CLP pre-cleaner

Type No. 053 25 07

Operating instructions
03/2012 en
These operating instructions contain information protected by copyright. No part of these operating instruc-
tions may be copied, printed, filmed or reproduced, processed, duplicated or disseminated by any other
means, either in whole or in part, without our prior written consent.
We are not liable for damage or problems arising from the use of items of special equipment, parts and
replacement parts which are not original Trützschler products or replacement parts.
Some of the functions described here may not be available, depending on the version and construction of
the machine.
© 2012 Trützschler GmbH & Co. KG, Mönchengladbach
Translation of the original operating instructions
All rights reserved

Trützschler GmbH & Co. KG

Textilmaschinenfabrik
D-41241 Mönchengladbach
Postfach 41 01 64
Telephone +49 2166 607-0
Fax +49 2166 607-405
e-mail info@truetzschler.de
Internet www.truetzschler.com
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
About these operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Purpose of these operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Definition of machine sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety of persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Avoiding machine damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety devices on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Symbols employed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conventions employed in these operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly groups and function of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Position within the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Master switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pre-cleaner operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Basic keys (jog, stop, start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Preparing for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Daily preparations for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Preparing and starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Reacting to fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Switching off the drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Switching off the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Control settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Code levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
........................................................................... 36
Lot management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Lot data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Activating communication interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

053 25 07 • CL-P • en • 03/2012

 Test door locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Diagnostics / Statistic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Sensors / Measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Mechanical settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Setting the material suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Setting the cleaning efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Basic procedure in the event of a fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
LED displays in the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Central control unit KSZ5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DEA2 input and output module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Switching on service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Carrying out tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Maintenance and servicing schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cleaning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Cleaning the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking and setting belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Updating the control software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacing the cut-out fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Options and additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ISO 4871 noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Expendable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Anti-corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
EC conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

053 25 07 • CL-P • en • 03/2012

 Introduction

Introduction
In this chapter you will find important safety instruc-
tions as well as explanations of the structure of this
set of operating instructions and the symbols and
conventions employed.

About these operating instructions

Purpose of these operating Further information

instructions Should you have any questions about the opera-
Using these operating instructions, you will tion of the machine which are not answered in
become acquainted with the CL-P pre-cleaner and these operating instructions, please contact:
learn how to operate and maintain the machine Trützschler GmbH & Co. KG
safely. Textilmaschinenfabrik
Initial commissioning and removal from service are D-41241 Mönchengladbach
not contained in this operating and service manual Postfach 41 01 64
as these tasks must be carried out by Trützschler Telephone +49 2166 607-0
after-sales service staff only. Fax +49 2166 607-209
E-mail service@truetzschler.de
Trützschler attaches great importance to you oper- Internet www.truetzschler.com
ating the machine safely, correctly and economi-
cally. It is therefore important that you read these
operating instructions through carefully before
you start to work on or with the machine. These
operating instructions contain important informa-
tion which will help you to avoid hazards and to
increase the reliability and service life of the
machine and the attached components.
Make sure in particular that you read the section
Safety measures starting on page 7. Follow all the
instructions precisely so that you do not endanger
yourself or other persons and in order to avoid
damage to the machine.
These operating instructions must be available at
all times on the machine. They must be read and
used by every person given the task of working on
or with the machine.

053 25 07 • CL-P • en • 03/2012 5

Introduction

Proper use
The CL-P pre-cleaner is designed for cleaning cot-
ton and synthetic fibres in spinning mills only.
Use of the machine for any other purposes consti-
tutes improper use and is strictly prohibited.
Proper use also includes adhering to the operating
instructions and complying with the intervals for
servicing and maintenance.

Definition of machine sides

The definition of the machine sides, "left" and
"right", complies with the definitions for spinning
mill machines in DIN/ISO 92. For machines with a
material flow in one direction, the machine sides
are defined looking against the direction of material
flow.
Example: The operating unit (1) is situated on the
right-hand side of the machine.

Type plate
A type plate (2) for exact identification of the
machine is situated on the rear of the housing.
You require this data from the type plates for corre-
spondence with Trützschler's customer service
department, for instance, in order to be able to
match individual components to the machine.
The machine's type plate contains the following
data:
1 2
– Type designation
– Type number
– Commission number
– Year of manufacture

6 053 25 07 • CL-P • en • 03/2012

 Introduction

Safety measures

Organisational measures Avoiding machine damage

The machine has been built using state-of-the-art As the owner of the machine, you are responsible
technology and in accordance with the recognised for the following points:
safety regulations. If used in an improper manner,
– Use the machine exclusively for applications
however, the machine may pose a danger to the
described as proper use.
life and limb of the operator or of other persons, or
machine functions may be impaired. – Observe the operating conditions and materi-
als for the machine described in these operat-
The personnel employed to work on or with the
ing instructions.
machine must have read and understood these
operating instructions before starting work. This – Observe the stipulated maintenance intervals.
applies in particular to personnel who are only
– Use only original Trützschler spare parts and
required to work on the machine occasionally,
process media recommended by Trützschler.
e.g. for maintenance work.
The owner of the machine has the responsibility to
ensure that the machine is operated safely and
does not present a hazard. He can achieve this
through the following measures:
– Ensuring that the service manual is available
on the machine at all times.
– Carrying out regular training courses.
– Regularly checking that personnel are paying
attention to safety and are aware of the haz-
ards whilst working.
Warning plates and danger signs on the machine
must be clearly legible and kept free from damage
at all times and must not be removed.

Safety of persons
The personnel employed for operation and mainte-
nance must be qualified for their work or must have
been instructed by qualified persons.
Qualified persons are those with sufficient knowl-
edge of the machine as a result of their technical
training and experience. These persons are suffi-
ciently familiar with the relevant local and national
work safety and accident prevention regulations to
be able to assess the safe working condition of the
machine.
– Observe the working instructions for your
place of work.
– Observe the relevant accident prevention reg-
ulations.
– Observe the safety precautions contained in
these operating instructions.

053 25 07 • CL-P • en • 03/2012 7

Introduction
Safety instructions
Read the following safety instructions carefully and
observe them at all times. They are given for your
own safety, for the safety of your colleagues and in
order to avoid any damage to the machine and the
attached components.
Before switching on the machine
As owner of the machine, ensure that only qualified
personnel are employed to operate the machine.
Also make sure that specialist personnel inspect
the machine to make sure it is in a safe and hazard-
free condition before it is commissioned for the first
time, after maintenance work and after any techni-
cal modifications.
As the machine operator, you must make sure that
nobody is situated in the danger area of the
machine.
Electrical installation and control cabinet
Ensure that the door to the control cabinet is kept
locked at all times. The key should be kept by a
responsible and qualified person, e.g. the plant
electrician.
Ensure that no liquids are allowed to penetrate into
the control cabinet or other components. Should
this nevertheless happen, switch off the machine at
the master switch, lock the switch to prevent unau-
thorised switching on and inform the responsible
specialist personnel or the Trützschler after-sales
service department.
Working on top of the machine
Work on top of the machine is only permitted on the
frame in front of the BR-COI condenser and on the
optional maintenance scaffold.
Use suitable barriers to ensure that there is no risk
of falling when working on the frame.
8 053 25 07 • CL-P • en • 03/2012
Maintenance work
As owner of the machine, make sure that only qual-
ified personnel are employed to carry out mainte-
nance work on the machine.
Install and activate all protective and safety instal-
lations correctly after all maintenance work.
Work on the machine going beyond the operations
described in the chapter Maintenance may only be
carried out by Trützschler after-sales service per-
sonnel or by persons authorised by Trützschler.
Do not start any set-up and maintenance opera-
tions until the machine has been disconnected
from the power supply and has come to a standstill.
Secure the master switch in the off position with
a padlock and a warning sign or other suitable
means to prevent it from being switched back on
without authorisation. This applies in particular for
machine combinations and machines which cannot
be monitored in all areas at the same time due to
their size.
Only ever carry out modifications to the machine
or its components after having consulted with the
Trützschler after-sales service staff. Otherwise
major malfunctions may occur, causing serious
personal injury and irreparable machine damage.
 Introduction

Starting/stopping the machine

The machine must only be commissioned or

removed from service by Trützschler after-sales
service staff. This also applies to a temporary
removal from service and re-commissioning by the
same owner (e.g. when transporting the machine to
another location).

Further instructions
If this machine is moved to another location or sold
to another company, this operating and service
manual must accompany the machine. It is an inte-
gral part of the machine.
Ensure that the floor around the machine is not
soiled with oil or grease after maintenance work.
Otherwise there is a risk of operators or other per-
sons slipping and suffering serious injuries.

Safety devices on the machine

Master switch
The machine's master switch (1) is situated on the
front control cabinet door. It is used to as a device
for disconnecting from the network and brings the
machine to a standstill in an emergency.
You can lock the master switch in the OFF position
with a padlock to prevent it from being switched
back on without authorisation.

Emergency stop push-button

The machine does not have an emergency stop
button.

053 25 07 • CL-P • en • 03/2012 9

Introduction

Safety mechanisms for doors and flaps

4 3 2

The doors and flaps on the machine are locked Warning plates and danger signs
with spagnolets. The spagnolets can only be Warning plates and danger signs are attached to
opened with a special key. many points of the machine. They warn of danger
The maintenance flaps (1) at the front and rear are areas and provide instructions on how to act.
secured by safety locking devices. These signs must not be removed and must remain
The doors (2) to the drive elements on the left-hand legible and free of damage at all times. Replace
side of the machine are secured by safety locking badly legible and damaged plates immediately with
devices and limit switches. When a limit switch is new plates of the same type.
opened, the drives of the machine are switched off.
You can only switch on the machine if all doors and
maintenance flaps are closed.
The doors to the control cabinet (3) are locked
using a special key.
The doors (4) on the right-hand side of the machine
are not locked.

DANGER
Risk of serious injuries from impacts and
crushing!
The safety locking mechanisms on
doors, maintenance flaps or other open-
ings must not be bypassed or disabled,
either mechanically or electrically.

10 053 25 07 • CL-P • en • 03/2012


Symbols employed
The following symbols are employed in these oper-
ating instructions:
DANGER
This symbol draws attention to a potential
hazard for the operator that could result
in serious personal injury or even death.
Caution
This symbol draws attention to hazards
that could result in machine damage or
data loss.
Note
This symbol draws attention to tips and
points of particular note that make opera-
tion of the machine easier for you.
Every safety warning specifies the source of the
hazard, the potential hazard and the measures to
be taken to avoid the danger.
053 25 07 • CL-P • en • 03/2012
Introduction
Conventions employed in
these operating instructions
Bold type
Messages and designations of keys are printed in
bold type.
1. Press the YES key.
Italics
Cross-references to other sections of the text or
other chapters are printed in italics.
References between text and pictures
Numbers shown in the text in brackets, e.g. (1),
refer to the numbers of items shown in the figures
on the same page.
Operating steps
Operating steps which are to be carried out in a set
order are numbered as shown in the example:
1. Unfasten the bar.
2. Pull the plug.
Lists
Lists which are not sorted in any particular order
are shown as in the following example:
Carry out the following tasks:
– Remove any soiling.
– Check the belt tension.
Replace any defective parts.
11
Introduction

12 053 25 07 • CL-P • en • 03/2012

 Description

Description

Assembly groups and function

of the machine

1 2 3

10

9
4

5
8

7
6

The BR-COI condenser (1) delivers material via The cleaned material is extracted by the down-
the material trunk (10) to the first opening roll (9). stream machine (2). The material suction pipeline
It moves the material over a grid (8) and circulates contains a fresh air inlet screen (3) for regulating
it. This removes foreign parts from the material. the suction pressure. The pressure in the material
suction system is measured in the volumetric
The processed material is cleaned again by the
nozzle (4).
second opening roll (5) with grid (6).
The separated impurities drop through both grids.
You can adjust the grids to adjust the machine to
the material being processed and the desired qual-
ity.
The entire waste is extracted through the waste
duct. A bucket wheel lock (7) prevents good fibres
from being extracted.

053 25 07 • CL-P • en • 03/2012 13

Description

Position within the installation

The machine can be fed via the integrated BR-COI
condenser by the following machines:
– BO-U universal opener
– SP-MF multi-functional separator
– SP-EM Electronic Metal Separator
The machine can feed the following machines or
machine combinations:
– MX-I or MX-U mixer with a BR-FD fan
installed as an intermediate device
– BR-COI or BR-COU condenser
With a production rate of 800 kg/h the machine can
also be used to feed a CL-R waste cleaner with
FD-R feeding unit. To do so, a BR-COI condenser
has to be installed as an intermediate device.
The machine can be used in recycling installations
to feed an SP-H heavy part separator.
A BR-MC manual change box can be installed on
the waste duct.

14 053 25 07 • CL-P • en • 03/2012

 Description

Operating elements
You must be familiar with the following operating
elements and how to operate them in order to oper-
ate the machine.
– Operating unit (1)
– Master switch (2)
– Settings lever for the grids (3) 1
The setting levers for the grids are accessible
through the doors (3) on the right-hand side of the
machine. A description of the setting can be found
in the chapter Mechanical settings starting on
page 46.

Master switch
The machine's master switch (2) is situated on the
control cabinet door at the rear of the machine. It is
used as a device for disconnecting from the net-
work and brings the machine to a standstill in an 3 2
emergency.
You can lock the master switch in the OFF position
with a padlock to prevent it from being switched
back on without authorisation.

Operating unit
The operating unit (1) is installed on the right-hand
side of the machine.
It comprises:
– the keyboard with keys and LEDs
– the two-line display
– the key switch
The operating unit is used to set and monitor the
machine. All machine data and messages are dis-
played here.
The keypad is made up of push-buttons, covered
by a protective foil. The keys react when pressed
lightly.

Caution
Possible damage to the operating panel!
Do not press the keys with excessive
force. Do not hit the keypad or the dis-
play.

053 25 07 • CL-P • en • 03/2012 15

Description

Pre-cleaner operating unit

The operating unit is used to set and monitor the
machine. All machine data and messages are dis-
played here. The operating unit consists of the
touch screen monitor (1), a combined display and
input panel, and the basic keys (2). The touch
screen monitor displays messages and diagrams
in the same way as a normal monitor. In addition,
inputs can be made and functions selected by
touching the displayed buttons.
If a button cannot currently be used, it is displayed
faded.

Machine ready 1

Power BAE 6

Caution
Possible damage to the touch screen!
Only ever touch the buttons lightly with
your fingers. Do not bang or hit the touch
screen. Do not use any objects such as
pens or tools.
Touch the desired symbol lightly with the tip of your
finger. Depending on the button, a value will be
marked and selected or a function will be called up
and a new window is shown.

16 053 25 07 • CL-P • en • 03/2012

 Description

Basic mask

Automatic mode

Power BAE 6

1 Top row of buttons / display fields Basic keys (jog, stop, start)
2 Main area The basic keys (4) for machine control have the fol-
lowing functions:
3 Bottom row of buttons / display fields
4 Basic keys for machine control
Run machine in jog mode
The main section of the screen (2) changes,
depending on the selected function. It displays
texts, diagrams and in some cases, buttons that Stop machine
can be pressed. The top (1) and bottom (3) rows
of buttons and the display fields are valid for all
screen-filling displays. Start the machine

After a certain amount of time, the touch screen

switches off the background lighting without losing The operating unit also has additional lamps above
any data. Touch the touch screen once to reacti- the keys. The corresponding lamp lights up for as
vate it. After activating, it takes a short while before long as you press a key.
the touch screen can be operated again.

053 25 07 • CL-P • en • 03/2012 17

Description

Power
The green power lamp shows when the operating
unit is switched on and active, even if the screen
saver is active and no display appears on the
screen. Touch the screen once briefly to switch the
display back on.

Jog key / jog mode

With each touch of the jog key you increase
the material conveyed. If you press and
hold the jog key, the conveying of material
is continuously accelerated. The yellow
inching mode lamp flashes if currently only
inching mode is available.

Stop key
You can stop the machine with this key.

Start key
If the green start lamp is flashing, you can
press the start key. Using this key, you start
the machine when it is ready for operation.
In most cases the jog key is also active
when the start lamp is flashing.

18 053 25 07 • CL-P • en • 03/2012

 Description

Basic mask, top rows

2 3 4 5 6 7

1
Automatic mode

No. Symbol Designation Function or significance

1 Message line Machine status, warnings and fault messages
2 Language Display: Current language as a flag symbol
selection

3 Machine status 1 Display: Current machine status

Press button: Call up log book
Further symbols for machine status 1 are listed on page 20.
4 Machine status 2 Display: Current machine status
Press button: Display manufacturer information
Further symbols for machine status 2 are listed on page 20.
5 Information Display: Machine type
Press button: Display machine and manufacturer information and
the current programme version
6 Lot data Display: Active lot
Press button: Call up lot management, e.g. change lot name and
lot data
7 Date and time Display: Date and time
Press button: Set date and time

053 25 07 • CL-P • en • 03/2012 19

Description

Symbols for machine status Basic buttons

Depending on the status of the machine, one of the Apart from the buttons in the basic mask, a few
following symbols appears both status displays: other basic buttons are frequently used:
Machine status 1:
Button Functions
Symbol Meaning Accept, corresponds to "Enter" on a
The machine runs in automatic mode computer keyboard
Delete the character last entered
Machine not ready
Yes, confirm prompt or switch on
Machine ready for preparation function
No, refuse prompt or switch off
Machine ready function
Increase value, display next value,
Drives starting scroll up
Decrease value, display previous
Drives running value, scroll down
Cancel current function
Drives slowing down
(Escape) Abort input without sav-
Material transport ready for starting ing.
Delete selected or displayed data

Machine status 2:
Select the basic mask
Symbol Meaning
Display: Machine is running properly
Press button: Display manufacturer
information
Display: Maintenance interval
exceeded
Press button: Display current warn-
ings and maintenance interval
Display: One of more warnings have
occurred
Press button: Call up window with
current warnings
Display: One of more faults have
occurred
Press button: Call up the first fault
message
Service mode

20 053 25 07 • CL-P • en • 03/2012

 Description

Basic mask, main area

1 2

5 4

No. Meaning
1 Speed of the dust cage
2 Speed of the condenser fan
3 Speed of the second opening roll
4 Suction pressure in the waste line
5 Speed of the first opening roll
6 Material suction volume flow

053 25 07 • CL-P • en • 03/2012 21

Description

Basic mask, bottom row

1 2 3 4 5 6 7

No. Symbol Designation Function or significance

1a Standard level Display: Standard level selected;
Press button: Call up code input
1b Code level 1 Display: Code level 1;
Press button: Change code or exit code level
1c Code level 2 Display: Code level 2;
Press button: Change code or exit code level
2 Settings / Press button: Machine settings, lot data, communication, service
programming functions
3 Diagnostics Press button: Sensors / measured values, maintenance

4 – No function assigned to button

5 Page back Press button: Previous page, if available

6 Page forward Press button: Next page, if available

7 Basic mask Press button: Return to the basic mask

22 053 25 07 • CL-P • en • 03/2012

 Description

Selection lists

Selection lists are offered for numeric inputs when

the values exist only in predetermined steps.
When you press a value in the list (1), the value is
displayed above the list (2). Press the "accept" (8)
button to select the value.

4
3

5
2

No. Symbol Function or significance

1 Press the list value to highlight it
2 The current or newly highlighted value is displayed with the preset unit of measure-
ment
3 Designation of the input value
4 Scroll bar for navigation in long lists
5 Close the selection list without changing the current value or making a selection

6 Highlight previous value from the list

7 Highlight next value from the list

8 accept highlighted value

053 25 07 • CL-P • en • 03/2012 23

Description

Numeric inputs
Numeric values can be entered. These are then
automatically checked for validity.

4 5
Roller speed limit

3
6
2

No. Symbol Function or significance

1 Numerical keypad for entering numerical values
2a (3.00 … 7.00) Permissible values for this input variable
(3.00 … 7.00)
2b The entered value is outside the admissible range (red): Accept (9) or abort (5) the
input
3 The current value and unit of measurement is displayed as selected
4 Designation of the input value
5 Close the input window without changing the current value or delete the entered fig-
ures and restore the old value
6 Delete the last figure

7 Scroll upwards through several list values

8 Scroll downwards through several list values

9 Check and accept the entered value

24 053 25 07 • CL-P • en • 03/2012

 Description

Messages

A message window is superimposed on the current

mask. New inputs can only be made once the win-
dow has been closed. There are four types of mes-
sage, all of which are described in the following.
The structure of fault messages and how to handle
them is described in the chapter Faults.

Symbol Message type Explanation Operator action

Wait This message is only shown briefly and disap- Wait

pears automatically. No inputs are required
whilst the message is active.

Prompt Confirm or reject the action to be carried out Yes No

(e.g. delete data).

Caution An important message is displayed and must be Confirm

confirmed by the operator.

Cancel The aborting of an action must be confirmed by Confirm

the operator.

Example of a prompt:

Delete data?

053 25 07 • CL-P • en • 03/2012 25

Description

Control cabinet
The pre-cleaner's controller is fitted in the control
cabinet at the rear of the machine.
The doors (1) of the control cabinet can only be
opened with a special key.
The following modules are fastened to the mount-
ing plate in the control cabinet (1):
– KSZ5
– DEA 2
The service key switch is also installed in the con-
trol cabinet. You will find further information on the
service key switch in the chapter Maintenance
starting on page 58.

26 053 25 07 • CL-P • en • 03/2012

 Operation

Operation
In this chapter you will be given an overview of the
operating elements and an introduction to the func-
tion and how to use the operating unit. All activities
performed during normal operation mode, e.g.
switching the machine on and off and checking the
operating status are described in this chapter.
Settings and changes on the machine which go
beyond the requirements of everyday normal oper-
ation are described in both the following chapters
Control settings and Machine settings starting on
page 45.
You must be familiar with the following operating
elements and how to operate them in order to oper-
ate the machine.
Preparing for operation
Initial commissioning
The initial commissioning of the machine and con-
figuration of all operating parameters is performed
by the Trützschler after-sales service department
directly after assembly/installation.
Switching on the machine
DANGER
Possible injuries!
Before operation, make sure that all
operational safety devices are fully func-
tional and that all regulations for safety
and the prevention of accidents are being
observed.
You can only switch on the machine if no fault has
occurred. Information on faults and how to remedy
them can be found in chapter Faults, starting on
page 47.
1. If necessary, switch on the higher-level instal-
lation control unit and the power supply to the
machine.
2. If necessary, remove the padlock from the
master switch.
3. Turn the master switch to the ON position.

Daily preparations for operation

Make sure that all the requirements for safe and
fault-free operation have been fulfilled before
switching on the machine.

DANGER
Possible injuries!
Before operation, make sure that all
operational safety devices are fully func- The voltage supply is switched on. The control unit
tional and that all regulations for safety is initialised. The LEDs above the keys all flash at
and the prevention of accidents are being the same time.
observed. 4. Observe the display and LEDs on the operat-
– Carry out a visual spot check of the entire ing unit.
machine.
– Close all doors, maintenance flaps and sheet-
metal casings.
– Remove all soiling such as oil and grease res-
idue.
– If necessary, replace faulty or damaged parts
with original Trützschler replacement parts.

053 25 07 • CL-P • en • 03/2012 27

Operation

Preparing and starting the machine

The computer starts up and the display screen
switches the basic mask. When the message
"Machine ready" appears, you can start the drives.
Machine ready
1 2
1. Drives to be switched on.

6
The machine's service flaps are not locked. The fol- 3
lowing message appears:
Drives starting 5
4
and then:
Automatic mode

You can read the most important operating data Power BAE 6

from the basic mask:

No. Meaning
1 Speed of the dust cage
2 Speed of the condenser fan
3 Speed of the second opening roll
4 Suction pressure in the waste line
5 Speed of the first opening roll
6 Material suction volume flow

28 053 25 07 • CL-P • en • 03/2012

 Operation

Operation
During normal operation you must ensure that the
machine works fault-free and efficiently. To do so
you must carry out the following basic tasks:
– Observe operating data
– Reacting to fault messages
– Check the material compartment and air ducts
through the inspection window for material
build-up and if necessary, remove the material
build-up.

Notes
The inspection window to the material
compartment is accessible during opera-
tion through the maintenance doors on
the right-hand side of the machine.
Proceed as follows if you find soiling or build-up of
material residue:
1. Switch off the drives and wait till the drives
have come to a full standstill.
2. Clean the machine as described in chapter
Maintenance which starts on page 57.
3. Switch off the drives.

053 25 07 • CL-P • en • 03/2012 29

Operation

Reacting to fault messages

In the event of a fault, the machine is switched off
1
automatically. In addition, the red "fault" symbol (1)
appears in the upper row of keys and a fault mes-
sage window is displayed. Proceed as follows in
the event of any faults:
E0385 Memory error
Note
When a fault has occurred, symbol (2)
appears in grey and you cannot acknowl-
edge the fault. When the fault has been
remedied, the symbol changes to red and
the fault can then be acknowledged.
1. With the help of the fault message, localise
and remedy the fault.
2. Acknowledge the fault with
button (2).
3. Re-start the machine.
2

The detailed description of faults and measures for

remedying them can be found in chapter Faults,
starting on page 47. You will find explanations on
further information texts and status messages in
the display.

Switching off the drives

DANGER
Risk of serious injuries from rotating parts
of the drives!
Only open the maintenance doors and Automatic mode
flaps when all the drives have come to a
complete standstill.
1. Switch off the machine.

The drives are switched off. You cannot open the

maintenance doors and flaps until the message
Machine ready appears.

Power BAE 6

30 053 25 07 • CL-P • en • 03/2012

 Operation

Switching off the machine

Switch the machine off if it is not going to be used
for a longer period or for maintenance work. In
emergencies or in the event of faults, the machine
is automatically switched off by the machine control
unit or the higher-level installation control unit.
1. Switch off the drives.
To disconnect the machine from the power supply,
proceed as follows:
2. Turn the master switch to the OFF position.

DANGER
Risk of serious injuries from rotating parts
of the drives!
Secure the master switch to prevent it
from being switched back on without
authorisation.
3. Use a padlock to secure the master switch
from being switched back on.

Servicing and maintenance

Various types of maintenance work are necessary
throughout the entire operational life of the
machine. These help to assess the condition of the
machine and detect and eradicate any defects and
generally keep the machine in an ideal condition.
The necessary measures and tasks for mainte-
nance and repair are described in chapter Mainte-
nance, starting on page 57.
All other work must only ever be carried out by the
Trützschler after-sales service staff.

053 25 07 • CL-P • en • 03/2012 31

Operation

32 053 25 07 • CL-P • en • 03/2012

 Control settings

Control settings
This chapter describes all settings for controlling Basic settings
the machine.
The basic settings include functions which you can
Caution call up using buttons in the basic mask:
Risk of damage to assembly groups and – Code levels,
production faults!
Incorrect settings can disturb the produc- – Language,
tion process and lead to extensive – Lot management and
repairs and adjustments.
Settings must be changed by properly – Date and time
trained, specialist personnel only.
The order of the settings is determined by the order
of the menu commands in the touch screen menus.
In the chapter Description you will find basic infor-
mation on the touch screen and how to operate it.
If you are looking for a particular function, refer to
the Index at the end of these operating instructions.
The starting point for each of the sequences of but-
tons described is the basic mask. The functions are
displayed as symbols on the buttons. Menus, menu
commands and window names on the touch
screen are shown in bold type.
Example:

1. Select the basic mask.

2. Select Diagnostics / Statis-

tic.

053 25 07 • CL-P • en • 03/2012 33

Control settings

Code levels
The machine settings are protected by different Changing the code
code levels. Basic settings can only be changed if In code level 2, you can change codes 1 and 2.
you switch the machine to code level 1 or 2. You In code level 1 you can only change code 1.
either enter the respective code when prompted or
you switch the code level as described in the fol- 1. Select code from code level 1
lowing. or 2.

Note 2. Enter code 1 or 2 again.

This symbol appears if the incorrect code
has been entered. 3. Accept, enter new code once
more.
Selecting standard level
At standard level you can only view most of the val- 4. Accept.
ues and carry out "normal" operation of the
machine. The machine is locked to prevent
changes to settings. Resetting codes to default values
If a code has been changed unintentionally or is not
1. Select code from code level 1
known, you can reset both codes to the default val-
or 2.
ues. The default value for code level 1 is "1234".
2. Activate standard level. The default value for code level 2 is "12345".
If the machine is already in the standard level,
begin with step 3.
Code level 1
1. Select code input from code
If you want to change values, e.g. the lot data, you
level 1 or 2.
must first enable code level 1 using a 4 digit code.

1. Enter four-digit code in stan-

dard level. 2. Activate standard level.

2. Accept.
3. Select standard level code
input and enter reset code
753951.
Code level 2
If you want to make basic machine settings, you 4. Confirm prompt Reset codes.
must first enable code level 2 using the five digit
code. 5. Accept.
1. Enter five-digit code in stan-
dard level.
2. Accept.

34 053 25 07 • CL-P • en • 03/2012

 Control settings

Language
You can select the basic settings for messages and
display values on the touch screen here.

Selecting language
There are different languages available for the
messages on the operating unit: Select one of the
available languages as follows:

1. Select Language selection

2. Select the language.

3. Accept.

Log book

1 2 3 4 5

Logbook 6

1 Date Calling up the log book

2 Time Call up the log book from the top row on the basic
screen using the "Machine status 1" button:
3 Description of the event
4. Select Logbook.
4 Press button: Update the log book
5 Press button: switch between
– show fault messages only or 5. Show fault messages only.
– show all events
6 Warning number, fault number, frequency of 6. Show all events.
event
7 Scroll bar for navigating in the log book 7. Update the log book.

053 25 07 • CL-P • en • 03/2012 35

Control settings

Machine operation is recorded in the log book.

These are events which the machine reports and
all operator interventions. Changes to settings are
also partly recorded in the log book. You can either
list all events or fault messages only. The log book
is not automatically updated whilst being displayed.

Information
This screen gives information about the machine.
The programme version and its release date are
displayed below the machine designation. Information
The time and quantity produced in automatic mode
are shown after the operating hours counter (time
connected to the mains). The final thing you see is
the current temperature in the control cabinet.
The following page contains further functions for
the Trützschler after-sales service department.
1. Select Information.

This menu page gives information about the

machine:
– The programme version and its date are dis-
played on the right below the machine desig-
nation.
– The machine's serial number is displayed
underneath that.
– The production time is shown next to the
operating hours counter (time connected to
the mains).
Trützschler Service
– The final thing you see is the current tempera-
ture in the control cabinet.

2. Scroll to the page Trützschler

Service.

This information is for servicing work which is car-

ried out by Trützschler after sales service staff.

36 053 25 07 • CL-P • en • 03/2012


Lot management
Lot management
1
7 5
The data which leads to optimum production data
and quality data for a particular type of material are
stored in a lot. The lot data concerns the mechani-
cal and electrical machine settings and the func-
tions of the machine control system (software).
You can only change lot data in an active lot.
If lot data becomes invalid (e.g. due to a pro-
gramme change), it is marked in magenta and can
now only be deleted.
053 25 07 • CL-P • en • 03/2012
Control settings
2
1 Selected lot (white) with following options:
Copy (2), paste (3), delete (4), activate or
change lot (5)
If you press the selected lot (1) once more,
the data from this lot will be displayed
2 Copy selected lot to intermediate memory
3 Fill or overwrite selected lot slot with the data
from the intermediate memory
4 Delete the date and data of the selected lot
5 Change of lot: activate selected lot
6 Active lot (yellow), contains the current lot
data of the machine (working memory)
A date next to a lot symbol indicates that the
lot contains data. The date itself shows the
day of the last change to this lot data.
7 Free lot ---
37
Control settings

Displaying a lot Creating a new lot

Select the lot data from the top row of the basic A new lot can be created (copied) using an old lot
screen using the "Lot data" button. You can display as the basis; there are no empty lots. Select a suit-
the data from any lot. able lot as the template:

1. Select Lot data from the title 1. Select Lot data.

bar.
2. Select a lot. 2. Select a lot as a template.

3. Display an overview of lot 3. Copy the lot data.

data.
4. Select a target for the new lot.
This is where you find the setpoints for the active lot
as well as the set limiting values which have been
defined for this lot. 5. Paste the lot data to the
selected lot memory.
If you wish to change the lot data, you must first
select the lot as the active lot ("Change of lot"). 6. Confirm the prompt Overwrite
You can then change the data. data? as necessary.

Selecting a lot 7. Accept.

If you wish to use an existing lot, proceed as fol-
lows:
Deleting a lot
1. Select Lot data. Use this function to delete the marked lot and its lot
data. The active lot cannot be deleted.
2. Highlight the desired lot.
1. Select Lot data.

3. Accept.
2. Select the lot to be deleted.

The name of the selected lot is displayed along 3. Delete the lot.
with the coloured lot symbol in the top right of the
basic mask. 4. Confirm the prompt Delete
data?.

38 053 25 07 • CL-P • en • 03/2012

 Control settings

Programme change / programme version

Existing lot data which is not compatible with the
new software may become invalid when updating
the control software. Display and make a note of all
important data in the lot data before a programme
change. If you have a connection to an external PC
or printer, you can output the data by pressing the
printer symbol on the touch screen.
You must create this lot data again.

Date and time

The date and time affects functions such as the
"log book" or "shift data". If you are using external
shift management, you cannot change the date
and time here.

1. Select Date and time.

2. Use the arrow keys to set the

day, month and year and
hours, minutes and seconds.

3. Accept.

053 25 07 • CL-P • en • 03/2012 39

Control settings

Machine settings
In the "Machine settings" section you set the Speed limit of BR-CO dust cage
speeds of opening rolls, the fan drive and the dust With this setting you set the maximum speed of the
cage. dust cage

Roller speed limit 1. Select Settings / program-

With this setting you set the maximum speed of the ming.
opening rolls. 2. Select Machine settings.
1. Select Settings / program-
ming. 3. Select Speed limit of BR-CO
2. Select Machine settings. dust cage and enter the max-
imum speed.
4. Accept.
3. Select Roller speed limit and
enter the maximum speed.
4. Accept.

Speed limit BR-CO fan

With this setting you set the maximum speed of the
condenser fan.

1. Select Settings / program-

ming.
2. Select Machine settings.

3. Select Speed limit BR-CO

fan and enter the maximum
speed.
4. Accept.

40 053 25 07 • CL-P • en • 03/2012

 Control settings

Lot data
The lot data encompasses production parameters Waste duct maximum pressure
for the machine which you can combine to suit the This is where you can set the upper limit value for
material and the plant which you are using. On suction pressure in the waste duct. If the value
delivery of the machine, a default data set which drops exceeds this limit, a fault message is dis-
serves as the basis for further lot data is already played.
stored in the system.
1. Select Settings / program-
You always establish the lot data in a series of trials
ming.
depending on the machine configuration and the
material to be processed. Once you have achieved 2. Select Lot data.
a satisfying result, you can save the parameters
you have established as a lot under an instantly
recognisable name and call them up as required. 3. Select Waste duct maximum
pressure and enter the maxi-
Waste duct minimum pressure mum pressure.
This is where you can set the lower limit value for 4. Accept.
suction pressure in the waste duct. If the value
drops below this limit, a fault message is displayed.

1. Select Settings / program-

ming.
2. Select Lot data.

3. Select Waste duct minimum

pressure and enter the mini-
mum pressure.
4. Accept.

053 25 07 • CL-P • en • 03/2012 41

Control settings

Communication Service functions

Using this menu item you select via which inter- Unlike the "Service" mode which can only be called
faces the machine can communicate with other up with the key-switch in the control cabinet, func-
systems. tions are included here which can be called up
directly.
Activating communication interfaces
The card has the following data interfaces: Test door locking
You can use this function to check whether all elec-
– The TST ("Trützschler Service Tool") gives
trical door locking systems are working properly.
the Trützschler after sales service staff insight
The function is only available when the drives are
into all system areas and supports diagnos-
at a standstill.
tics and trouble-shooting.
– The individual machines of an installation are 1. Select Settings / program-
controlled via the TKN (Trützschler Kommuni- ming.
kationsnetzwerk (Trützschler communication 2. Select Service functions.
network)) using a central computer.

1. Select Settings / program- 3. Select Test door locking.

ming.
2. Select Communication.
The button Test door locking is highlighted in yel-
low. The display switches depending on the test
3. Activate the TST. result:

When connected, a green field green: Door locking mechanisms ready

is displayed on the right. for operation
or
Deactivate TST; the green
field is extinguished. red: Door locking systems not ready for
operation

– Repeat the steps described above for the

TKN if required for the given system environ- 4. End the test and close the
ment. window Test door locking.
– Enter the network address for the TKN net-
work. 5. If necessary, inform the Trützschler after-
sales service department.
Once the connection has been established,
a green field is displayed to the right of the TST
button.

42 053 25 07 • CL-P • en • 03/2012

 Control settings

Diagnostics / Statistic

Sensors / Measured values Maintenance

You can use this menu item to display the mea- In this dialogue window the components are listed
sured values on the machine. whose maintenance intervals are monitored by the
machine controller. The second column lists the set
1. Select Diagnostics / Statis- maintenance intervals. The third column lists the
tic. production times currently reached. Once the
2. Select Sensors / Measured respective maintenance interval has elapsed,
values. a fault message appears which makes reference to
the maintenance.

The current values for the suction pressure and Caution

volume flow of the material suction device are dis- Risk of malfunctions or damage to
played. machine!
You must only reset the respective run-
time counters if you have carried out the
maintenance work described in the chap-
ter Maintenance.

1. Select Diagnostics / Statis-

tic.
2. Select Maintenance.

3. Select the desired interval.

A security prompt Maintenance accomplished?

is displayed.

4. Confirm prompt
or
cancel without changes.

5. Accept.

053 25 07 • CL-P • en • 03/2012 43

Control settings

44 053 25 07 • CL-P • en • 03/2012

 Mechanical settings

Mechanical settings
This chapter describes all the manual settings
which can be made on the machine's mechanical
components.

DANGER
Risk of serious crushing!
If covers and flaps are open long hair or
open clothing may become entangled in
the rotating rolls or the combing system.
Wear close-fitting clothing and keep it
buttoned and tucked in at all times.
Staff with long hair must wear a hair net.
Do not touch the rolls with your hand!

Caution
Unauthorised changes to the machine
configuration can cause to the machine
and malfunctions!
Only carry out the settings described in
the following. If you have any doubts,
contact the Trützschler after-sales ser-
vice department.

Setting the material suction

The suction pressure for the material is determined
by the fan of the downstream machine: 1
– In order to increase the suction pressure,
close the fresh air inlet screens (1).
– In order to reduce the suction pressure, open
the fresh air inlet screens (1).

053 25 07 • CL-P • en • 03/2012 45

Mechanical settings

Setting the cleaning efficiency

In order to adjust the machine to the desired qual-
ity, you can set the alignment and the position of the
grids. To do so you have to determine the exact 1
setting by trial and error.
To change the setting, proceed as follows:
1. Open the maintenance door on the right-hand
side of the machine.
The setting levers for the grids (1) are attached
underneath the grids.

2. Undo the star knob (2).

3
– To reduce the cleaning efficiency, turn the
setting lever (4) clockwise. 2
– To increase the cleaning efficiency, turn the
setting lever (4) anti-clockwise.
You can read the current setting from the dial (3).
The higher the value, the higher the cleaning effi- 4
ciency.
3. Firmly tighten the star knob.
4. Make the desired setting on the second grid.
5. Switch on the machine and check the quality.
6. If necessary, repeat the setting.

46 053 25 07 • CL-P • en • 03/2012

 Faults

Faults
When a fault occurs, the red "Fault" symbol (1) is
displayed in the upper row of buttons. A fault mes- 1
sage is shown and the material transport is
stopped.
All faults are recorded in the log book. Faults take
priority over warnings. E0385 Memory error

Basic procedure in the event of a fault

In the event of a fault, proceed as follows:

DANGER
Risk of serious injuries from impacts and
crushing!
Before switching on the machine, make
sure that there is nobody in the working
area.
1. With the help of the fault message, localise
and remedy the fault. 2
Whilst the fault is not cleared, the Acknowledge
fault button (2) is shown in grey. You cannot
acknowledge/cancel the fault. When the cause of
the fault has been remedied, the symbol changes
to red and the fault can then be acknowledged.
If a fault message is displayed and a button outside
the fault message window is pressed, the fault
message will disappear. However, the fault has not
yet been acknowledged.
In this case, press the Select fault button in the
upper row of buttons again. The fault message is
displayed again. You can then eradicate the fault
and confirm by pressing the Acknowledge fault
button.
2. Acknowledge the fault by
pressing the button (red).

3. If necessary, remedy further faults and

acknowledge and cancel the fault messages.
The machine is ready to be started up.

4. Re-start the machine.

053 25 07 • CL-P • en • 03/2012 47

Faults

Fault table
If a fault occurs during machine operation that you DANGER
cannot remedy using the fault table below, please Material damages to the machine and
contact the Trützschler after-sales service depart- personal injuries may be caused by
ment. improper work!
Have parts replaced and work on the
The following table provides you with an overview
electrics performed by specialist staff
of possible fault messages for the machine. It is
only.
sorted by the No. of the fault message in ascending
Only ever carry out modifications to the
order.
machine or its components after having
For every fault message there is a short description consulted with the Trützschler after-sales
of the possible cause and you are given instruc- service staff.
tions on how you are advised to proceed.

No. Fault message Cause or significance Remedy

311 Motor protection switch The motor protection switch for Have the motor checked by spe-
has tripped the opening rolls, the fan or the cialist personnel.
dust cage has been triggered by
an overload or a short circuit.

380 Safety circuit is interrupted The safety circuit is interrupted Press the limit switch and check
and no feedback was detected the corresponding LED display on
from the limit switch terminals. the plug-in boards.
Have qualified specialist staff
check the plug connections and
the terminal connections.

381 Safety module The safety chain is broken. A Have the safety circuit checked
limit switch or a motor protection by specialist personnel.
switch has been activated.

382 Fuse monitoring One or more circuit breakers Check all the devices which are
have tripped. connected to the circuit breakers.
Switch all circuit breakers back
on.

385 Memory error Changes have been made on
the machine. The control pro-
gram has been changed or a
genuine memory error has
occurred.
If the error occurs again after
switching back on, check the bat-
tery on the ZPB5 and acknowl-
edge/cancel the fault. If the error
endures, inform the Trützschler
after-sales service department.

48 053 25 07 • CL-P • en • 03/2012

 Faults

No. Fault message Cause or significance Remedy

386 EEprom memory error The EEPROM is defective or the Acknowledge the fault. If the error
control program has been endures, inform the Trützschler
replaced. after-sales service department.

404 Machine control The temperature in the Have the modules of the TMS-2
temperature Trützschler TMS-2 microproces- modules checked for soling and
sor controller has reached a crit- cleaned.
ical value.

406 TKN network faulted The TKN network cable is defec- Check the network cable and
tive. replace it as necessary.

The TKN and the machine are Have the connection between the
not communicating. TKN and the machine checked by
specialist staff.

1029 _ maintenance flap The maintenance flap is open. Close the maintenance flap.

1032 Right hand doors _ The right-hand door is open. Close the maintenance door.

1033 Left hand doors _ The left-hand door is open. Close the maintenance door.

1112 Roller _ did not start The speed of the opening roll is
still below 50 rpm 3 seconds
after switching on.
Check the belt tension on the roll
drive.
Have the roll's drive checked by
specialist staff.

1113 Roller _ speed not attained The opening roll has not
reached the set lower speed
limit 40 seconds after switching
on.
Check the belt tension on the roll
drive.
Have the roll's drive checked by
specialist staff.

1114 Roller _ speed below The speed of the opening roll Check the belt tension on the roll
nominal value has dropped below the set limit. drive.
Have the roll's drive checked by
specialist staff.

053 25 07 • CL-P • en • 03/2012 49

Faults

No. Fault message Cause or significance Remedy

1115 RIK _ impulses not active The RIK relay interface module Have the RIK relay-interface
is faulty. module checked by qualified spe-
cialist personnel.
Inform the Trützschler after-sales
service department.

One of the sensors on the Check the sensors.

BR-CO or on the CL-P is faulty.
Inform the Trützschler after-sales
service department.

1169 Pressure monitoring The pressure for the waste suc- Check the settings and adjust
waste _ tion has exceeded the set limit them as necessary.
value.
Remove any material blockages
from the waste suction system.

1266 Safety circuit fault in Emergency stop circuit in the Unlock or cancel emergency stop
installation installation control unit is broken. switch or respective other device
in the installation control unit.

1379 _ dust cage has not started The speed of the dust cage is Check the belt tension on the dust
still below 50 rpm 3 seconds cage drive.
after switching on.
Have the dust cage's drive
checked by specialist staff.

1380 _ dust cage speed not The dust cage has not reached Check the belt tension on the dust
reached the set lower speed limit 40 sec- cage drive.
onds after switching on.
Have the dust cage's drive
checked by specialist staff.

1381 _ dust cage below nominal The speed of the dust cage has Check the belt tension on the dust
speed dropped below the set limit. cage drive.
Have the dust cage's drive
checked by specialist staff.

50 053 25 07 • CL-P • en • 03/2012


No. Fault message Cause or significance
1382 _ fan has not started The speed of the fan is still
below 50 rpm 3 seconds after
switching on.
1383 _ fan speed not reached The fan not reached the set
lower speed limit 40 seconds
after switching on.
1384 _ fan speed below nominal The speed of the fan has
speed dropped below the set limit.
1469 Front flap _ The machine's front mainte-
nance flap is open.
1470 Rear flap _ The machine's rear mainte-
nance flap is open.
2202 I/O-module faulted The I/O module is not recog-
nised by the main module or the
I/O module has no power sup-
ply.
The I/O module DEA2 or KSZ5
central control unit is faulty.
053 25 07 • CL-P • en • 03/2012
Faults
Remedy
Check the belt tension on the dust
cage drive.
Have the fan's drive checked by
specialist staff.
Check the belt tension on the fan
drive.
Have the fan's drive checked by
specialist staff.
Check the belt tension on the fan
drive.
Have the fan's drive checked by
specialist staff.
Close the maintenance flap.
Close the maintenance flap.
Check the switch and the connec-
tion line between the main mod-
ule and the I/O module.
Check DEA2 I/O module and
KSZ5 central control unit.
Have specialist staff replace the
miniature controller.
51
Faults

LED displays in the control cabinet

During troubleshooting, the LEDs of the electronic
modules in the control cabinet can give additional
information.
In general red LEDs indicate a fault. Green LEDs
normally indicate the normal operation of a compo-
nent.

1 2

Modules
The KSZ5 central control unit (1) is installed on
the mounting plate in the control cabinet. The
DEA2 I/O module (2) is installed on the control unit.

52 053 25 07 • CL-P • en • 03/2012

 Faults

Central control unit KSZ5

The KSZ5 central control unit is the basic module
for machine control.
L1 Run – KSZ5 in operation
L2 Err – KSZ5 error

Z0 Roll 1 pulse
Z1 Roll 2 pulse
Z2 –
Z3 –
Z4 –
Z5 Fan pulse
Z6 Dust cage pulse
Z7 –

Z8 –
14 Z9 –
KSZ5

13
12
11
Z10 –
10
9 Z11 –
8
Z12 –
7
6
Z13 –
5
4
Z14 –
3
2
1

L2 L1

053 25 07 • CL-P • en • 03/2012 53

Faults

DEA2 input and output module

The DEA2 input and output module is fitted on the
KSZ5 central control unit.
FAIL Fault on the DEA2 module

E10.7
E6.0 Emergency stop safety circuit, no fault
E10.6 E6.1 LC-I safety circuit, no fault
E10.5
E10.4 E6.2 Safety device OK
A1.0 E10.3
A1.1 E10.2 E6.3 –
E10.1
A1.2 E10.0 E6.4 –
A1.3
A2.0
E9.7 E6.5 Service On
E9.6
A2.1 E9.5 E6.6 RIK CL-P pulses OK
A2.2 E9.4
A2.3 E9.3 E6.7 Drives stand still
E9.2
A3.0 E9.1
A3.1 E9.0
A3.2 E8.7
E7.0 Service Off
A3.3 E8.6 E7.1 Motor protection switch OK
A3.4 E8.5
A3.5
E8.4 E7.2 Safety monitoring OK
E8.3
A3.6 E8.2 E7.3 Rear flap
A3.7 E8.1
E8.0 E7.4 Left doors
A4.0
A4.1
E7.7 E7.5 Front flap
A4.2 E7.6
A4.3 E7.5 E7.6 –
E7.4
A4.4
A4.5 E7.3 E7.7 –
A4.6 E7.2
E7.1
DEA2

A4.7
E7.0
A5.0
E6.7
E8.0 –
A5.1
A5.2
E6.6 E8.1 –
E6.5
A5.3
A5.4
E6.4 E8.2 –
E6.3
A5.5
A5.6
E6.2 E8.3 –
E6.1
A5.7 E6.0 E8.4 –
E8.5 –
E8.6 –
E8.7 –

E9.0 –
E9.1 –
E9.2 –
E9.3 –
E9.4 –
E9.5 –
E9.6 –
E9.7 –

E10.0 BR-CO RIK pulses OK

E10.1 BR-CO maintenance flap
E10.2 BR-CO safety switch, left
E10.3 BR-CO safety switch, right
E10.4 –
E10.5 Machine not off (from LC-I)
E10.6 Machine on (from LC-I)
E10.7 Bucket wheel lock On (from LC-I)

54 053 25 07 • CL-P • en • 03/2012

 Faults

A1.0 Fan
A1.1 Dust cage
E10.7
A1.2 –
E10.6 A1.3 Roll drive
E10.5
E10.4
A1.0 E10.3
A1.1 E10.2 A2.0 Roll drive, delta contactor / start contactor
E10.1
A1.2 E10.0 A2.1 Bucket wheel lock
A1.3
A2.0
E9.7 A2.2 –
E9.6
A2.1 E9.5 A2.3 Machine ready for operation to LC-I
A2.2 E9.4
A2.3 E9.3
E9.2
A3.0 E9.1 A3.0 –
A3.1 E9.0
A3.2 E8.7
A3.1 –
A3.3 E8.6 A3.2 –
A3.4 E8.5
A3.5
E8.4 A3.3 –
E8.3
A3.6 E8.2 A3.4 –
A3.7 E8.1
E8.0 A3.5 –
A4.0
A4.1
E7.7 A3.6 –
A4.2 E7.6
A4.3 E7.5 A3.7 –
A4.4 E7.4
A4.5 E7.3
E7.2
A4.6
E7.1 A4.0 Emergency stop acknowledgement
DEA2

A4.7
E7.0
A5.0
E6.7
A4.1 Drives on, safety locking devices closing
A5.1
A5.2
E6.6 A4.2 –
E6.5
A5.3
A5.4
E6.4 A4.3 –
E6.3
A5.5
A5.6
E6.2 A4.4 –
E6.1
A5.7 E6.0 A4.5 –
A4.6 –
A4.7 –

A5.0 –
A5.1 –
A5.2 –
A5.3 –
A5.4 –
A5.5 –
A5.6 –
A5.7 –

053 25 07 • CL-P • en • 03/2012 55

Faults

56 053 25 07 • CL-P • en • 03/2012

 Maintenance

Maintenance
This chapter describes measures which keep the
machine it proper condition or restore it to proper
condition. Maintenance includes all servicing,
maintenance and repair work described in these
operating instructions.
As owner of the machine, make sure that only qual-
ified personnel are employed to carry out mainte-
nance work on the machine.
Install and activate all protective and safety instal-
lations correctly after all maintenance work.
Work on the machine going beyond the operations
described in the chapter Maintenance may only be
carried out by Trützschler after-sales service per-
sonnel or by persons authorised by Trützschler.
General guidelines
The machine must be maintained regularly by qual-
ified staff so that it will work properly and economi-
cally continuously when subject to the demands
which are to be expected.
The owner of the machine must determine the nec-
essary measures for maintenance and servicing
based on the operating conditions and experience
and set them out in sets of operating instructions.
The owner must carry out all the necessary mea-
sures for servicing and maintenance in accordance
with the national regulations of the location in which
the machine is installed.

DANGER
Risk of serious injuries from impacts and
crushing!
Secure the machine against unauthor-
ised access, e.g. using locking devices.
Make sure that nobody operates the
machine whilst people are situated in the
danger areas, carrying out work there.
Erect warning signs everywhere where
dangers may arise.

DANGER
Risk of serious crushing!
When the maintenance doors are open,
long hair or loose items of clothing may
become entangled in the rotating rolls.
Wear close-fitting clothing and keep it
buttoned and tucked in at all times.
Staff with long hair must wear a hair net.
Do not touch the drive elements with your
hand.

DANGER
Risk of injury from modification work on
the machine!
Only carry out modifications to the
machine or its components after consul-
tation with Trützschler after-sales ser-
vice.
Otherwise major malfunctions may occur
causing serious personal injury and irrep-
arable machine damage.

053 25 07 • CL-P • en • 03/2012 57

Maintenance

Service mode
In service mode you can check the function and
direction of rotation of the following drives:
– Dust cage drive on the BR-COI
– Fan drive on the BR-COI
– Opening roll drive
– Bucket wheel lock drive
You can only switch on service mode with a special
service key. This service key switch is fitted in the
control cabinet (1).

DANGER
Risk of serious injuries from impacts and
crushing!
Make sure that the machine is not unin-
tentionally switched to service mode.
Block the danger area of the drive parts
to deny bystanders access.
1
The safety mechanisms do not function in service
mode. Service mode must therefore only be used
by specialist staff who have been specially trained
to do so. Make sure that no unauthorised person
gains access to the key for service mode. Other
people must not be allowed to enter the machine`s
danger area during service mode.

Switching on service mode

1. Switch off the machine.

2. Open the control cabinet (1).

3. Set the key-operated switch to 1
(service mode) position.
The symbol for service mode (a hand on a blue
background) appears on the top row of the touch
screen. 


58 053 25 07 • CL-P • en • 03/2012

 Maintenance

You can switch the selected drives on and off using

the start and stop keys as described. You can also
use the jog key in order to just quickly test the com-
ponents.
To end service mode you must switch the key
switch in the control cabinet back from I to 0.

Service mode
Motor test

A range of buttons featuring the symbols of the

respective motors are to be found touch screen dis-
play page Motor test. The buttons can show three
different statuses:

blue: drive available for selection

dark blue: drive is selected

yellow: drive is in operation

053 25 07 • CL-P • en • 03/2012 59

Maintenance

Carrying out tests

1. Select the dust cage.

2. Start motor and check func- Service mode

Motor test BR-CO dust cage
tion and sense of direction.
3. Switch off the motor.

The buttons are assigned to the drives as follows:

M115 BR-CO dust cage drive
M116 BR-CO fan drive
M122 CL-P roll drive
M121 Bucket wheel rock drive Power BAE 6

4. Carry out the checks for the other drives in the

same way.

Switching off service mode

1. Set the key-operated switch to 0
(normal mode) position.
2. Close the control cabinet.
The machine is in normal mode.

60 053 25 07 • CL-P • en • 03/2012

 Maintenance

Maintenance
DANGER
Risk of serious injuries from impacts and
crushing!
Make sure that nobody can switch on the
machine without authorisation whilst
maintenance is being performed.

Maintenance and servicing schedule

The maintenance schedule gives you a quick over-
view of the maintenance and cleaning work which
must be carried out regularly on the machine.
This work maintains the safety and optimum oper-
ational condition of the machine and it is imperative
that it is carried out with the utmost care.

Notes
Directly after the maintenance and ser-
vicing schedule, individual tasks are
described in detail.
The description of maintenance and
servicing work to be carried out on the
BR-COI condenser is included in the
operating instructions for the BR-COI.
The following maintenance intervals can
be drastically reduced by the presence of
adhesive substances and a high level of
soiling in the material.

053 25 07 • CL-P • en • 03/2012 61

Maintenance

Maintenance schedule

1 2 3

7 6 5 4

Maintenance interval
No. Task in hours

170 700

4 Have the control cabinet cleaned by qualified specialist staff x

6 Clean the grids x

7 Clean the ventilation hoods on the motors x

1 Clean the side seals on the opening rolls and remove any build-up x
of fibres

2 Clean the drive belts and check the belt tension x

3 Clean the side seals on the maintenance flaps and remove any x
build-up of fibres

5 Clean the bucket wheel lock x

Check the condition of the stripper on the bucket wheel lock

– Clean the outside and inside of the machine frame x

Clean the material compartment

62 053 25 07 • CL-P • en • 03/2012

 Maintenance

Lubrication schedule
DANGER Caution
Possible injuries from slipping! Risk of damage to machine!
It is imperative that you remove any Only operate the machine with undam-
excess grease and clean the area after aged bearings.
lubricating. In case of running noises, switch off the
drives immediately.
Note Have damaged bearings replaced by
The types of lubricants to use are shown specialist staff.
on the type plates of the motors.

1 2

4 3

Maintenance interval in
Item Lubricant hours

4,000 40,000

1 Lubricate the bearings on the tension roller K2K-20 x

2 Lubricate the bearings on the opening rolls K2K-20 x

3 Lubricate the bearings on the bucket wheel K2K-20 x

lock roll

4 Drive motors and gear units are lubricated for – x

life

053 25 07 • CL-P • en • 03/2012 63

Maintenance

Lubricants

Lubricants with the specification K2K-20 are Caution

required to lubricate the machine in the proper
manner.
The following table contains various manufacturer
and product names to provide you with alternatives
when purchasing.
Machine elements may be subject to pre-
mature wear!
Do not mix mineral lubricants with syn-
thetic lubricants under any circum-
stances! Only use lubricants which are
specified in this table.

Company K2K-20

ARAL Aralub HL 2

BP Energrease LS 2

CASTROL Olista Longtime 2

Longtime PD 2
Spheerol MP 2

ESSO Unirex N 2

FUCHS Renolit GP 2

KLÜBER Centoplex 2

SHELL Shell Gadus S2 V100 2

SRS Wintershall Wiolub LFK 2

TEXACO Texaco Multifak MP 2

TOTAL Multis 2

Trützschler
Part number
50 kg 0 350 83 302 003
200 kg 0 350 83 302 000

64 053 25 07 • CL-P • en • 03/2012


Cleaning the machine
3 2
You must clean the following components of soiling
and build-up of fibres every week:
– Ventilation hoods on the motors
– Grids
You must clean the following components of soiling
and build-up of fibres every month:
– Machine housing
– Material component above the opening rolls
– Side felt seals on the opening rolls
– Side seals on the maintenance flaps
– Bucket wheel lock
– Drive belts
053 25 07 • CL-P • en • 03/2012
Maintenance
DANGER
Risk of serious injuries from impacts and
crushing!
Make sure that nobody can switch on the
machine without authorisation whilst
maintenance is being performed.
1. Switch off machine and secure it to prevent it
from being switched back on.
2. Open the maintenance doors (2, 3).
3. Open maintenance flaps (1).
4. Vacuum clean the machine.
5. Wipe off any stubborn soiling and fibre build-
up with a soft cloth.
6. Close all maintenance doors and flaps.
65
Maintenance

Cleaning the control cabinet

DANGER
Risk of serious injuries from electric
shock!
Make sure that all work in the control cab-
inet is carried out by specialist staff only.
1. Switch off the machine and secure it against
being switched back on without authorisation.
2. Open the control cabinet (1) with a special
key.
3. Have soiling in the control cabinet removed by
specialist staff.
4. Close the control cabinet.

Checking and setting belt tension

Checking the tension of belts
You have to check the condition and the tension of
the drive belts every month.

DANGER
Risk of serious injuries from impacts and
crushing!
Switch off the machine before all mainte-
nance work.
Do not start any maintenance work until
the machine has been disconnected from
the power supply and all drives have
come to a standstill.
Make sure that the machine cannot be
switched on without authorisation.

66 053 25 07 • CL-P • en • 03/2012

 Maintenance

To do so, proceed as follows:

1. Switch off the machine and secure it against
being switched back on without authorisation.
2. Open both the maintenance doors (1) on the
left-hand side of the machine with a special
key.

3. Hold the belt tension measuring device on the

belt in the position indicated by the arrows. 2
4. Carry out a check in accordance with the
operating instructions for the belt tension
measuring device.
The following frequencies must be shown, depend-
ing on the type of belt being used:
– Pos (2): Type XPB 2240: 50 Hz ±2 Hz
– Pos (3): Type XPB 3000: 25 Hz ±1 Hz
5. Repeat the check on the second belt.
6. If necessary, adjust the belt tension as 3
described in the following section.
7. Close the maintenance doors.

053 25 07 • CL-P • en • 03/2012 67

Maintenance

Setting belt tension

You can set the tension of the belt on the tension
roller (1) and on the drive of the opening rolls (2). 1

Tension roller
1. Unfasten the two screws (3) on both sides of
the tension roller bearing.
2. Unfasten the nuts (4).
– To increase the tension of the belt, shift the
tension roller (1) upwards.
– To reduce the tension of the belt, shift the
tension roller (1) downwards.
3. Firmly tighten the nuts (4).
4. Firmly fasten the two screws (3) on both sides
3 4
of the tension roller bearing.
5. Check the belt tension again.
6. If necessary, reset the belt tension.

68 053 25 07 • CL-P • en • 03/2012

 Maintenance

Motor suspension mount

In order to change the tension of the drive belt, you
have to unfasten the motor suspension mount (2)
and shift the motor.
7. Unfasten the four locking screws (2).
1
8. Unfasten two nuts (4) on both adjusting
screws (3).
9. To increase the tension of the V-belt (1), turn
both adjusting screws (3) evenly clockwise. 2
– To decrease the tension of the V-belt (1),
turn both adjusting screws (3) evenly anti-
clockwise. 3
– Firmly tighten two nuts on both adjusting
screws (4).
10. Firmly tighten the four locking screws (2).
4
11. Check the belt tension.
12. If necessary, reset the belt tension.
13. Close the maintenance doors.

053 25 07 • CL-P • en • 03/2012 69

Maintenance

Updating the control software

Caution!
Risk of loss of data! Take note of all
machine settings and machine configura-
tions, the lot data and the machine's net-
work address (if available) before install-
ing a new software version.
1
Proceed as follows to update the control software:
The machine is switched off.
1. Open the control cabinet and insert the Com-
pactFlash card (CF) as far as it will go in the

CompactFlash
slot (1) on the KSZ5 module.
The raised edge (2) on the CF card must be DEA2

on the right-hand side.

2. Switch on and start up the machine.

3V
The new control software is installed.
2
Note
The installation may take several min-
utes.

3. When the display screen shows the prompt

Ready: Remove CF-Card and restart con-
trol, remove the CF card and then
– press the Reset key on the VNB power
module (on TMS-2 only) or
– switch the master switch off and back on
again.
The system is then re-started with the updated
control software. In the case of machine control
systems without an operating unit, the green "Run"
LED underneath plug-in connector X12 lights up
constantly to indicate that the update has been
completed successfully.
4. Check all the setting values on the machine
and put the machine back into operation once
you have made sure they match the noted
data.

70 053 25 07 • CL-P • en • 03/2012

 Maintenance

Maintenance
General guidelines DANGER
Any faulty machine elements must not be used any Risk of personal injuries and serious
further and must be replaced by the same type of damage to the machine.
element. Repair and maintenance work which is
not described in this operating and ser-
This includes, for instance: vice manual, must only be carried out by
– Worn, cracked and bent screws or fastenings Trützschler after-sales service staff.

– Damaged nuts or threads

– Bent clamps or stirrups
– Damaged seals
– Damaged warning plates and danger signs
All the necessary measures for repairs and mainte-
nance must be carried out in accordance with the
national regulations of the location in which the
machine is installed.

Replacing the battery

DANGER
Risk of fatal electric shock! E6.0 A5.7
Only carry out work on the control unit
E6.1
A5.6
E6.2
A5.5
E6.3
when the machine is switched off and
A5.4
E6.4
A5.3
E6.5
A5.2
secured to prevent it from being switched E6.6
E6.7
A5.1

DEA2
A5.0
back on. E7.0
E7.1 A4.7
A4.6
E7.2
A4.5
1. Switch off machine and secure it to prevent it
E7.3
E7.4 A4.4
E7.5 A4.3

from being switched back on. E7.6

E7.7
A4.2
A4.1
A4.0
E8.0
2. Open the control cabinet. E8.1
E8.2
A3.7 1
A3.6
E8.3
A3.5
3. Unscrew the six screws (1) on the DEA2 mod- E8.4
E8.5 A3.4
E8.6 A3.3
ule. 14
KSZ5

E8.7 A3.2
13
E9.0 A3.1
12
E9.1 A3.0 11
E9.2 10
Caution E9.3
E9.4
A2.3
A2.2
9
8
Possible damage to the machine control E9.5
E9.6
A2.1
A2.0
7
unit! E9.7
E10.0
A1.3
A1.2
6
5
Carefully remove the DEA2 module from E10.1
E10.2 A1.1 4
3
E10.3 A1.0 2
the KSZ5 module. Do not use brute force. E10.4
E10.5
1

E10.6
4. Remove the DEA2 module (2) from the KSZ5 E10.7

module (3).

053 25 07 • CL-P • en • 03/2012 71

Maintenance

Caution
Possible control unit malfunctions! 2
1 3
Carefully take the battery out of the
holder. Do not bend the clamping spring
(1) up, otherwise the battery will no lon-
ger have a contact.
5. Carefully press the black plastic lug (3) out-
wards with a suitable tool so that the button
cell (2) is released from the bracket by the
force of the spring from below.

6. Remove the button cell from the bracket.

Caution
Possible damage to the machine's con-
trol unit!
Insert the battery carefully into the holder.
Do not use brute force.
Only use a type CR 2032 3V button cell
with 200 mAh.

7. Insert a new 3V button cell into the holder with

the labelled plus pole (5) facing upwards. 4 5
To do so, push the button cell under the
clamping spring (4) and push it down so that it
clicks into place underneath the plastic lug (6).

Note
To prevent the battery from discharging
prematurely, you can clamp a piece of
non-conductive material between the
battery and the clamping spring as insu-
lation when the control unit is not in use. 6
8. Place the DEA2 on the KSZ5 and fasten it
with the six screws.
9. Close the control cabinet.
10. Switch on the machine.

72 053 25 07 • CL-P • en • 03/2012

 Maintenance

Replacing the cut-out fuse

DANGER
Risk of fatal electric shock!
Only carry out work on the control unit
when the machine is switched off and
secured to prevent it from being switched
back on.
1. Switch off the machine (see page 31) and
secure it to prevent it from being switched
back on.
2. Open the control cabinet.

3. Open the screw fastening (1) on the defective

cut-out fuse.
4. Take the defective cut-out fuse out of the
holder.
5. Establish and eradicate the cause of the fault.
Caution
Possible damage to the control unit!
Only insert fuses of the appropriate type.
You must use different types of cut-out fuse
depending on the voltage:
– For operating voltage of 380 V ... 600 V: 35 A
fuse protection
– For operating voltage of 200 V ... 220 V: 63 A
fuse protection

053 25 07 • CL-P • en • 03/2012 73

Maintenance

6. Insert the new cut-out fuse of the appropriate

type in the holder.
7. Put on and firmly tighten the screw fastening.
8. Close the control cabinet.
9. Switch on the machine.
10. If the fuse blows again, switch off the
machine.
11. Have the control unit checked and the cause
of the fault eliminated by specialist staff.

74 053 25 07 • CL-P • en • 03/2012

 Appendix

Appendix

Technical data

Dimensions

1.590

4.250
ca. 2.400

2.120

981 1.485

3.528
2.780
1.300

1.900

053 25 07 • CL-P • en • 03/2012 75

Appendix

Weights
CL-P approximately 1,550 kg
Trunk approximately 225 kg
BR-CO approximately 580 kg
Total weight approximately 2,355 kg
Specific floor load approximately 8,188 N/m2
Surface pressure per base plate approximately 174 N/m2

Drive data

Opening roll drive 800 kg/h 1,000 kg/h

Type 3 phase alternating current

motor

Power P 7.5 kW 11 kW 1)

Speed n 1,465 rpm 1,470 rpm

1)
optional equipment

Bucket wheel lock drive AC gear motor

Power P 0.37 kW

Speed n 15 rpm

Total power 800 kg/h 1,000 kg/h

Continuous power consumption Pmax. 5.5 kW 8.0 kW

Installed power Pmax. 7.87 kW 11.37 kW

76 053 25 07 • CL-P • en • 03/2012

 Appendix

Production and air data

7.5 kW 11 kW

Suction air rate 2,000 m3/h 2,500 m3/h

+10 % +10 %

Maximum material feed rat 1,000 kg/h 1,200 kg/h

Maximum continuous production 800 kg/h 1,000 kg/h

Maximum material suction rate 1,000 kg/h 1,200 kg/h

Material suction operating pressure –260 Pa –400 Pa

Waste suction
Maximum waste quantity 50 kg/h (or higher when using recycling installations)
Suction air rate 1,200 m3/h +10 %
Operating pressure –530 Pa

053 25 07 • CL-P • en • 03/2012 77

Appendix

Options and additional equipment

– BR-WS maintenance scaffold
– BR-MC manual change box for waste sam-
pling
– Drive motor 11 kW

Abbreviations
KSZ5 Central control unit 5, machine controller
IFW Internal frame width
RIK "Relais-Interface-Karte" =
relay interface board
TKN Trützschler Kommunikations Netzwerk =
Trützschler communication network

ISO 4871 noise emission values

Operating status without material, maximum speed 645 rpm

Constructional properties Working width 1300 mm

2 x fully spiked rolls, D=600 mm

Effective perceived emission sound pressure level

66
LpA [dB(A)]

Danger for the emission sound pressure level

4
KpA [dB(A)]

The values have been determined in line with noise test standard DIN EN ISO 9902 with reference to basic
standard DIN EN ISO 11204 The sum of the measured noise emission value and the corresponding dan-
ger represents the upper limit which may occur during measurements

78 053 25 07 • CL-P • en • 03/2012

 Appendix

Expendable parts
The intervals for replacement are based on stan- Note
dard materials and proper use of the machine. You will find further expendable parts in
Depending on the material used and the ambient the catalogue of replacement parts.
conditions, the actual wear and tear may differ.
The table is sorted by the frequency of replacement
and in ascending alphabetical order.

Frequency of
Designation Part No. Quantity
replacement

Felt 905300300035 4x 2 years

Narrow V-belt DIN7753-XPB 2240 035081753774 1x 2 years

Narrow V-belt DIN7753-XPB 3000 035081753775 2x 2 years

Edge protection sealing profile 035081221353 6.2 m 5 years

Flange bearing unit 035081732057 2x 5 years

Flanged bearing Ø 30 (fixed bearing) 923800340023 1x 5 years

Flanged bearing Ø 30 (flanged bearing) 915700340026 1x 5 years

Floating bearing, feed/opening roll 923800303008 2x 5 years

Pneumatic spring 035081810599 4x 5 years

Sealing rubber 905325310009 8x 5 years

Sealing strip 3 x 20, self-adhesive 035081232441 5.2 m 5 years

Sealing strip 9 x 3, self-adhesive 035081260050 10 m 5 years

Tension roller 905300302101 1x 5 years

Window pane, undrilled A 160 x 350 035081213022 2x 5 years

Damp-proof luminaire 230 V, 50 Hz, 1 x 18 W 136082071010 1x as required

Fluorescent tube 18 W/25; 588 mm long 136082072044 1x as required

Gear motor AC 200/60 037181761569 1x as required

Gear motor AC 220/380/50 440/60 037181761570 1x as required

Gear motor AC 220/380/60 037181761571 1x as required

Gear motor AC 346/50 400/60 037181761572 1x as required

Gear motor AC 400/50 460/60 037181761573 1x as required

Gear motor AC 420/50 480/60 037181761574 1x as required

Gear motor AC 440/50 037181761585 1x as required

Gear motor AC 460/60 EPACT 037181761586 1x as required

Gear motor AC 500/50 575/60 037181761587 1x as required

Gear motor AC 550/50 037181761588 1x as required

053 25 07 • CL-P • en • 03/2012 79

Appendix

Frequency of
Designation Part No. Quantity
replacement

Gear motor AC 550/60 037181761589 1x as required

Gear motor AC 575/60 CSA 037181761590 1x as required

Grid bar 905325450001 46 x as required

Inductive proximity switch 136082205046 2x as required

Motor AC 200/60 037181767306 1x as required

Motor AC 200/60 037196762601 1x as required

Motor AC 200/60 037197762410 1x as required

Motor AC 200/60 037181767293 1x as required

Motor AC 220/380 60 037197762411 1x as required

Motor AC 220/380/50-440/60 037197762413 1x as required

Motor AC 220/50 037181767294 1x as required

Motor AC 220/50 037181767307 1x as required

Motor AC 220/50 037196762619 1x as required

Motor AC 220/60 037181767295 1x as required

Motor AC 220/60 037181767308 1x as required

Motor AC 220/60 037196762620 1x as required

Motor AC 345/50 400/60 037181767297 1x as required

Motor AC 345/50 400/60 037181767310 1x as required

Motor AC 346/50 400/60 037196762618 1x as required

Motor AC 380/50 440/60 037181767296 1x as required

Motor AC 380/50 440/60 037181767309 1x as required

Motor AC 380/50 440/60 037196762616 1x as required

Motor AC 380/60 037181767298 1x as required

Motor AC 380/60 037181767311 1x as required

Motor AC 380/60 037196762621 1x as required

Motor AC 400/50 460/60 037181767299 1x as required

Motor AC 400/50 460/60 037197762417 1x as required

Motor AC 400/50 460/60 037181767312 1x as required

Motor AC 400/50 460/60 037196762573 1x as required

Motor AC 400/60 037197762414 1x as required

Motor AC 415/50 480/60 037181767300 1x as required

80 053 25 07 • CL-P • en • 03/2012

 Appendix

Frequency of
Designation Part No. Quantity
replacement

Motor AC 415/50 480/60 037181767313 1x as required

Motor AC 420/50 480/60 037196762575 1x as required

Motor AC 420/50 480/60 037197762419 1x as required

Motor AC 440/50 037181767314 1x as required

Motor AC 440/50 037196762617 1x as required

Motor AC 440/50 037197762425 1x as required

Motor AC 440/50 037181767301 1x as required

Motor AC 500/50 575/60 037181767302 1x as required

Motor AC 500/50 575/60 037181767315 1x as required

Motor AC 500/50 575/60 037196762622 1x as required

Motor AC 500/50 575/60 037197762435 1x as required

Motor AC 550/50 037181767303 1x as required

Motor AC 550/60 037181767304 1x as required

Motor AC 550/60 037181767317 1x as required

Motor AC 550/60 037196762629 1x as required

Motor AC 550/60 037197762464 1x as required

Motor AC 555/50 037181767316 1x as required

Roll 1 905325302001 1x as required

Roll 2 905325302002 1x as required

Safety locking device 136082204053 3x as required

Safety switch 136082204060 1x as required

053 25 07 • CL-P • en • 03/2012 81

Appendix

Storage
After unloading, the machine must be stored in a
dry environment. Do not remove the packaging
material and foil until shortly before installation.
Protect the machine from external damage and the
elements.

Anti-corrosion protection
If you do not use the machine for a longer period,
you must protect all non-lacquered parts of the
machine from corrosion. This applies in particular
to the functional surfaces which you can best pro-
tect with special anti-tarnish paper. You can pre-
serve other non-lacquered machine parts with a
light oil mist.

Transportation
DANGER
Risk of serious injury from falling loads! 950 mm
Only ever use the transportation aids
delivered with the machine and adhere to ~1550 kg
the following guidelines on transporta-
tion.
Make sure that no persons are situated in
dangerous areas during transportation.
We recommend that you transport the packages on
a pallet using a fork lift truck. The forks on the fork
lift truck must be at least 1,800 mm in length and
the load bearing capacity at least 2,500 kg 2500 kg

min. 1800 mm

82 053 25 07 • CL-P • en • 03/2012


Removal from service
Initial commissioning and removal from service,
disassembly and disposal are not contained in
these operating instructions as these tasks must be
carried out by Trützschler after-sales service staff
only. This also applies to temporary stoppage of
the machine, for instance, if the machine is to be
transferred to another location.
Attention
Risk of serious damage to the machine!
If you wish to remove the machine from
service yourself, make sure that there
is no residual material in the machine.
Residual material hardens and can
cause damage serious to the machine
when it is being re-started.
You can prepare removal from service as follows:
1. Convey or manually remove residual material
from the machine.
2. Switch off the master switch.
3. Allow all further steps to be performed by the
Trützschler after sales service department.
053 25 07 • CL-P • en • 03/2012
Appendix
Disassembly
Attention
Possible damage to the machine assem-
bly groups!
If disassembled/removed incorrectly, the
assembly groups may become irrepara-
bly damaged. For more information, con-
tact the Trützschler after-sales service
department.
Disposal
Operating media, electronic modules, recyclable
materials and other parts of the machine must be
disposed of according to national and regional
environmental laws. For more detailed information
on disposal, contact the relevant local authority.
83
Appendix

EC conformity
as per EC Machinery Directive 2006/42/EC, Appendix II, 1. A.

Manufacturer
Name Trützschler GmbH & Co. KG
Address Postfach 41 01 64
D-41241 Mönchengladbach

The following machine, in its delivered state, is in conformity with the EC directives listed in the following.

Machine
Designation and type CLP pre-cleaner
Type No. 053 25 07

The following EC Directives have been applied:

2006/42/EC
2006/95/EC
2004/108/EC

The following harmonised standards have been applied:

DIN EN ISO 12100 - 1+2
EN ISO 13849 - 1
DIN EN ISO 11111 - 1+2
EN ISO 14121 - 1
DIN EN 60204 - 1

84 053 25 07 • CL-P • en • 03/2012

 Index

Index

A Operating elements 15
Diagnostics / Statistic 43
Abbreviations 78
Dimensions 75
Accident prevention regulations 7
Disassembly 83
Anti-corrosion protection 82
Disposal 83
Anti-rust 82
Door safety mechanisms 10
Assembly groups 13

B E
EC conformity 84
Basic keys 17
Equipment, additional 78
Battery, KSZ4, replacing 71
Expendable parts 79
Belt tension
checking 66
Setting 68
Belt tension, checking and setting 66
F
BR-COI 13 Fault table 48
Buttons 16, 20 Faults
Basic procedure 47
LED displays 52
C Flaps, safety mechanisms 10
Function 13
Call up log book 35
Fuse
Central control unit KSZ5 53
Replacing fuses 73
Cleaning
control cabinet 66
Cleaning efficiency, setting 46
Code
G
changing 34 Grids, setting 46
Resetting to default values 34
Code levels 34
Communication 42 I
Communication interfaces, activating 42 Information about the machine 36
Condenser 13 Information on the machine 36
Conformity 84 Initial start-up 27
Control cabinet 26
Cleaning 66
Conventions 11 J
Current programme version, displaying 19 Jog key 18
Cut-out fuse, replacing 73

K
D Keys 17
Daily preparations for operation 27 KSZ5 53
Danger signs 10 Replacing the battery 71
Date and time, setting 39
DEA2 54
DEA2, meaning of the LEDs 54 L
Description
Language, selecting 35
Assemblies 13
LED displays 52
control cabinet 26
Limit switches 10
Function 13
Load bearing capacity, fork lift 82
Master switch 15

053 25 07 • CL-P • en • 03/2012 85

Index

Lot R
Creating a new 38
Removal from service 83
Deleting 38
Repairs and maintenance 71
displaying 38
Renaming 38
Selecting 38
Lot management 37
S
Lubricants 64 Safety devices 9
Lubrication schedule 63 Safety instructions 8
Safety locking devices 10
Safety measures 7
M Sense of rotation, checking 60
Sensors / Measured values 43
Machine
Serial number 36
switching off 31
Service functions 42
switching on 27
Service key switch 26
Machine designation 36
Service mode
Machine, putting out of operation 9
Carrying out tests 60
Mains disconnection device 9
Switching on 58
Maintenance 43, 57
Setting
Lubrication schedule 63
cleaning efficiency 46
Maintenance and servicing schedule 61
material suction device 45
maintenance schedule 62
Setting the speed of the fan 40
Master switch 9, 15
Settings
Material suction, setting 45
Control 33
Modules on the mounting plate 52
mechanical 45
Motor suspension mount for the opening rolls 69
Sides of machine, definition 6
Software information 36
Speed limit BR-CO fan 40
O Speed limit, roll 40
Opening roll Start key 18
Setting the maximum speed 40 Start-up 9
Opening rolls Stop key 18
Motor suspension mount 69 Storage 82
Operating elements Switching on 27
master switch 15 Symbols 11
Operating panel 16
Operating unit 15
Operating hours counter 36 T
Operating panel 16
Technical data 75
Operating unit 16
Temperature 36
Operation 27, 29
Tension roller for V-belt 68
Faults 30
Test door locking 42
preparing 27
Time, setting 39
Switching off 31
TKN 42
Switching on 27
Touch screen 16
Options 78
Transportation 82
TST 42
Type plate 6
P
Position within the installation 14
Production time 36 U
Programme change 39
Updating the control software 70
Programme version, displaying 36
Proper use 6

86 053 25 07 • CL-P • en • 03/2012

 Index

W
Warning plates 10
Work safety regulations 7

053 25 07 • CL-P • en • 03/2012 87

Index

88 053 25 07 • CL-P • en • 03/2012

Trützschler GmbH & Co. KG
Textilmaschinenfabrik
D-41241 Mönchengladbach
Postfach 41 01 64
Telephone +49 2166 607-0
Fax +49 2166 607-405
e-mail info@truetzschler.de
Internet www.truetzschler.com