintenance
38 Felt Carder - Mesdan Lab
Maintenance
Electrical diadiagram
Felt Carder - Mesdan Lab 39
Maintenance
40 Felt Carder - Mesdan Lab
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