Working Instructions

Translation of the original instructions

Istruzioni per l’uso

Betriebsanleitung
Instrucciones de Servicio
Instructions de Service

BC-A
FIXED

KARL MAYER ROTAL S.r.l.

Via Trento 117 • 38017 Mezzolombardo (TN) • Italy
Tel. (+39) 0461 608611 • Fax (+39) 0461 601790

Conservare per l’uso!

Keep for future use! Versione 1.2 (2016-05)
Fur kunftige Verwendung
Conservar para un uso futuro! Italian/English
Conserver pour l’utilisation à l’avenir!
TABLE OF CONTENTS PAGE
1. Appropriate use ................................................................................................ 1
1.1. Principle........................................................................................................................ 1
1.2. Execution ..................................................................................................................... 1
1.3. Production technology ............................................................................................... 1
1.4. Material ......................................................................................................................... 1
1.5. Personnel ...................................................................................................................... 2
1.6. Behavior ....................................................................................................................... 2
1.7. Technical service ......................................................................................................... 2
1.8. Inappropriate use ........................................................................................................ 3
1.9. Prevention of environmental and water pollution ................................................. 3
2. Safety instructions ............................................................................................ 4
2.1 Terms ............................................................................................................................ 4
2.2 Warning, symbols........................................................................................................ 5
2.3 Safety precautions for the user.................................................................................. 6
2.4 Safety precautions for the service staff .................................................................... 6
2.5 Particular safety precautions ...................................................................................... 7
2.6 Suitable cloths.............................................................................................................. 8
3. Beam Creel ..................................................................................................... 10
3.1 Main parts .................................................................................................................. 10
3.2 Airborne noise emissions ......................................................................................... 11
3.3 Control elements ....................................................................................................... 11
3.4 Yarn passage .............................................................................................................. 13
3.5 Yarn breakage ............................................................................................................ 13
4. Maintenance and lubrication ......................................................................... 15
4.1 General maintenance rules ...................................................................................... 15
4.2 Checking and cleaning.............................................................................................. 16
4.3 Lubrication chart ....................................................................................................... 19
4.4 Lubrication jobs – general view .............................................................................. 20
4.5 Table for the lubricant selection ............................................................................. 21

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1. Appropriate use

1.1. Principle
Appropriate use of the KARL MAYER ROTAL Beam Creel type BC-A.

Your KARL MAYER ROTAL Beam Creel have been built according to the lastes
technological developments, the technical safety regulations and the know standards and
prescriptions.

1.2. Execution
The KARL MAYER ROTAL Beam Creel runs in automatic and semiautomatic mode, in the
same way as the rest of the dyeing and/or sizing plant.

1.3. Production technology

Provides the yarn to the dyeing and/or sizing plant.

1.4. Material
The following kinds of spun yarn can be used or processed:
• Cotton
• Wool
• Man – made yarns
• Artificial yarns
• Blended yarns

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1.5. Personnel
Only reliable, authorized skilled personnel having received adequated training may be
permitted to use the machine. Nobody may work on the machine, even temporaly, without
required training.

The responsibilities of the personnel charged with transport, installation, preparation, setting -
up, operation, attendance and maintenance must be clearly defined and observance has to be
controlled.

1.6. Behavior
Before setting the machine into operation the competent personnel must have read and
understood the operation manual. In particular the safety-related instructions must be
observed.

Furthermore the enterprise is obliged to permanently control the technical generals

conditions of the machine (from outside noticeable defects and damage as well as changes in
operational behavior).

1.7. Technical service

Repair work may only be done by skilled personnel trained for the specific purpose bearing
in mind the maintenance and repair instructions.

The safety instructions must be observed.

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1.8. Inappropriate use
The following points do not comply with the appropriate use of the machine and
exclude any liability of the manufacturer:
• The first start – up of the KARL MAYER ROTAL machines and the instructions
for the service staff are carried out by KARL MAYER ROTAL service staff. An arbitrary
start – up of the machines is not permitted and makes any warranty claim void.
• Any use departing from the above-mentioned points of any use surpassing the
intended purpose.
• If the machine is put into use without being in a perfect technical conditions and
without sticking to the maintenance and repair conditions.
• If malfunctions wich can impair the safety are not cleared before setting the machine
into operation.
• Only genuine spare parts by the company KARL MAYER ROTAL shall be use.
• Any changes to and bridging of as well as any kind of switching-off of a device on
the machine wich is necessary to ensure perfect operation, unrestricted use active and
passive safety.

This could result in unforeseeable danger:

• to Human Life
• to the machine and to other assets of the enterprise and operator.

1.9. Prevention of environmental and water pollution

The machine described herein is a facility using materials wich are harmful to water according
to the italian law on water supply.

That means that for operation, switching-off and dismounting of the machine or of parts
thereof the provisions of the law on water supply and similar legal prescriptions in force in
the land of user must be observed. For detailed relevant information please refer to the local
regulation on the use of substances wich are dangerous to water.

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2. Safety instructions
The instructions given must be observed.
The instructions and safety directions must be handed over to other users as well as to the
personnel charged with carrying out tasks on the machine.

2.1 Terms

The user
He is the entrepreneur using the system for the production, or the person in charged
appointed by the entrepreneur (department foreman or similar).

Service staff
Person charged with: ♦ installation
♦ operation
♦ cleaning
♦ maintenance
♦ repairing
♦ transport
of the machine.

The service staff must be trained by the user and by the producer on the machine correct
utilization, and on the safety and accident – preventing regulations force.

Authorized or skilled staff

Person able to carry out these steps according to their qualification and education.

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2.2 Warning, symbols

1. Notes
Particular information on operational procedures, machine reactions and on
the efficient use of the machine.

2. Caution
Particular notes, instructions and prohibition for preventing damage.

3. Danger
Information or instructions and prohibitions for preventing personal injury or
heavy material damage. In these cases a particularly cautions behaviour is
required in order to avoid accidents.

4. Danger due to voltage

Beware of dangerous voltage. There is danger of death!
In these cases a particularly cautions behaviour is required in order to avoid
danger to persons due to electric tension.

5. Protection and guards installation

Before the start – up, all the protections and guards must be installed.
The machine covers that must be removed for the repairs or maintenance must
be re – installed in their seats.

6. Danger due to overhead loads

The beam, empty or loaded with yarn, when transported by air, involves risks
to people or things. A sudden downfall might happen!
The lifting and transporting devices must be in order!

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2.3 Safety precautions for the user
The user engages to use the system only and always if it is in perfect conditions.
The user shall inform the service staff on the safety and accident – preventing regulations in
force.
While repairing, only genuine spare parts by the company KARL MAYER ROTAL shall be
use. Otherwise the system operating safety may be endangered, and any warranty claim is
void.

Technical modifications on the system must be carried out only by the producer specialized
staff or by the persons authorized by the same.
If these precautions are not complied with during the warranty period the producer is released
from his responsibility obligations.
Modifications made after the warranty period without the aid of the specialized staff,
authorized by the producer, or without the producer written authorization release the latter
from his responsibility obligations.

The first system’s purchaser engages also to inform in writings the later purchasers on this
provision.

2.4 Safety precautions for the service staff

The service staff must take care that only authorized persons operate the system.
The machine can be dangerous when used by unskilled staff.
Never operate in a way that may jeopardize the safety of the system mechanics and electric or
electronic elements.

The service staff must immediately inform the user if there have been modifications in the
system that may damage the safety.
The system protections and safety devices must not be disasembled or by - passed; otherwise,
the safety during the system operation of the service staff or third persons is not guaranteed

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anymore.
If this case there is risk of:
♦Death
♦Damages to the machine or to other user’s estates
♦Machine operation inefficiency

Steps on electrical, electronic, hydraulic and mechanical devices must be carried out by
authorized and skilled staff only, in compliance with the safety regulations in force.
The steps for the system operation must be defined and followed strictly, so as to avoid steps
unclear as for the safety.

2.5 Particular safety precautions

The machine location must enable the access from all the sides.

Beams
The beams could be a dangerous objects. The weight of them is a factor that
must be always considered.
Special attention must be done whereas moving, transporting, storing and/or
placing (removing) the beams.
All the operations mentioned before should be effectuated observing all the
precautions indicated on this manual.

Machine moving parts that cannot be guarded (beams, brake flanges, etc.)
must not be touched while in operation.

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Electrical connection
The electrical connection must be made by an electrician, following the
indications of the relevant supplying company.
The system must be grounded.
Possible electrical failures must be repaired by authorized technical staff only.

Platform
Be careful when going onto the platform or working on this.
There is a risk to stumble and to fall inside the beams’ area!

Machine switched - off

During the service and maintenance steps there is a high risk. Therefore, all
these steps must be performed with the machine switched – off by the general
switch.

Before starting the system again check nobody is in a dangerous area.

2.6 Suitable cloths

While working on the machine, wear only protective cloths according to national laws. Avoid
personal injury as a result of hang up or catch with the yarn.
a. Wear close-fitting clothing
b. Roll up your sleeves
c. At work, do not bring watches, jewelry (bracelets or necklaces) or rings

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During the tasks concerning the loading and unloading of the warp beam, it is
possible that, despite the precautions, the beam goes to roll on one foot. You
should bring protective footwear when working.

During the steps of preparation, such as the drawing-in of the yarn, exists the
risk to be close to the delivery roller and the squeezing rollers. In these
circumstances it could be fatal long hair or beards. Wear a hairnet or cap
suitable for your hair or a suitable protection for the beard.
If it is necessary to handle the beams, use gloves to avoid abrasions. The
addecuate gloves, permit a safety grip when the beam rolls.

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3. Beam Creel
The installation and first start – up of the Beam Creel must be carried out by a specialized
technician from the company KARL MAYER ROTAL.
It is anyway useful to note the used procedure.

3.1 Main parts

A. Beam support
B. Brake chain
C. Return roller
D. Platform

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3.2 Airborne noise emissions
The airborne noise emissions of the machine are ≤70 dB (A).

3.3 Control elements

1.1. Emergency push button:

a) Pressing the mushroom push button, the machine will stop
immediately.
b) After having eliminated the cause of the emergency stop, release the
mushroom push button.

On your Beam Creel, could be installed and Emergency push button with a
colored ball inside. The middle of the ball, should be red colored. The another
one, green colored. Using this type of push button, the correct procedure to
operate will be as explained bellow.

1.1. Emergency push button:

a) Pressing the mushroom push button, the machine and the entire plant
is stopped. The ball must rotate from green to red.
b) After having released the mushroom push button, the machine can be
re-started. The ball must rotate from red to green.

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To complete the procedure, press the RESET button on the control panel.
Now is possible to restore the interrupted machining.

Press the mushroom push button only in an emergency case!

1.2 Stop push button

The machine stops with a controlled deceleration

1.3 First speed push button

The first speed is set at KARL MAYER ROTAL factory. For safety reasons,
the set value is five meters per minute (5 m/min).

1.4 Production (automatic) speed push button

The machine accelerates till reaching the value set on the control computer.

1.5 Slow speed push button

The machine operates at a crawl speed (Inching speed).

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3.4 Yarn passage
There are many different ways to do the yarn passage on the KARL MAYER ROTAL creels.
Each option, presents its own vantages and disavantages.

The choise will be done, dipending on the yarn type and/or the production batch or
according to the customer’s direct experience.

3.5 Yarn breakage

In case of yarn breakage, proceed as described below:

1. Stop the machine by pressing the stop push button (1.2).

Danger of accident! The space available between the beams could be tight.
To avoid the danger of to stumble and to fall, strictly observe the following
instructions.

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2. Using an appropriate knife, cut the breach yarn and remove this from the beam. Be
careful to do not damage the rest of the yarn!

This operation should be performed only when the machine is stopped!

3. To restart the machine, press the first speed push button (1.3).

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4. Maintenance and lubrication
Maintenance and repair work may only be carried out by trained persons who are authorized
to do so.

Danger of accident due to moving machine parts and lines under pressure
(e.g. pneumatic pipes).
♦Before carrying out any maintenance work set the main switch “O”
and secure it against switching on by using a padlock.
♦Before disassembling relieve pressure in the lines.

Danger of accident due to electrical tension!

♦Prior to any intervention on electric devices or on the switch
cabinet, open the power lead circuit by removing the fuse and provide
a corresponding note.

Danger of accident due to remove protecting devices

♦Before setting the machine into operation re – install the previously
removed covers and protecting devices.
♦At the end of all maintenance and repair work, make sure the safety
and protecting devices are operative.

4.1 General maintenance rules

Do not use any fuzzy material for cleaning, such as cleaning wipes.

Waste disposal
Lubricating oil, hydraulic oils, grease, etc. may not be dumped into water, the drains or the
ground. They must be disposed of in accordance with the environmental standards.

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4.2 Checking and cleaning
This chapter describes all control work required to keep the machine always in an operative
and perfect conditions.

This maintenance work should be carried out weekly.

Work to be carried out

Clean the guiding elements of the beam supports by using a cloth.

Check one time every month the chain brake pad wear. The wear should be
uniform, otherwise, you need to check the correct positioning of the brake
assembly consists of the pneumatic cylinder, the chain brake and their points
of support.

The pneumatic cylinder must be located in the side in which at the time of
closing and generate the braking force, this force will go in the opposite
direction to the rotation of the beam.

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Furthermore, it is important to note that the air pressure upstream the
pneumatic circuit of the creel is 6 bar. This pressure on the creel, will be
adjusted automatically depending on the diameter of the beam (the diameter to
which reference is made, consists of yarn onto the beam).

The friction existing between the pads of the chain brake and the beam’s
flange, generates heat! The heat generated does not represent risk of burn!

Considerations before each new production batch

• Clean the guiding elements of the beam supports by using a cloth.
• Clean and degrease all braking flanges of the warp beams
• Check the warp beams for damage or defects, if necessary repair or
replace the entire beam

• Every 150 hours: Carry out a visual and acoustic check of the brakes
and repair if necessary.

• Every 600 hours:

Check for smooth movement and airtightness of the brake cylinders.
Check the chains and brake pads for wear and tear, in the case of hardening of
the brake lining surface (whistling and screeching) roughen the surfaces by
means of emery tape or replace.
Check the smooth rotation of roller supports and bearings.
Check that the complete crane system for raising the beams is in perfect
working order.

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On the immagine below, it is possible to see a minimun contact between the centering
supports of the beam and the beam.

The beam must be positioned ensuring the rotation of the wheels on its support. In this way,
it is possible to get a correct central position of the beam.

An excessive contact could damage the horizontal wheel (1) even when the wrong contact
continue only for a few minutes!

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4.3 Lubrication chart

The Warp tension control platform could be present near to the creel only
when the customer has ordered one.

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4.4 Lubrication jobs – general view

Hours Intervention Intervention point Job to do

symbol

150 2 Bearing of the return Grease by the suitable

rollers greasers

500 1 Truck for bar of guide Grease by the suitable

greasers

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4.5 Table for the lubricant selection

LUBRICATING LUBRICATING
OIL GREASE

Blasia 220

Spartan EP 220

Mellana Oil 220

Gear 630

Omala 220

Kluberoil GEM Stabutherm GH 462

1-220N

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