01 A18 Electronic Control System

Ypres - Belgium
EN
Content :
Introduction ................................................................................................................................... 5
• Different sections .............................................................................................................................5
• The electronic control system ..........................................................................................................5
• The Electronic Wiring System..........................................................................................................5
Pictographs, wire abbreviations and safety devices ..................................................................... 7

• Pictographs used .............................................................................................................................7
• Wire abbreviations ...........................................................................................................................8
• Safety Devices.................................................................................................................................9
General ....................................................................................................................................... 11
Connection conditions.........................................................................................................................12
• Power supply cable specifications .................................................................................................12

• Supply cable protections................................................................................................................14
• Shielded wire connections .............................................................................................................15
• Data cables....................................................................................................................................15
Control system and machine drive .....................................................................................................16
• Principle .........................................................................................................................................16
• Security..........................................................................................................................................16
• Power supply - motor switches ......................................................................................................17
• Control system of the main motor control box ...............................................................................17
• Main motor.....................................................................................................................................17
• Brake .............................................................................................................................................18
• Cooling system ..............................................................................................................................18
• Pickfinding .....................................................................................................................................19
• Weaving (driving the machine) ......................................................................................................19
• Let-off ............................................................................................................................................20
• Take-up motion..............................................................................................................................21
Overview of the weaving machine ......................................................................................................22
• Division of the weaving machine ...................................................................................................22

• Overview of the weaving machine 1 ..............................................................................................22
Board naming........................................................................................................................................24
The Control Box (CB) ................................................................................................................. 25

The sides of the control box................................................................................................................26
• Overview of the control box ...........................................................................................................26

• Button side.....................................................................................................................................26
• Cable entry side.............................................................................................................................27
• Front ..............................................................................................................................................28
• Power Panel side...........................................................................................................................30
• Identification sticker .......................................................................................................................31
• Maintenance ..................................................................................................................................31
EN 1 / 134
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The rack .................................................................................................................................................32
• Boards ...........................................................................................................................................33
• CBFSB-1 (Common Board Fast Serial Bus)..................................................................................33
• CBMP-3 (Common Board Main Processor)...................................................................................35
• CBSD-1 (Common Board Sensors and Devices) ..........................................................................39
• ABSD-2 (Airjet Board Sensors and Devices).................................................................................42
Bus systems..........................................................................................................................................44
• Overview........................................................................................................................................44
• FSB (Fast Serial Bus) ....................................................................................................................44
• Locan bus ......................................................................................................................................44
• Pican bus .......................................................................................................................................46
Mains entry ............................................................................................................................................48
• Diagram .........................................................................................................................................48
• QM: Overload protection switch Mains ..........................................................................................49
• FL: EMI FiLter ................................................................................................................................50
• LR: Line Reactor............................................................................................................................50
High voltage part...................................................................................................................................51
Power panel...........................................................................................................................................55
• MPS-2 (Main Power Supply) .........................................................................................................56

• SRDD (Switch Reluctance Dual Drive)..........................................................................................58
• NG_LDEC (New Generation Loom Drive Electronic Converter) ...................................................62
• MMCU-1 (Main Motor Control Unit) ...............................................................................................63
• EBMM-1 (Elco Board Main Motor).................................................................................................64
• OBMM-1 (Output Board Main Motor).............................................................................................65
• MMRB-1 (Main Motor Rectifier Board) ..........................................................................................65
Devices on the machine ............................................................................................................. 67

• PDP (Picanol DisPlay) ...................................................................................................................67
• Control buttons on the breast plate................................................................................................69
• RS: ReSolver .................................................................................................................................70
• Proximity switches .........................................................................................................................72
• Safety light curtain .........................................................................................................................73
• EPR (Electronic Pressure Regulator) ............................................................................................75
• ELSY: Electric Leno SYstem .........................................................................................................76
• IRO Control Box.............................................................................................................................76
• NG_FDCB: Filling Detector Control Box........................................................................................77
• E-Leno ...........................................................................................................................................78
• Can Dobby S3XXX ........................................................................................................................79
• Jacquard ........................................................................................................................................79
• Cam motion with leveling system (1681, 1781) .............................................................................81
• Cam motion with leveling system (S1692).....................................................................................83
• Parking brake.................................................................................................................................84
• Electrical cutters ............................................................................................................................86
• Thermal cutter................................................................................................................................87
• PKE................................................................................................................................................88
Service........................................................................................................................................ 91
• General ..........................................................................................................................................91
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2 / 134 EN
Replacing boards and/or assemblies .................................................................................................92
• General ..........................................................................................................................................92
• RMA (Return Merchandise Authorization) .....................................................................................92
• Replacing the assem. NG_LDEC ..................................................................................................93
• Replacing the EBMM .....................................................................................................................94
• Replacing the OBMM.....................................................................................................................95
• Replacing the MMRB.....................................................................................................................98
• Removing and mounting boards from the rack............................................................................101
• Replacing the assem. SRDD .......................................................................................................103
• Replacing the CBFSB..................................................................................................................105
• Replacing the CBMP ...................................................................................................................107
• Replacing the PDP ......................................................................................................................109
• Replacing the protection foil on the assem.PDP_9inch...............................................................111
Software...............................................................................................................................................113
• Installing Software .......................................................................................................................113

• CSF (Customer System File).......................................................................................................115
• Machine log .................................................................................................................................116
• Screen capture ............................................................................................................................117
Fuses ...................................................................................................................................................118
• Marking ........................................................................................................................................118
• Fuse details .................................................................................................................................118
Tools ....................................................................................................................................................119
• Masterstick (BE316654) ..............................................................................................................119

• USB-stick (N1038701) .................................................................................................................119
• F-contact tools .............................................................................................................................120
• Burndy (TRIM TRIO) contact tools ..............................................................................................121
• D-sub contact tools ......................................................................................................................122
• Molex Mini-Fit Jr contact tools .....................................................................................................123
• Molex Mini-Fit Sr contact tools.....................................................................................................124
• Torx screwdriver ..........................................................................................................................125
• Wire strip tool...............................................................................................................................125
• Crimp tool for wire end-sleeves (0,08 mm² - 16 mm²) .................................................................126
Electrical Wiring ........................................................................................................................ 127

• General ........................................................................................................................................127
• TPVN ...........................................................................................................................................127
• Cable identification ......................................................................................................................128
• Diagrams .....................................................................................................................................129
• Color coding wires .......................................................................................................................129
• Cable number ..............................................................................................................................130
• Shielded wire connections ...........................................................................................................131
Abbreviations ............................................................................................................................ 133
EN 3 / 134
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4 / 134 EN
Introduction
Different sections
2 Sections The electronic part of the manual is divided into 2 sections:

• The Electronic Control System (This section)
• The Electronic Wiring System
The electronic control system
Description The electronic control system is the general section. This section describes the electronic control and is
not specific, but general to all OMNiplus Summum machines.
The Electronic Wiring System
Description The electronic wiring system is the specific section. This section is only valid for machines with the
TVPN-number mentioned in this section. See: TPVN [127].
All diagrams and cables listed in this section are generated only for the machines with this TPVN-
number.
EN170410N Introduction 5 / 134

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Original setting manual - e-mail: TecDoc@picanol.be
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6 / 134 Introduction EN170410N

Pictographs, wire abbreviations and safety devices
Contents • Pictographs used ........................................................................................................................ 7
• Wire abbreviations ...................................................................................................................... 8
• Safety Devices............................................................................................................................ 9
Pictographs used
The following table shows the safety pictographs used in this manual:
Pictograph Name Description
Note Provides additional information concerning important topics in
the text.
Warning Disregarding this warning may result in the loss of electronic
data or in mechanical damage.
Danger Disregarding this warning may lead to material damage but
also and in particular to physical injury to persons.
CE version Only applies to the CE version.
Liability Provides information about the legal liability.
EN170410N Pictographs, wire abbreviations and safety devices 7 / 134

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Wire abbreviations
Introduction The abbreviations for the colors of cable wires are determined here.
Other abbreviations are explained in the “Abbreviations” section in the Picanol manual.
Colored wires The following table gives an overview of the abbreviations

Abbreviation In full Description
WH WHite white
BN BrowN brown
GN GreeN green
YE YEllow yellow
GY GreY grey
PK PinK pink
BU BlUe blue
RD ReD red
BK BlacK black
VT VioleT violet
GY/PK GreY/PinK grey with pink rings
RD/BU ReD/BlUe red with blue rings
WH/GN WHite/GreeN white with green rings
BN/GN BrowN/GreeN brown with green rings
WH/YE WHite/YEllow white with yellow rings
YE/BN YEllow/BrowN yellow with brown rings
WH/GY WHite/GreY white with grey rings
GY/BN GreY/BrowN grey with brown rings
WH/PK WHite/PinK white with pink rings
PK/BN PinK/BrowN pink with brown rings
WH/BU WHite/BlUe white with blue rings
BN/BU BrowN/BlUe brown with blue rings
WH/RD WHite/ReD white with red rings
BN/RD BrowN/ReD brown with red rings
WH/BK WHite/BlacK white with black rings
BN/BK BrowN/Black brown with black rings
GY/GN GreY/GreeN grey with green rings
YE/GY YEllow/GreY yellow with grey rings
PK/GN PinK/GreeN pink with green rings
YE/PK YEllow/PinK yellow with pink rings
GN/BU GreeN/BlUe green with blue rings
YE/BU YEllow/BlUe yellow with blue rings
GN/RD GreeN/ReD green with red rings
YE/RD YEllow/ReD yellow with red rings
GN/BK GreeN/BlacK green with black rings
YE/BK YEllow/BlacK yellow with black rings
GY/BU GreY/BlUe grey with blue rings
Earth wire The following table gives an overview of the abbreviations.

Abbreviation In full Description
GNYE GreeNYEllow green/yellow earth wire
8 / 134 Pictographs, wire abbreviations and safety devices EN170410N

Safety Devices
Emergency stop
The control box remains live when the emergency stop button is pressed.
• This is a red button on a yellow background.

• If any emergency stop is locked, the control buttons will not work => unlock = 1/8 turn clockwise.
Safety light grid

The safety light grid does not function when the machine is operating at full speed.
• Is located over the pressure roll.

• The safety light grid prevents movement of the sley during start-up, slow motion and pick finding.
The machine motion can be started again following the normal procedure.
STAND-BY • The machine must be placed in this condition for all repair activities and lubrication work.
• Condition for setting the machine.
• All machine movements are blocked, but the electronic components will remain live.
POWER ON • Power circuits are turned on.

• All motors, except for the prewinder motor, remain switched off.
• The main motor will only start after:
- The start button has been pressed.
- Any automatic movement and also machine start-up is indicated by clear flashing warning lights.
- In case of emergency, all machine actions can be interrupted by means of an emergency stop.
Warning lights
If the warning lights are flashing, do not touch the weaving machine.
Main switch • Is located on the right hand side of the main control box.
• Must be padlocked in the -0- position when major work is performed.
Work to be • The control boxes may only be opened and connected by qualified and authorized members of staff.
performed This means that they must have a basic knowledge of the fundamental rules of electricity and the
relevant legislation, and that they must have experience with electric wiring, electric components and
with the symbols on electric diagrams.
• If, for work to be performed, it is required that the earth connections are disconnected, then these
must be reconnected in the original way before the control system is switched on again.
• When a control box is open, EMC (electromagnetic compatibility) is not guaranteed.
• While work is going on with a control box open and the main switch on, no appliances producing
strong electromagnetic fields – such as mobile phones or walkie-talkies – may be brought near the
control box.
Earth connection • The weaving mill must have an effective earth connection. This must have been checked and
verified by the responsible services.
• After the control box has been placed, the earth wire must first be connected to the machine. For
more information on the earthing, see the “Installation” section.
• The earth wire of the bobbin stand must be connected to the prewinder stand, see the “Installation”
section.
• The machine must be connected to the mains earth connection in the prescribed manner.
• The earth connections interconnecting machine components may not be interrupted. If during work
on the machine they are disconnected, they must be reconnected in the original way before the
control system is switched on again.
Stepping motors • The machine is equipped with several stepping motors: the filling cutters, the waste cutters, the
selvedge motions…
• These motors may never be opened, as some loss of torque may result from opening and re-closing
them.
• In the event of a fault or failure, these motors should be sent to Picanol.
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EN170410N Pictographs, wire abbreviations and safety devices 9 / 134

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10 / 134 Pictographs, wire abbreviations and safety devices EN170410N

General
Contents Connection conditions................................................................................................................... 12
• Power supply cable specifications ............................................................................................ 12
• Supply cable protections........................................................................................................... 14
• Shielded wire connections ........................................................................................................ 15
• Data cables............................................................................................................................... 15
Control system and machine drive ............................................................................................... 16

• Principle .................................................................................................................................... 16
• Security..................................................................................................................................... 16
• Power supply - motor switches ................................................................................................. 17
• Control system of the main motor control box .......................................................................... 17
• Main motor ................................................................................................................................ 17
• Brake ........................................................................................................................................ 18
• Cooling system ......................................................................................................................... 18
• Pickfinding ................................................................................................................................ 19
• Weaving (driving the machine) ................................................................................................. 19
• Let-off........................................................................................................................................ 20
• Take-up motion......................................................................................................................... 21
Overview of the weaving machine ................................................................................................ 22

• Division of the weaving machine .............................................................................................. 22
• Overview of the weaving machine 1 ......................................................................................... 22
Board naming.................................................................................................................................. 24
EN170411N General 11 / 134

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Connection conditions
Power supply cable specifications
Contents • Load demands [12]

• Rated power [12]
• General conditions [12]
• Electrical requirements of the weaving room [13]
• Cable section [13]
Load demands Power consumption is the energy consumption during normal machine operation.
The power consumption depends on:
• the machine configuration,
• the machine speed;
• the type of fabric and the machine settings.
The required load must be calculated separately for each machine.
Rated power The rated power depends on external factors during a cold start or in specific working environments.
The mains must always be able to supply enough power in similar extreme situations.
The rated power is also taken into account when calculating the mains cable conductor size.
Rated supply The table below shows the rated supply voltage (Vnom):
voltage Vnom (3 phase/PE/no Neutral) Transformer used?
200V to 346V YES
380V to 460V NO
480V to 600V YES
General conditions • Stability of the power supply

- Supply voltage fluctuations must be between -10% and +10% of the nominal operating voltage
(EN50160).
- e.g.: at Unom = 460V, the supply voltage must never drop below 414V or be higher than 506V.
• Power consumption at cold start

At a cold start (e.g. after a weekend stop) power consumption is twice as high as compared to the
consumption at typical operating temperature conditions. It takes about 3 hours for the power
consumption to drop to normal.
The electrical wiring and the transformer (if present) must be able to support this high power
consumption at a cold start.
• Conditions at machine start-up

At machine start-up, the power consumption is approximately 80KVA (for 0,2sec).
During this short time lap, the voltage at the machine should not drop below 85% of the nominal
operating voltage.
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12 / 134 General EN170411N

Electrical The weaving machines need a nominal voltage between 380V and 460V.
requirements of the If the weaving room does not dispose of a power supply between these values, a transformer must be
weaving room used.
The machine is foreseen to be used on electrical installations according IEC 60364 and power supplies
according EN 50160
Distribution system:
• 3AC 380V - 460V ±10% +PE
• 3AC 200V - 346V ±10% +PE; autotransformer used; WYE 3AC 440V secondary
• 3AC 480V - 600V ±10% +PE; autotransformer used; WYE 3AC 440V secondary
WYE grounded in star point preferred; delta ungrounded can be used, however more
susceptible to effects of ground faults.
System of live conductor:
• Three-phase 3 wire
Neutral is not used inside the control box. There is a terminal for connecting the neutral
conductor.
Mono-phase 230VAC is not available in the control box. For further information, please contact
your Picanol service engineer.
System earthing:
• TB (TN-C; TN-C_S; TN-S);
• TT;
• IT
If an IT-type is used, insulation monitoring should be installed by the customer. Picanol does
not supply such a monitoring system.
Cable section The tables below show the minimum value of the cable section for a specific supply voltage and the
maximum cable length from the power source to the machine. These tables take the above mentioned
requirements into account.
These tables apply if:
• every machine has a separate supply cable to the power source.
• the supply voltage equals the nominal level.
If the supply voltage drops below the nominal voltage, the cross section of the connection cable
must be increased to compensate for that loss in voltage.
For the calculation of the cable cross section, the following resistances are taken into account (copper
wires):
Cable section in mm² Resistance per meter in 
50 0,000387
35 0,000524
25 0,000727
16 0,00115
10 0,00183
6 0,00308
4 0,00461
• The table below is used for stable supply voltages (which meet the European standard EN50160),
or corresponding standard that apply to your country.
cable section Supply voltage (V)
(mm²) 200 220 260 280 346 380 400 415 440 460 480 500 550 575 600
10 6 4-6** 4-6** 4-6** 4-6** 4 4 4 4 4 4 4 4 4 4
power source - machine
20 10 10 6 6 4-6** 4 4 4 4 4 4 4 4 4 4
30 16 16 10 10 6 4 4 4 4 4 4 4 4 4 4
Cable length
40 25 16 16 10 6 6 6 4 4 4 4 4 4 4 4
(meter)
50 25 25 16 16 10 6 6 6 6 6 4 4 4 4 4
60 35* 25 16 16 10 10 10 6 6 6 6 6 4 4 4
70 35* 25 25 16 10 10 10 10 10 6 6 6 4 4 4
80 35* 35* 25 25 16 10 10 10 10 10 6 6 6 6 4
90 50* 35* 25 25 16 16 10 10 10 10 10 10 6 6 6
100 50* 50* 25 25 16 16 16 10 10 10 10 10 6 6 6
* 25 mm² single wire is the maximum cable section that can be connected on QM.
** The cable is 6 mm² for reason of overload protection.
EN170411N General 13 / 134

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• The table below is used for power voltages where voltage fluctuations may be expected (the
fluctuations may not exceed 10%).
cable section Supply voltage (V)
(mm²) 200 220 260 280 346 380 400 415 440 460 480 500 550 575 600
10 10 10 6 6 4-6** 4 4 4 4 4 4 4 4 4 4
power source - machine
20 25 25 16 16 10 6 6 6 6 4 4 4 4 4 4
30 35* 25 25 16 10 10 10 10 10 6 6 6 4 4 4
Cable length
40 50* 35* 25 25 16 16 10 10 10 10 10 10 6 6 6
(meter)
50 70* 50* 35* 25 25 16 16 16 16 10 10 10 10 10 6

60 70* 70* 50* 35* 25 25 16 16 16 16 16 10 10 10 10
70 95* 70* 50* 50* 25 25 25 25 16 16 16 16 10 10 10
80 95* 70* 50* 50* 35* 25 25 25 25 16 16 16 16 10 10
90 95* 95* 70* 50* 35* 25 25 25 25 25 16 16 16 16 10
100 120* 95* 70* 70* 35* 35* 25 25 25 25 25 16 16 16 16
* 25 mm² single wire is the maximum cable section that can be connected on QM.
** The cable is 6 mm² for reason of overload protection.
When using one cable to connect the main distribution point with multiple machines and another
distribution point is available close to the machines, the copper of the cables can be used in a more
efficient way as the cable is rated with a higher voltage. As a result, the difference between
nominal power and peak power at start-up of one of those machines becomes smaller.
In most cases, there is no influence on the nominal voltage during start-up of a machine. The
nominal voltage can drop 15% during startup.
Supply cable protections
Overload The overload protection upstream of the power cable of the weaving machine protects:
protection • the power supply cable,
• the main switch in the control box.
The thermal protection can be done with fuses of the type aM or D (according to the
standard IEC 60269-1).
The table below shows the fuses to use:
Supply voltage Value of the type aM or D fuse
200V to 346V 32A
380V to 460V 25A
480V to 600V 25A
Icu value of the The maximum allowed short circuit current (Icu) supplied to the main switch, is limited, according to the
control box standard IEC 60947-2. The power distribution must be able to cope with that.
The maximum allowed short circuit current (Icu) can be found in the table below.
Supply voltage Icu (kA)
200V to 346V 10
380V to 460V 4
480V to 600V 3
Leak current The machine control has no leak current protection.

protection If the local laws demand a leak current protection, it must be provided in the power distribution of the
weaving mill.
The leak current protection should have the following properties:
• time delayed leak current protection
• should not be lower than 300mA.
• one leak current protection per machine.
14 / 134 General EN170411N

Shielded wire connections
Yellow cable ties Yellow cable ties are used where a shielded wire must make contact with the ground plane of the
machine.
The shield, made of braided copper strands, is used to reduce interference with other devices.
After removing a yellow cable tie, the shielded wire must always be reconnected to the ground
plane of the machine.
Shielding For more information concerning the shielding connections see: Tools [119].
connections
Data cables
Interferences In case data cables are installed, Picanol recommends not to lay the data cables next to the power line
cables to the weaving machines to avoid interferences.
EN170411N General 15 / 134

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Control system and machine drive
Contents • Principle [16]
• Security [16]
• Power supply - motor switches [17]
• Control system of the main motor control box [17]
• Main motor [17]
• Brake [18]
• Cooling system [18]
• Pickfinding [19]
• Weaving (driving the machine) [19]
• Let-off [20]
• Take-up motion [21]
Principle
Block diagram The following illustration shows the principle:
SRDD
D G
C
E H
A CBMP
F
RS
NG_LDEC
I J
B
A. Input signal from the PX_ref B. Signal to the VPF

C. LOCAN communication D. Drive motor 1
E. Drive motor 2 F. Drive main brake
G. ELO H. ETU
I. MMCU J. Main motor [17]
K. Brake main motor RS. ReSolver
.
Security
The safety system combines software and hardware protection.

The hardware protection consists of:
• the second contact (PB-*-2) (where * = SMF, SMR, PFF or PFR) of the buttons controlling machine
movements.
• the activation of the STAND-BY position
• the relay control unit on the CBMP board.
• the emergency stops.
16 / 134 General EN170411N

Power supply - motor switches
NG_LDEC
motor switch Function

KMM Switches 2 contacts (1-2 and 5-6), while 1 contact (3-4) is connected through.
• The INRUSH print is located across 1 contact (1-2). This print makes sure the
ELCOs' loading current on the NG_LDEC is restricted and that the ELCOs
remain charged in case of an open KMM.
• The motor switch switches on after POWER-ON.
Control system of the main motor control box
• The control system is located on the MMCU board. The MMCU board is part of the NG_LDEC board.
• The NG_LDEC board is controlled and monitored via the LOCAN bus.
Main motor
Stator coils • Contains 8 stator coils (4 double coils).

• 2 by 2 coils in opposite positions are placed in parallel.
• R = 0.22  (per double stator coil in cold condition).
Main motor test See chapter: the Drive’-section.
Rotor shaft The rotor shaft can move both radially and axially.
Radially
The radial movement is controlled by the 4 double stator coils.
A
D MM B
C
Radial movement Function The stator coils are controlled in such a way
that...
first machine drive the rotor rotates.
second brake movement they have a braking effect on the rotor and stop
the machine.
EN170411N General 17 / 134

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Axial
The axial movement is produced by valve V-PF and a pneumatic piston (inputs PF-IN and PF-OUT).
PF-OUT
PX-WP
PX-PFP
PF-IN
93)
3)287 3),1
V-PF The rotor shaft... The gear wheel on the rotor shaft... Controlled by...
energized V-PF shifts 32 mm to the is disengaged from the sley drive gear PX-PFP
right
non-energized V-PF is not extended is engaged in the sley drive gear PX-WP
Brake
Machine running The running machine is braked by controlling the main motor stator coils in a way resulting in a braking
effect on the rotor shaft.
Machine stopped When the machine is stopped, it is held motionless by a brake.

Brake Shed system When the brake is actuated, the On power OFF, the
machine is... machine is...
holding brake outside cam motion held released
parking brake - outside cam motion released held
- dobby
- jacquard
Cooling system
Oil One circulating lubrication system oil circuit cools the stator of the motor.
Heatsink The following components are fitted against the heatsink:

• the power control system control modules composed of 2 OBMM prints;
• the MMRB print (3-phase rectifier);
• the dump resistor.
18 / 134 General EN170411N

Pickfinding
Function The pickfinding procedure lets the motor drive the shed mechanism independently from the sley
mechanism. The sley mechanism is blocked by a peg during pickfinding.
Process The illustration below shows the pickfinding process:

PX-WP PX-PFP
PF--OUT
B
A
93) C
93) D
3)287
3)287 3),1
E
1. Weaving --> Pickfinding A. Peg

2. The machine moves slowly to a pickfinding position B. Engaged
3. Valve VPF is switched on C. Sley gear
4. Air is directed to PF-OUT D. Disengaged
5. • The piston moves to the right. E. Main motor gear
• The sley gear is disconnected from the main
n=0 .
motor gear.
• The peg serving to hold the sley gear is
engaged.
• The position is verified by means of PX_PFP
and PX_WP:
Weaving (driving the machine)
Process The illustration below shows the weaving process:

PX-WP PX-PFP
B
PF--IN
93)
A
3),1
C
D
1. Pickfinding --> Weaving A. Peg

2. Valve VPF is switched off B. Disengaged
3. Air is directed to PF-IN C. Sley gear
4. • The piston moves to the left. D. Engaged
• The sley gear engages the main motor gear. E. Main motor gear
.
• The peg holding the sley gear is disengaged.

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EN170411N General 19 / 134

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Let-off
General There are two Let-off versions:

• without speed change gear box;
• with speed change gear box.
A speed change gear box offers more pick density and let-off speed options to ensure an optimal
working of the let-off.
The electrical connection is the same for both versions. The configuration is part of the machine
identification.
Without speed The following illustration shows the Let-off without change gear box:
change gear box
BR RS M
With speed change The following illustration shows the Let-off with change gear box “A”:
gear box
BR RS M
The let-off motor(s) Principle of the motor drive

ELO_LHS and • The stator coils are controlled by means of a chopper voltage from the SRDD drive.
ELO_RHS • The power supply to the SRDD board for power stages is the 290V DC.
• The current in the different motor phases is monitored by means of current sensors. If 1 measurement is
incorrect, the control modules for the motor concerned are switched off by means of the Drive Enable signal.
Maximally 2 let-off motors can be present, depending on the machine configuration.
These are:
• ELO_RHS
• ELO_LHS
The motor (A, B, C and D)
The motor contains 4 double stator coils.
=> R = 2.3  (per double stator coil)
The resolver (RS)

A resolver is mounted on the rotor shaft. The signals of the resolver are used to continuously calculate
the motor speed.
This data is used to control the motor.
The brake (BR)

• The motor brake is of the normally closed type: 
- The brake must be powered to open.
- The brake keeps the warp beam in place while power is OFF or in extended downtime situations.
• Power supply = 26V DC choppered
• R = ±26 
Temperature control (DTTH)

A normally closed bimetal is provided as thermal protection. This opens when the temperature rises
above 100°C.
20 / 134 General EN170411N

Warp tension The warp tension sensors
protection 2 types:
• TSF
• TSW
Machine type TSF TSW
single beam standard 1 sensor optional 1 sensor
double beam 2 sensors 2 sensors
fancy let-off on the machine 2 sensors not possible
• The warp tension sensor converts the warp tension into an analogue current (4-20 mA).
• The warp tension sensors must be calibrated before accurate measurements are possible.
See section “The warp” part “TSF” or “TSW”.
• Power supply for the warp tension sensors = +26V DCS
Warp tension limit values

• Warp tension and warp tension limit values are set using the machine terminal.
• If the warp tension limit values are exceeded, the machine stops.
Monitoring the sensors
The DTWTCAL signal is used to detect the connection of the warp tension sensor.
Take-up motion
General The SRDD board microprocessor controls the ETU motor on the basis of:
• the set pick density;
• the machine speed.
The ETU motor drives the sand roller through a gear train.
The take-up motor Principle of the motor drive

ETU • The stator coils are controlled by means of a chopper voltage from the SRDD board control modules.
• The power supply to the SRDD board for power stages is the 290V DC.
• The current in the different motor phases is monitored by means of current sensors. If
1 measurement is incorrect, the control modules for the motor concerned are switched off by means
of the Drive Disable signal.
The motor (A, B, C and D)

The motor contains 4 double stator coils.
=> R = 2.3  (per double stator coil)
The ReSolver (RS)

A resolver is mounted on the rotor shaft. The resolver signals are used to:
• continuously calculate the motor speed;
• determine the motor’s angle position.
This data is used to control the motor.
The brake (BR)

• The motor brake is of the normally closed type.
- The brake must be powered to open.
- The brake keeps the cloth roll in place while power is OFF or in extended downtime situations.
• Power supply = 26V DC choppered.
• R = ±26 
Temperature control (DTTH)

A normally closed bimetal is provided as thermal protection. This opens when the temperature rises
above 100°C.
EN170411N General 21 / 134

24
Overview of the weaving machine
Contents This section contains the following subjects:
• Division of the weaving machine.............................................................................................. 22
• Overview of the weaving machine 1 ........................................................................................ 22
Division of the weaving machine
Illustration The illustration belows shows how the machine is divided into different sections:
A B C
A. Left-hand side B. Middle

C. Right-hand side D. Warp beam side
E. Weaver’s side
.
Overview of the weaving machine 1
Illustration The illustration below shows the overview of the weaving machine part 1:
A B WL_LHS HS_RX
ES_LHS WL_RHS ES_RHS
HS_TX
C
DTTHLU
PB
DTLUFL
A. Bobbin creel B. PRW: Prewinders
C. PDP (Picanol DisPlay) [67] WL_LHS, WL_RHS: Warning Lights
ES_LHS, ES_RHS: Emergency Stops HS_TX: HandSafety_Transmitter
HS_RX: HandSafety_Receiver PB: Push Buttons
.
DTTHLU: DeTection THermal LUbrication DTLUFL: DeTection LUbrication FiLter
22 / 134 General EN170411N

ETU ES_RRHS E-Leno_LHS CB SL_CB
DTWT1
E-Leno_RHS
FDCB
DTLUPRESS
ELO_RHS
ETU: Electronic Take Up ES_RRHS: Emergency Stop_Rear Right Hand
Side (Only CE).
DTWT1: DeTection WarpTension1 CB: Control Box,see: The Control Box (CB) [25]
SL_CB: Signal Light_Control Box ELO_RHS: Electronic Let_Off Right-Hand Side.
E-LENO_LHS, E-LENO_RHS: See: E-Leno [78] FDCB: see: “NG_FDCB: Filling Detector Control
Box” op pagina – 77
DTLUPRESS: Detection LUbrication PRESSure
ES_RHS WL_RHS ES_RRHS WYD_RHS
HS_TX
ETU
ELO_RHS
FDCB
HSOTX: HandSafety_Transmitter WL_RHS: Warning Lights_Left Hand Side
ES_RHS: Emergency Stop_Right Hand Side ES_RRHS: Emergency Stop_Rear Right Hand
Side (Only CE).
ETU: Electronic Take Up FDCB: Filling Detector Control Box
ELO_RHS: Electronic Let Off_Right Hand Side WYD_RHS: Waste Yarn Detection_Right Hand
Side
EN170411N General 23 / 134

24
Board naming
Name format The illustration belows shows how the board name is formatted:
A
C
D
A. Function number
B. Board name
C. Board version number
D. Board revision number
E. BE-reference
F. Board serial number
Read the serial number as RSxxxxxxxx
eg. RS1619982743
Board name and The board name shows the name of the board and the function number. The board name is also a
BE-reference reference to the BE-number of this board.
Use the BE-number to order a new board.
Every board has a collection of functions. Extending the functions on a board, will increase the function
number at the end of the board name and change the BE-number.
The function number is preceded by the minus sign.
Location name In case a board can be positioned in different locations, the location will be specified by the combination
of the board name and a capital letter between brackets.
F.e. ABSD(A), ABSD(B), ABSD(C), CBSD(A) and CBSD(B).
Assemblies
When the board name is preceded by ‘assem.’ always completely replace the assembly. Never
remove the board from the heatsink.
F.e. ‘assem. SRDD_L’.
24 / 134 General EN170411N

The Control Box (CB)
Contents The sides of the control box.......................................................................................................... 26
• Overview of the control box ...................................................................................................... 26
• Button side................................................................................................................................ 26
• Cable entry side........................................................................................................................ 27
• Front ......................................................................................................................................... 28
• Power Panel side...................................................................................................................... 30
• Identification sticker .................................................................................................................. 31
• Maintenance ............................................................................................................................. 31
The rack ........................................................................................................................................... 32

• Boards ...................................................................................................................................... 33
• CBFSB-1 (Common Board Fast Serial Bus)............................................................................. 33
• CBMP-3 (Common Board Main Processor).............................................................................. 35
• CBSD-1 (Common Board Sensors and Devices) ..................................................................... 39
• ABSD-2 (Airjet Board Sensors and Devices)............................................................................ 42
Bus systems.................................................................................................................................... 44
• Overview................................................................................................................................... 44
• FSB (Fast Serial Bus) ............................................................................................................... 44
• Locan bus ................................................................................................................................. 44
• Pican bus .................................................................................................................................. 46
Mains entry...................................................................................................................................... 48
• Diagram .................................................................................................................................... 48
• QM: Overload protection switch Mains ..................................................................................... 49
• FL: EMI FiLter ........................................................................................................................... 50
• LR: Line Reactor....................................................................................................................... 50
High voltage part ............................................................................................................................ 51
Power panel..................................................................................................................................... 55
• MPS-2 (Main Power Supply) .................................................................................................... 56
• SRDD (Switch Reluctance Dual Drive) ..................................................................................... 58
• NG_LDEC (New Generation Loom Drive Electronic Converter) .............................................. 62
• MMCU-1 (Main Motor Control Unit) .......................................................................................... 63
• EBMM-1 (Elco Board Main Motor) ............................................................................................ 64
• OBMM-1 (Output Board Main Motor)........................................................................................ 65
• MMRB-1 (Main Motor Rectifier Board) ..................................................................................... 65
EN170410N The Control Box (CB) 25 / 134

66
The sides of the control box
Overview of the control box
Different sides The illustration below shows the different sides of the control box:
.
B C D E
A. SL: Signal Light D. Cable entry side [27]

B. Button side [26] E. Power Panel side [30]
C. Front [28]
Button side
Parts .
B
A H
C
E
D I
F
A. PBFA: Push Buttons FAncy beam (if applicable). F. Unwinding of the ground beam (single or double).
B. Winding up the fancy beam (if applicable). G. PBPTHR: Push Button Pull THRough.
C. Unwinding of the fancy beam (if applicable). H. ES_CB: Emergency Stop Control Box.
D. PBLO: Push Buttons Let-Off. I. PBPWRON: Switch Push Button PoWeR ON.
E. Winding up the ground beam (single or double).
26 / 134 The Control Box (CB) EN170410N

Cable entry side
Parts
.
A B
D
A. Connections for the main power supply E. Entries for batching motion
2 cable glands M20x1.5
B. Cable bundle F. Identification sticker [31]

C. Diagnostic - Picascope plug G. Entry for ethernet, Bicom and Loomgate.
n
Cable diameter: 4-6 mm
D. Ground connection between Control Box and

machine

66
Front
Parts
.
C
D
A. QM: Overload protection switch Mains [49] C. Connections for the Main Transformer.
Used with cable sheath PMSI0734
B. To open the front side of the control box. D. Connections for the main power supply.
Cable diameter: 10-28 mm

.
A B
A. The rack [32] C. LR: Line Reactor [50]

B. QM: Overload protection switch Mains [49] D. High voltage part [51]

66
Power Panel side
Parts .
A. Warning Sticker; wait 3 minutes after switching B. Door-key to open and close the panel.
off the power to open the control box. .
A B C
F
H
E
A. Power panel [55] E. NG_LDEC (New Generation Loom Drive

Electronic Converter) [62]
B. MPS-2 (Main Power Supply) [56] F. Components hotwire cutter.
C. The rack [32] G. Fan_CB
D. SRDD (Switch Reluctance Dual Drive) [58] H. CTTH

Identification sticker
Explanation
.
A
B
A. Voltage and frequency D. Rated ultimate short circuit braking capacity

(Short circuit current QM main switch).
B. Maximum possible current installation in regime E. This number stands for the frequency.
• 5 = 50Hz
• 6 = 60Hz
C. Maximum possible current main motor in regime. F. Voltage
Maintenance
Dust To avoid fire or malfunction, Picanol recommends removing all dust from the inside of The Control Box
(CB) [25], and from the cooling plates of the MPS-2 (Main Power Supply) [56], SRDD (Switch
Reluctance Dual Drive) [58] and NG_LDEC (New Generation Loom Drive Electronic Converter) [62].
Screw connections Picanol recommends to regularly check and, if necessary, tighten the screw connection on the High
voltage part [51]. (KMM, QMLVL, QMASP,...)

66
The rack
Illustration The illustration below shows the rack:
.
B P1
C
P3
A. Rack position [32] B. CBFSB-1 (Common Board Fast Serial

Bus) [33]
C. Fast Serial Bus Power distribution [34] P1, P3. G-connectors, see: G-connectors
.
[32].
.
Rack position The rack position is marked with a name related to the name of the board that must be mounted in that
specific position, see: Rack label [32].
Some boards can be mounted in multiple positions, depending on the execution of the machine.
When a board can be put in multiple positions, the position is marked with a letter between brackets.
F.e. ABSD(A), ABSD(B), ABSD(C), ABSD(D) and ABSD(E).
The position where the board is put determines the function of the board. This way the board can have
multiple functions depending on the position in the board rack.
Rack label The following illustration shows the rack label:
B
A. Slot names B. Slots
.
G-connectors The G-connectors connect the boards in the rack with the devices on the machine.
To avoid misinterpretation of the connections on the G-connectors, the name of the connection depends
on the side of the connector.
The table below explains the names of the G-connectors connections:
Side Name Example Illustration
A. PCB side (Printed XP XP_CBMP_P1
Circuit Board) A
B. Wiring side XW XW_CBMP_P1 B
.
A
B

Boards
Boards The following boards are used:

• CBFSB-1 (Common Board Fast Serial Bus)............................................................................ 33
• CBMP-3 (Common Board Main Processor)............................................................................. 35
• CBSD-1 (Common Board Sensors and Devices) .................................................................... 39
• ABSD-2 (Airjet Board Sensors and Devices)........................................................................... 42
CBFSB-1 (Common Board Fast Serial Bus)
Function The different boards connected to the board rack communicate through the Fast Serial bus.
The CBFSB distributes the Fast Serial Bus and the supply voltages for the board rack.
The CBFSB also contains the following features:
• Identification for the slot position in the rack.
• Unique machine serial number.
• Distribution and protection of the different supply voltages.
Illustration The following illustration shows the CBFSB:

9 8 7 6 5 4 3 2 1 M
A B C
D4 D5
A. Slave slots (1-9) B. MID

C. Fast Serial Bus Power distribution [34] D4. LED, ON when the 5V is present.
D5. LED, ON when the 26V is present. M. Master slot
.
Block diagram The following illustration shows the block diagram of the CBFSB board:
A
B
C
D
E
A. Bus connector B. Fast Serial Bus
C. Fast Serial Bus Power distribution [34] D. Machine identification controller
E. Rack position identification
.

66
Fast Serial Bus The following illustration shows the power distribution on the CBFSB board:
Power distribution
P11 P13 D1 P12
A
C
D2
F1 D
F2 E
P14 D6
F
A. Fast Serial Bus power distribution B. Regulator
C. Machine Identification controller D. Detection Pican 26V
E. Detection Locan 26V F. IRO control box
P11. 5VDC coming from the MPS P12. 26VDC/290VDC to SRDD and IRO control box
P13. 290VDC/48VAC coming from the MPS P14. 26VDC coming from the MPS
D1. ON (yellow) when 290V from MPS is present. F1. Fuse 6, 26V to the SRDD
F2. Fuse 6, 26V to the IRO control box
.
See Fuse Value list Electrical Wiring, E-plan.
LED indications The voltages on the CBFSB board can visually be checked by means of a lit LED:
LED ON OFF
D1 (Yellow) 290V from MPS is present 290V from MPS is missing
D2 (red) F1 failure F1 is ok
D6 (red) F2 failure F2 is ok
Machine The Machine identification controller has two functions:

Identification • Giving the machine a unique identification number.
controller • Verifying the 26V going to the Prewinder control box and the SRDD devices (SRDD_26V).
Voltage check Measure the DC voltages between the ‘DGD’-point and the corresponding voltage point:
48VAC
26V
DGD 5V
Fusing The CBFSB board contains the following fuses:

Fuse Remark
F1 26V to the SRDD
F2 26V to the IRO control box
See Fuse value list Electrical Wiring, E-plan.
.

CBMP-3 (Common Board Main Processor)
Function The CBMP is the heart of the Bluebox platform and has three major blocks:
• The Main processor [35];
• The FPGA [35] (Field Programmable Gate Array);
• The Safety microcontroller [36].
Illustration
A Push to eject the SD card!
P22
TP209: 1V5
P10
LED1 P1
LED2
LED3
P12
P9
F2
F1
LED5
P8
P7
P2
TP503: DGD
LED4 P27
P6 F4
LED7
P13 F3
P29
P5
LED6 P3
P4
P35 P34
A: SD card
LED1: 26V (yellow) LED2: reset_ok (green)
LED3: status main processor (orange) LED4: status DISPLAY connection
LED5: ST_FPGA LED6: status safety processor
LED7: status EXTERNAL connection P5: signal cable between MPS and CBMP
P6: display connection P7: LOCAN (CAN)
P8: LOCAN P9: Parallel/Bicom [37]
P12: PICAN (PT1024) P13: EXTERNAL (eg. Loomgate)
Main processor The main processor loads its program from the sd card.
The RUN-led (LED3) will blink slowly while loading and will blink fast once the application is fully loaded.
FPGA The FPGA is an integrated circuit which contains programmable logic designed to be configured by
software.
The ST_FPGA-Led (LED5) will blink slowly while loading the software and will blink fast in normal
operation.

66
Safety The safety microcontroller is a second processor that independently controls the safety features.
microcontroller The ST_SFT-led (LED6) will blink fast when the safety micro-controller is running.
Block diagram The illustration below shows the block diagram of the CBMP:
A
L
D
C
K
I H F
J
G
A. SD card B. Main processor

C. Input/Output D. Power management
E. Machine identification controller F. Resolver
G. Input/Output H. Safety processor
I. Ethernet switch J. production network
K. PDP (Picanol DisPlay) [67] L. Parallel / bicom
.
Fusing The CBMP board contains the following fuses:

Fuse Remark
F1 26V PICAN_LHS
F2 26V PICAN_RHS
F3 DGN_26V (diagnostic plug)
F4 26VF (Fused 26V for different functions on CBMP)

Parallel/Bicom There are 3 ways to connect a loom monitoring system to the machine:
• Parallel loom monitoring:
Parallel loom monitoring loads the basic information (stops, picks woven...) from the machine. The
weaving machine is equipped with a connector that includes 5 contacts which become high or low
depending on the machine status (running, stopped...).
The monitoring system supplier connects to this interface by using a data unit to record production
and stops.
A separate terminal is needed in case of additional communication between the operator and the
monitoring system. This terminal must be provided by the monitoring system supplier.
Bidirectional communication between the machine and the server is not possible through the
PDP.
Connector Pin Short name Description

6 PI_LD Selvedge stop
7 PI_PP Signal that toggles every pick
8 PI_WD Warp stop
CBMP_P9 9 PI_STRT Running / stopped
10 PI_FD Filling stop
11 SUP_PI Supply voltage
12 PI_RES Bobbin brake stop
• Bicom: Serial and Ethernet:

Via bicom it is possible to have communication between the machine and the monitoring system.
The monitoring system can send commands to the machine and vice versa.
In case of bicom, the user can send declarations from the machine to the monitoring system via
the PDP.
- Serial bicom: The data is exchanged via a RS422 interface. The monitoring system
supplier must install additional boards in the controlbox to capture the data from the
machine and send it to the monitoring system
- Ethernet bicom: The machine is connected to a LAN network (ethernet cable). Each
machine connected to this network has its own IP address. By means of these IP
addresses, the monitoring system can request or send data to each machine.
Bicom requires the monitoring system supplier to implement a communication protocol. This
protocol requires expert skills to implement and can be bought from Picanol. If the protocol is
purchased by the customer, the monitoring system supplier can only implement this at this
customer.
If the protocol is bought by the monitoring system supplier, it can be used at different
customers.

66
LOCAN The LOCAN-connector must be correctly connected and disconnected:
Disconnecting Connecting
A
A
Open both clips “A” to disconnect the cable. Push the connector until the clips “A” are
completely closed.
Also see Locan bus [44].

CBSD-1 (Common Board Sensors and Devices)
Illustration
P1
P9
LED1
F1
LED2
P2
LED3
P7
F2
P8
P3
P6
F3 F4 F5 F6
LED1: 26V (yellow) do not remove! LED2: reset_ok (green)

LED3: run (orange)
.
Function The function of the CBSD depends on the position in the rack.
Inserting the CBSD in another position in the rack, will result in another machine functionality.
The CBSD handles the input and output of several sensors and devices.

66
Possible devices
per board position CBSD(A) CBSD(B) CBSD(C)
• SLCBWH • SLMCWH • LED_REED_RHS
• SLCBRD • SLMCRD • LED_FBR_RHS
• SLCBOG • SLMCOG
• SLCBGN • SLMCGM
• SLCBBU • SLMCBU
• DWC_VUP • DWCFA_VUP
• DWC_VDOWN • DWCFA_VDOWN
• LED_REED_LHS • LED_BCKSHD_LHS
• LED_FBR_LHS • LED_BCKSHD_RHS
• FAN • CTTH_RUN
• PBLOF • PBFAF
• PBLOR • PBFAR
• PBPTHR • DTCTTH
• WYD1 • PXFASFTY
• WYD2 • 48VACP_IN
• DTLUFL • DWCFA_PRESS
• DTLUSHD • DTWT_FA
• PX_LVL
• DTKAUX
• DTQMASP1
• DTKMM
• DTQMLVL
• DTKMASP
• BMSTA
• WD_SUP
• WD1
• WD2
• LEDWD1
• LEDWD2
• DTTHMASP1
• DTTHTM
• 48VACP_IN
• 48VACP_OUT
• KLVLON
• KMASP1
• STRSTP
• KLVLOFF
• KAUX
• KMM
• FBRCT1
• WCT_RHS
• AIRPRESS_SUP
• AIRCON
• DWC_PRESS
• AIO_DGNS
• DTWT1
• DTWT2
LED indications The signals on the CBSD can visually be checked by means of the LEDs:
LED ON
LED1 26V is present
LED2 reset_ok signal is present
LED3 LED is blinking fast; FPGA is running.
.

Fusing The CBSD board contains the following fuses:
Fuse Remark
F1 26VU (26V for the upper CBSD part)
F2 26VL (26V for the lower CBSD part)
F3, F4 DTTH00: Protection bimetal transformer00)
F5, F6 DTTH01: Protection bimetal transformer01)

66
ABSD-2 (Airjet Board Sensors and Devices)
Function The ABSD board has the following devices:

• current drives;
• small stepper motor drivers;
• large stepper motor drivers.
The function of the ABSD board depends on its position in the rack.
Inserting the ABSD board in another position in the board rack will result in another machine
functionality.
Illustration
P15 P16
P1
LED1
F1
LED2
P2
LED3 F2
P10
P3
LED1: 26V (yellow) LED2: reset_ok (green)

LED3: run (orange)
LED indications The signals on the ABSD can visually be checked by means of the LEDs:
LED ON
LED1 26V is present
LED2 reset_ok signal is present
LED3 LED is blinking fast ==> running.

Functions per
board position Board position Possible devices
ABSD(A) • CH1-2 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT,
VCLMP_MNM)
• VRN[1-17] (max T220)
• ELSY_LHS, ELSY_RHS
• FICT, VSN, VSNEX/VSU, V_PRA_SU, CRDL_VCLMP
• FD1, FD2, FDSU
ABSD(B) • CH3-4 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT,
VCLMP_MNM)
• VRN[18-25] (max T340)
• MTI/ATI_LHS, MTI/ATI_RHS
ABSD(C) • CH5-6 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT,
VCLMP_MNM)
• ATI_MID1_MCT, ATI_MID2_MCT
ABSD(D) • CH7-8 (VMNF, VMNM, ELCA_MNF, ELCA_MNM, VRA, EPR, PFT,
VCLMP_MNM)
• VPMMN
ABSD(E) • VRN[26-29] (max T400)
• ELSY_MID1, ELSY_MID2, ELSY_MID3
• ATI_MID1, ATI_MID2
• TI_MID1, TI_MID2, TI_MID3
• FBRCT2, FBRCT3
• VMNTF_CH[1-4]
• ELCA_TF_CH[1-4]
Block diagram
A. 32 valve drivers B. Power management

C. rack position D. 5 inputs
E. 10 small stepper motor drivers F. 3 large stepper motor drivers
.
Fusing The ABSD board contains the following fuses:

Fuse Remark
F1 26VU (26V for the upper ABSD part)
F2 26VL (26V for the lower ABSD part)

66
Bus systems
Overview
Diagram
ABSD
NG_LDEC
FSB (Fast Serial Bus)
See section CBFSB-1 (Common Board Fast Serial Bus) [33]
Locan bus
Function The Locan bus is a bus system that connects the CBMP with the following devices:
• SRDD (Switch Reluctance Dual Drive) [58];
• NG_LDEC (New Generation Loom Drive Electronic Converter) [62].
The Locan bus consists of the following functionalities:
• CAN communication (500kbps);
• Position signal;
• Drive and brake enable signals.
The Locan cable is a twisted pair flat cable that start at the CBMP and ends at the NG_LDEC.
1st Position = brown wire

Illustration
Front [28] Power Panel side [30]
A. Connection on the CBMP B. Connection on the SRDD

C. Connection on the NG_LDEC
.
The connector “A” should be closed properly. See: LOCAN [38].
Block diagram
NG_LDEC SRDD
A
B CBMP
NG_LDEC (New Generation Loom Drive Electronic SRDD (Switch Reluctance Dual Drive) [58]
Converter) [62] CBMP-3 (Common Board Main Processor) [35]
A. CAN communication B. Position signal
C. Drive and brake enable signals
.

66
Pican bus
Function The Pican bus is a bus system that connects the CBMP board with the following devices:
• Prewinder Control box (LHS_PICAN)
• Pican_FDCB (RHS_PICAN)
• E-leno’s (RHS_PICAN)
• Jacquarette
• Can dobby (RHS_PICAN)
• Jacquard (RHS_PICAN)
The Pican bus consists of the following functionalities:

• CAN communication (500kbps): bidirectional communication between the CBMP and the other
Pican devices;
• Position signal (PT1024): Used to transfer the machine position (coming from the resolver) to the
Pican devices;
• 26V supply voltage, protected by the fuses F1 (RHS_PICAN) and F2 (LHS_PICAN) on the CBMP;
• Event line: not used.
The Pican communication and the PT1024 position signal are always terminated on both sides
with a 120 ohm resistor.
Block diagram

Measuring the 1. Switch off the machine.
Pican bus Do not remove any board or Pican device.
2. Measure the resistance between the points on the XW_CBMP_P1 connector mentioned in the table
below:
Points Value What?
30Z (green) and 32Z (yellow) 60 Ohm CAN communication termination
30B (white) and 32B (brown) 60 Ohm PT1024 position signal termination
30D (black) and 32B (brown) 70k Ohm or higher Drivers
30D (black) and 30B (white) 70k Ohm or higher
30D (black) and 30Z (green) 70k Ohm or higher
30D (black) and 32Z (yellow) 70k Ohm or higher
A. XW_CBMP_P1 B. PICAN_RHS
C. PICAN_LHS
.
Also see:
• Can Dobby S3XXX [79]
• Jacquard [79]
• E-Leno [78]
• IRO Control Box [76]

66
Mains entry
Diagram
Mains diagram The illustration below shows the mains diagram when the machine is not executed with a transfo:
L1
L2
L3
1 3 5
QM
2 4 6
R S T
FL 3~
R’ S’ T’
X_L21
X_L22
X_L23 A
LR
X_L11
X_L12
X_L13
A. Connections to:
• [53]
• QMASP1: Overload protection switch motor aspirator [53]
B. Connections to:
• MPS-2 (Main Power Supply) [56]
• NG_LDEC (New Generation Loom Drive Electronic Converter) [62]
• Mains supply
See E-plan.
.
When executed The illustration below shows the transfo:
DTTHTM
DTTHTM: DeTection THermal Transformer Mains

QM: Overload protection switch Mains
Overload The QM also has an overload protection. See: Overload protection [14].
Positions The table below shows the different positions of the main switch:
Main switch position... Machine status
0 - OFF dead
with the exception of the parts and conductors from the mains
terminals to the main switch input terminals.
I - ON live.
Safety
During a lubrication action or an intervention on the machine and/or the weaving mill
equipment, the main switch must be padlocked in the -OFF- position.
Proceed as follows to padlock the main switch:
1. Slide out the padlock part “A”.
2. Padlock the main switch.

66
FL: EMI FiLter
Function The FL has the following functions:

• to protect the main power supply against interferences,
• to prevent the control of causing interferences on the mains.
Illustration The following illustration shows the FL:
LR: Line Reactor
Function The LR improves the power factor.
Illustration The illustration below shows the LR:

High voltage part
Illustration
INRUSH
L1*
L2*
L3*
XW279A
FAN_CB

66
Contactors
KMM: Contactor main motor (is closed when you activate power-on).
KMASP: Contactor motor aspirator.
KAUX: Contactor auxiliary (which is used for the batching motion supply and the MLU (Motor
Lubrication).
KMLVLON: Contactor motor leveling ON.
KMLVLOFF: Contactor motor leveling OFF.
KWDDL: Contactor Warp Detection DropperLess
Filters ZMASP: Filter motor aspirator.

ZMLVL: Filter motor leveling.
Terminals X1, X2, X3, X4, X7, X8: Earth terminal.

L11, L12, L13: Terminal.
Terminal connections:
XKF: Terminal for the batching motion and the supply for the fan FAN_CB..

Overload
protection switch
QMLVL: Overload protection switch motor leveling (used in case of CAM S1692).
Current at 50Hz Current at 60Hz
Mains voltage
Breaker setting Breaker range Breaker setting Breaker range
360V 2.0A 1.4A
1,6A to 2,5A
380V 2.4A 1.5A 1,0A to 1,6A
400V 2.8A 1.6A
420V 3.2A 2,5A to 4,0A 1.8A
440V 3.6A 2.2A 1,6A to 2,5A
460V 4.2A 4,0A to 6,3A 2.5A
QMLVL: Overload protection switch motor leveling (used in case of CAM 1681, 1781):
Mains voltage Current at 50Hz Current at 60Hz
380V 4A 4A
400V 4,5A
415V 2A 4,5A
440V 2,2A
460V 2,4A 2,5A
QMASP1: Overload protection switch motor aspirator

380V
1,5A
400V
415V 1,4A
440V 1,3A
460V
QWDDL: Overload protection DropperLess

380V
400V
415V 0,4A 0,4A
440V
460V
Fuses FAUX1, FAUX2, FAUX3: fuses for the batching motion.

FCTTH1, FCTTH2: fuses for the thermal cutter.
FTWDDL: Fuse Transfo Warp Detection DropperLess
Fuse values, see electrical wiring.

66
Inrush INRUSH: board for pre-loading the NG_LDEC.
Fuse values, see electrical wiring.
Transfo TWDDL: Transfo Warp Detection DropperLess

Power panel
Latching the Power
panel Always latch the power panel while working on the rear side of the control box, using the fixation
tool “A”.
Proceed as follows to latch the power panel:

1. Switch off the power and wait for 3 minutes.
Wait for 3 minutes to discharge all drives.
2. Open the rear side of the control box
3. Remove the fixation tool “A” from the panel:
4. Place the fixation tool “A” in the holes above the wheel “B” to latch the power panel:
A A

66
MPS-2 (Main Power Supply)
Requirements The MPS board requires a three-phase voltage between 380VAC and 460VAC.
The required frequency of the supply voltage should be 50Hz or 60Hz.
Function The MPS board generates the following supply voltages:

• 290VDC
• 26VDC
• 12VDC (only used for the display)
• 5VDC
• 48VAC/55Hz
The 26VDC towards the FSB board is only available after a validation by the CBMP board.
The CBMP first checks if all installed boards are in a correct slot and then activates a switch on the
MPS to make the 26VDC towards the CBFSB available.
Signals The following signals can be found on the MPS:

• AC_UV: undervoltage is active when the supply voltage is below 310Vac.
• /AC_OK: Three-fase supply voltage (mains) is available.
• /DC_OK: All DC supply voltages are available.
Illustration The following illustration shows the MPS board “A”:

A

Connections The following illustration shows the MPS-board and its connections and fuses:
F3
F2
F1
P1
P2
P3
P4
P5
P6
P1: Mains input 3x400VAC + GND

P2: 290VDC output
P3: 5VDC / 48VAC output
P4: 26V_ENABLE, /AC_OK, /DC_OK, AC_UV
P5: 12VDC
P6: 26VDC
Diagram The following illustrations shows the communication between the MPS and the CBMP:
Signal
/AC_OK 0V 5V
/DC_OK 0V 5V
AC_UV 0V 5V
Fuses The MPS board contains the following fuses:

Fuse Remark
F1
F2 Mains protection
F3
.

66
SRDD (Switch Reluctance Dual Drive)
Function The SRDD has the following functions:

• The board drives two SR-motors, for example ELO and ETU
• The output stage for the machine brake.
SRDD_L: with low voltage brake system (26VDC). This board can drive a pneumatic valve which drives
a pneumatic parking brake, or an electrical holding brake.
Locan bus See: Locan bus [44].
M1
M2
M1. Motor 1 M2. Motor 2
Replacing To replace the SRDD, see: Replacing the assem. SRDD [103].
Board position It is possible to mount 2 SRDD assemblies. This results in a maximum of 4 SR-motors that can be
driven.
A. SRDD(A) B. SRDD(B)
.

Illustration
P3 P7 P11 P4
P1
P10
P12 P15
P17
P14 = dump P22 P23

P1. M1 resolver and identification P3. Machine brake
P4. M1 phases motor P7. M1 brake
P10. LOCAN P11. M2 brake
P12. Brake signal from NG_LDEC P14. Dump resistor
P15. M2 phases motor P17. M2 resolver and identification
P22. 26VDC / 290VDC coming from the CBFSB P23. 26VDC / 290VDC to the SRDD
In case of ETU ratio 34/43 or 39/25, a dump resistor is mounted on the SRDD board.
.
P14 = Dump
resistor

66
SR motor Every SRDD board can drive 2 SR motors. These SR motors contain the following parts:
• four-phase switched reluctance motor;
• resolver;
• holding brake;
• bimetal.
A BIM
BR RS
A. SR Motor BIM. BIMetal
BR. Brake RS. Resolver
.
Motor identification The SRDD identifies the SR motor by means of a jumper on the resolver connector:
Motor Jumper connection Illustration
ELO_RHS 5-12
ETU 6-13
ELO_LHS 7-14
ELOFA 8-15
A. Jumper
.

LED’s
M1
M2
290V
M1. Status LED’s motor 1 (L0-L3) M2. Status LED’s motor 2 (L0-L3)
290V. LED, on when 290V is present.
LED indications The LED’s (L0 to L2) on the SRDD board indicate an error code. The number of blinks in a sequence
show a typical error code.
After the sequence of flashes (D) there is a short pause followed by two flashes of all 4 LED’s (C). The
sequence will repeat itself again.
The following illustration shows an example of an error code:
L3 A
L2
L1 B
L0
C C C
D D D
A. Soft DEN_M1 or Soft DEN_M2 (DEN: Drive ENable)
B. These LED’s show the typical error code.
C. All LEDs flash two times
D. Sequence of flashes.
In this example the sequence counts 3 flashes, so the error code is 3.
.

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NG_LDEC (New Generation Loom Drive Electronic Converter)
Function The NG_LDEC controls, checks and protects the control of the main motor and it controls the machine
brake.
The NG_LDEC disengages the main motor or prevents it from starting if one of the following conditions
is exceeded:
• Overcurrent motor phases: 250A;
• Differential: ±2A;
• Overvoltage DC: 796V;
• Undervoltage DC: 370V;
• Temperature of the modules: 80°C;
• Low voltage check;
• Saturation protection.
If an error occurs, an error message will appear on screen and LEDs will light up on the NG_LDEC.
Also see: LED indications [64].
Replacing To replace the assem. NG_LDEC, see: Replacing the assem. NG_LDEC [93].
Illustration
Block diagram
E
A
C C D
G E G
D E D
F
G G
F
A. Main motor B. Connection box
C. Dump resistance D. EBMM-1 (Elco Board Main Motor) [64]
E. MMRB-1 (Main Motor Rectifier Board) [65] F. MMCU-1 (Main Motor Control Unit) [63]
G. OBMM-1 (Output Board Main Motor) [65] H. Machine brake
.

MMCU-1 (Main Motor Control Unit)
Function The MMCU board controls:

• the main motor (SUMO);
• the machine brake.
Illustration
A B
C
BREN_FB
D
DEN1_FB
LED-0
LED-1
LED-2
LED-3
A. 5V Indication B. Processor MMCU board.

C. LOCAN D. Brake signal going to the SRDD board.
.

66
LED indications The LED’s (LED-0 to LED-3) on the MMCU board indicate an error code. The number of blinks in a
sequence show a typical error code.
After the sequence of flashes there is a short pause followed by two flashes of all 4 LED’s.
The sequence will repeat itself again.
The following illustration shows an example of an error code:

.
All LED’s flash two times.
==> 10 flashes ==> error code 10
All LED’s flash two times.
. .
EBMM-1 (Elco Board Main Motor)
Function The EBMM has the following functions:

• Buffering the DC voltage;
• Discharging energy after power off.
There are 2 EBMM boards in the NG_LDEC. These 2 boards always have to be exchanged
together.
Replacing To replace the EBMM, see: Replacing the EBMM [94].

OBMM-1 (Output Board Main Motor)
Function The OBMM has the following functions:

• controlling the power stages for 2 motor coils;
• measuring the power at the motor phases;
• monitoring the temperature of the modules;
• protecting against saturation of the modules;
• generating voltage for the drivers.
There are 2 OBMM boards in the NG_LDEC. One board controls motor phases A and C
(OBMMac), the other OBMM board drives the motor phases B and D (OBMMbd).
Replacing To replace the OBMM, see: Replacing the OBMM [95].
MMRB-1 (Main Motor Rectifier Board)
Function The MMRB has the following functions:

• Rectifying the 3 phase AC power into DC power.
• Measuring the voltage and current towards the motor control system (OBMM boards).
• Controls the dump system.
Replacing To replace the MMRB, see: Replacing the MMRB [98].

66
.

Devices on the machine
Contents • PDP (Picanol DisPlay) .............................................................................................................. 67
• Control buttons on the breast plate........................................................................................... 69
• RS: ReSolver ............................................................................................................................ 70
• Proximity switches .................................................................................................................... 72
• Safety light curtain .................................................................................................................... 73
• EPR (Electronic Pressure Regulator) ....................................................................................... 75
• ELSY: Electric Leno SYstem .................................................................................................... 76
• IRO Control Box........................................................................................................................ 76
• NG_FDCB: Filling Detector Control Box ................................................................................... 77
• E-Leno ...................................................................................................................................... 78
• Can Dobby S3XXX ................................................................................................................... 79
• Jacquard ................................................................................................................................... 79
• Cam motion with leveling system (1681, 1781) ........................................................................ 81
• Cam motion with leveling system (S1692)................................................................................ 83
• Parking brake............................................................................................................................ 84
• Electrical cutters ....................................................................................................................... 86
• Thermal cutter........................................................................................................................... 87
• PKE........................................................................................................................................... 88
PDP (Picanol DisPlay)
Function The PDP is the user interface with the machine (CBMP).
The communication with the CBMP board is done via an Ethernet connection.
Versions There are 2 versions of the PDP:

assem. PDP_9INCH assem. PDP_12INCH
”
9” 12
Replacing To replace the PDP, see: Replacing the PDP [109].
Localization The following illustration shows the localization of the PDP:
EN170410N Devices on the machine 67 / 134

90
assem. PDP_9inch The following illustration shows the LED’s and connectors of the PDP_9inch assembly:
P7
A
P21
P17
LED2
PDP2_9inch
B
C
LED6
LED7
P6
P8
P23 P24 LED1

A. assem.PDP_USB B. SD-card
C. RESET button
P6. Communication with the CBMP board P7. TFT (Thin-Film Transistor screen)
P8. 12V supply from the MPS board P21. Touch screen
LED1. 12V LED2. USB supply
assem. PDP_12inch The following illustration shows the LED’s and connectors of the PDP_12inch assembly:
P17
P19 P20
P21 LED2
E
PDP_12inch
P4 F
LED4 LED6
LED5
LED7
P6
P8
P23 P24 LED1
D. assem.PDP_USB E. SD-card
F. RESET button
P4. Touch screen P6. Communication with the CBMP board
P8. 12V supply from the MPS board P19. TFT (Thin-Film Transistor screen)
LED1. 12V LED2. USB supply
LED4. Activity LED5. Communication link
.
68 / 134 Devices on the machine EN170410N

Control buttons on the breast plate
Compatibility
The OMNIplus Summum control buttons are NOT interchangeable with the OMNIplus 800 control
buttons!
Location The illustration below shows the control buttons on the breast plate:
Machine width Control buttons
T190-T280 A
T340-T400 G H
G. Push Buttons Left Hand Side H. Push Buttons Middle I. Push Buttons Right Hand Side
.
Control buttons The following illustration shows the control buttons:

PB-STRT
PB-PFR PB-SMR
PB-PFF PB-SMF
PB-STOP
PB_STRT: Push Button_STaRT PB_PFR: Push Button_PickFinding Reverse
PB_PFF: Push Button_PickFinding Forward PB_SMR: Push Button_Slow Motion Reverse
PB_SMF: Push Button_Slow Motion Forward PB_STOP: Push Button_STOP
Block diagram The following illustration shows the control buttons block diagram:
A. Push Buttons Left Hand Side B. Push Buttons Middle C. Push Buttons Right Hand Side
.

90
RS: ReSolver
Function The (brushless) resolver provides two voltages that represent the absolute position of the input shaft.
The resolver is a rotary transformer where the magnitude through the resolver windings varies
sinusoidal as the rotor shaft rotates.
Primary/secondary The resolver has two types of windings:

windings • Primary winding = the reference winding, located in the rotor;
• Secondary windings = the sinus and the cosine windings, mechanically displaced 90 degrees from
each other.
In the resolver, energy is supplied to the reference winding through a rotary transformer.
The inducted voltages in the sinus and cosine windings are equal to the value of the reference winding
voltage multiplied by the sinus or cosine of the angle of the input shaft from a fixed zero point.
Diagram The illustration below shows the diagram of the resolver:
A VC= VRCOS(Α)
B
VR
C D VS= VRSIN(Α)
a
A. Cosine winding (secondary windings) B. Sinus winding (secondary windings)
C. Rotary transformer D. Reference winding (primary winding)
VC. Cosine voltage VR. Reference voltage
VS. Sinus voltage α. Angle of the input shaft from a fixed zero point.
.
Illustration The following illustration shows an intersection of the resolver and the rotor and stator:
A B
A. Rotor B. Stator
.
When the resolver needs to be replaced, replace the rotor together with the stator.
The numbers on the new rotor “A” and the new stator “B” need to be the same.
A
B

Shielded resolver The shielded resolver cable contains 2 separate screens to maximise shielding.
cable
A B C
A. Outer shielding B. Aluminium foil C. Drain wire

.
Measuring the Proceed as follows to measure the resolver:

resolver 1. Switch off the machine.
2. Measure the resistance between the following points:
H1_27_116_116(*) T1_45_58_58(*)
02F White RS_REF_H
27 Ohm 45 Ohm
04F Brown RS_REF_L
02D Green RS_COS_H
CBMP_P3 116 Ohm 58 Ohm
04D Yellow RS_COS_L
02B Grey RS_SIN_H
116 Ohm 58 Ohm
04B Pink RS_SIN_L
(*): You can have 2 types of resolvers, H1_27_116_116 or T1_45_58_58
Additional For more information about mounting and setting the resolver, see chapter ‘Mechanical Settings >
information Drive’.

90
Proximity switches
Main proximity The following illustration shows the main proximity switches on the machine:
switches
PX_REF
PX_WP PX_PFP
PX_WP. ProXimity switch_Weave Position PX_PFP. ProXimity switch_PickFinding Position

PX_REF. ProXimity switch_REFerence
Additional For more information about the proximity switches, see chapter: ‘Mechanical Settings > Drive’.
information
Other proximity The table below describes the other proximity switches:
switches PX Description
PX-FA-SFTY Only in case of fancy beam. This PX detects if the
back rest roller is within its functional working area.
PX_LVL_WP Only in case of outside cam motion with leveling.
This PX detects if the machine is ready for weaving
(leveling OFF).
Function Proximity switches act as variable resistors. The output resistance depends on the presence of metal.
The table below shows the proximity switches output according its condition:
The proximity sensor state Output resistance
Uncovered low resistance
In front of metal high resistance
B
A. Proximity switch B. Metal plate

.

Diagram The illustration below shows a diagram of a proximity sensor (PX):
LDO: Low-Dropout regulator
.
LDO
Safety light curtain
Localisation The following illustration shows where the safety light curtain is located:
Emitter Receiver
Operation By interrupting the detection field, the following movements are prevented:
• starting;
• slow motion;
• pick finding
The safety light curtain does NOT work: 
- when a machine is operating at full speed; 
- during service operation mode.
Upon starting or shutting down the machine, every automatic slow-motion or pick finding
movement will be stopped when interrupting the safety light curtain.
Only applicable on CE machines.

90
Emitter The following illustration shows the emitter and its components:
Illustration Indicator On Blinking
A. Top-beam-state Turns on when the beam Blinks when cap error or
indicator is receiving light connection error occurs.
B. Stable-state indicator Turns on when incidence Blinks when the safety
level is 170% or more ofoutput is turned off due to
the output ON threshold.disturbance light or
A vibration.
C. On/Off-state indicator Green: Turns on when Red: Blinks when the light
safety output is on. curtain enters a lockout
Red: Turns on when safety
due to a safety output
B output is off. error.
D. Lockout indicator Turns on when the light Blinks when the light
C curtain enters a lockout on
curtain enters a lockout on
D the receiver. the emitter.
E. Power indicator Turns on when the power Blinks when the light
E of the emitter is on. curtain enters a lockout
due to power voltage/
F noise.
F. Test indicator — Blinks when external test
is being performed.
G. Bottom-beam-state Turns on when the bottom —
indicator beam is receiving light.
.
Receiver The following illustration shows the receiver and its components:
Illustration Indicator On Blinking
A. Top-bottom-state Turns on when the top Blinks when cap or
indicator beam is receiving light. connection error occurs.
B. Stable-state indicator Turns on when incidence Blinks when the safety
level is 170% or more of output is turned off due to
the output on threshold. disturbance light or
A vibration.
C. On/off-state indicator Green: Turns on when Red: Blinks when the light
safety output is on. curtain enters a lockout
Red: Turns on when safetydue to a safety output
B output is off. error.
D. Lockout indicator Turns on when the light Blinks when the light
C curtain enters a lockout on
curtain enters a lockout on
D the emitter. the receiver.
E. Communication Turns on when Blinks when the light
E indicator communication between curtain enters lockout due
emitter and receiver is to a communication error
F established. between receiver and
emitter.
G F. Configuration indicator — Blinks when the light
curtain enters lockout due
to a model type error
between receiver and
emitter.
G. Internal indicator — Blinks when the light
curtain enters a lockout
H due to an internal error.
H. Bottom-beam-state- Turns on when the bottom —
indicator beam is receiving light.
.

EPR (Electronic Pressure Regulator)
Illustration The following illustration shows the EPR-devices:
A. EPR_MN_[CH1-CH4] B. EPR_RN_MID
C. EPR_RN_LHS+RHS
.
Block diagram The following illustration shows the block diagram of an EPR device:
A. Pressure tank 1
.
Synchronisation After Power On, all EPR devices synchronise.

The following illustration shows an EPR in a random position and a synchronised EPR:
Random position Synchronisation position
Additional For more information about the EPR devices, see chapter: ‘Mechanical Settings > Insertion’.
information
.

90
ELSY: Electric Leno SYstem
Illustration The following illustration shows the ELSY devices:
ELSY_LHS ELSY_MID ELSY_RHS
ELSY Board position

• ELSY_LHS ABSD(A)
• ELSY_MID1 ABSD(E)
• ELSY_RHS ABSD(A)
Additional For more information about the ELSY devices, see chapter: ‘Mechanical Settings > Selvedge’.
information
IRO Control Box
Illustration The following illustration shows the IRO control box:
FB2
FB1
A. Pulse termination and CAN termination FB1. Fuse T3,15A

FB2. Fuse T5A
.

NG_FDCB: Filling Detector Control Box
Illustration The following illustration shows the FDCB:

90
E-Leno
Illustration The following illustration shows the E-Leno devices:
E-Leno_LHS
E-Leno_RHS
Termination The following illustration shows the termination connector on the E-Leno:
Measuring points The following illustration shows the different measuring points on the E-leno device:

Can Dobby S3XXX
Illustration The following illustration shows the S3XXX dobby, the connections and the pulse and CAN termination:
CH CL PH PL SH A
A. Pulse termination and CAN termination CH. CAN High
CL. CAN Low PH. Pulse bus High
PL. Pulse bus Low SH. SHielding
.
Measure the PICAN Proceed as follows to measure the PICAN bus on the CAN C4 board:
bus Points Value What?
CH - CL 60 Ohm CAN termination
PH - PL 60 Ohm PT1024 termination
Ground - CH 70K Ohm or higher Drivers
Ground - CL 70K Ohm or higher
Ground - PH 70K Ohm or higher
Ground - PL 70K Ohm or higher
Jacquard
Connections The controller of the jacquard must be connected on the right hand side of the machine:
The first cable is for the PICAN communication and the second cable is for the emergency stop and
48VAC.
• Machine without e-leno: The PICAN cable from the jacquard has to be connected on the
PICAN_OUT of the NG_FDCB “A”.
• Machine with e-leno: The PICAN cable from the jacquard has to be connected on the retour cable for
the LHS_E-leno W004A ES_J.
Connect the emergency stop cable from the jacquard on cable W004A “B”.

90
Diagram The following illustration shows the jacquard connection diagram:
w004a es_j
B
C
W067
Pican_LHS
W059
D Pican_RHS
W162B
E-LENO RHS TO LHS
W162A
FDCB TO E-LENO RHS
E F
W162C
A. The Control Box (CB) [25] B. CBMP-3 (Common Board Main
Processor) [35]
C. Control box jacquard. See manual supplier. D. Prewinder control box
E. E-leno left-hand side F. E-leno right-hand side
G. NG_FDCB
Emergency stop Before connecting the Emergency stop cable, the temporary plug (BE153972) on cable W004A ES_J
cable must be removed.
This plug is only needed for running-in the machine without jacquard.
Termination Staubli The following illustration shows the termination of the Staubli JC7 controller:
JC7 controller

Termination Bonas The following illustration shows the termination of the Bonas S600 and S800:
S600 and S800
Cam motion with leveling system (1681, 1781)
Leveling system The leveling of the cam motion is done with piston driven by oil pressure.
Diagram The following illustration shows the diagrams for the leveling system of the cam motion:
PX_LVL_WP: PX LeVeLing Weaving Position KMLVL_ON: Contactor Motor LeVeLing ON

MLVL: Motor LeVeLing QMLVL: Overload Protection Switch Motor
LeVeLing
KMLVL_OFF: Contactor Motor LeVeLing OFF
.

90
Location The following illustration shows the leveling system on the cam motion:
W035
W036B
W036B

Cam motion with leveling system (S1692)
Leveling system The leveling of the cam motion is done by a motor driven screw.
Diagram The following illustration shows the diagrams for the leveling system of the cam motion:
PX_LVL_LP: PX LeVeLing Leveling Position KMLVL_ON: Contactor Motor LeVeLing ON

PX_LVL_WP:PX LeVeLing Weaving Position QMLVL: Overload Protection Switch Motor
LeVeLing
KMLVL_OFF: Contactor Motor LeVeLing OFF MLVL: Motor LeVeLing

90
Parking brake
Location The following illustrations show the parking brake and the other devices for the working of the parking
brake:
VPBR
PBR_DTPRESS
PBR
VPBR. Valve Parking BRake PBR_DTPRESS. Parking BRake DeTection PRESSure

PBR. Parking BRake
.
The parking brake is controlled by the NG_LDEC, but the driver for the parking brake valve (26 VDC) is
located on the SRDD_L(A).
Voltage Valve is... parking brake is...
0 VDC closed closed
26 VDC open open

Diagram The following illustration shows the diagram of the parking brake system:
VPBR
PBR_PN_DTPRESS
Also see Brake [18].

90
Electrical cutters
Location The following illustration shows the location of the electrical cutters:
FICT WCT_LHS FBRCT 1-3 WCT_RHS
Overview The following illustration shows an overview of the possible electrical cutters on the machine, and their
board connection:
TYPE OF CUTTER
BOARD CONNECTION
.
FICT: FIlling CuTter WCT_LHS: Waste CuTter Left Hand Side

FBRCT1-3: FaBRic CuTter 1-3 WCT_RHS: Waste CuTter Right Hand Side

Thermal cutter
Device The thermal cutter device (CTTH) is located on the floor of the control box:
Overview The following illustration shows an overview of the thermal cutter devices and its board connection:
• Run signal: The machine gives 26V when the machine is running and 0V when the machine is
stopped.
• Status signal: the thermal cutter device can stop the machine by opening the switch when
something is wrong with the device. The switch is closed when there is no problem.

90
PKE
PKE with bobbin The following illustration shows PKE with knot sensor:
change sensor
BE316884
The following illustration shows the diagram:
The following illustration shows the parts:
A. Prewinder connection
B. Full PKE sensor
C. Bobbin change sensor
D. Connection box
.

Full PKE with knot The following illustration shows the diagram:
sensor

90
.

Service
General
Contents • General ..................................................................................................................................... 91
Replacing boards and/or assemblies ........................................................................................... 92

• General ..................................................................................................................................... 92
• RMA (Return Merchandise Authorization) ................................................................................ 92
• Replacing the assem. NG_LDEC ............................................................................................. 93
• Replacing the EBMM ................................................................................................................ 94
• Replacing the OBMM................................................................................................................ 95
• Replacing the MMRB................................................................................................................ 98
• Removing and mounting boards from the rack....................................................................... 101
• Replacing the assem. SRDD .................................................................................................. 103
• Replacing the CBFSB............................................................................................................. 105
• Replacing the CBMP .............................................................................................................. 107
• Replacing the PDP ................................................................................................................. 109
• Replacing the protection foil on the assem.PDP_9inch.......................................................... 111
Software......................................................................................................................................... 113
• Installing Software .................................................................................................................. 113
• CSF (Customer System File) .................................................................................................. 115
• Machine log ............................................................................................................................ 116
• Screen capture ....................................................................................................................... 117
Fuses ............................................................................................................................................. 118

• Marking ................................................................................................................................... 118
• Fuse details ............................................................................................................................ 118
Tools .............................................................................................................................................. 119

• Masterstick (BE316654) ......................................................................................................... 119
• USB-stick (N1038701) ............................................................................................................ 119
• F-contact tools ........................................................................................................................ 120
• Burndy (TRIM TRIO) contact tools ......................................................................................... 121
• D-sub contact tools ................................................................................................................. 122
• Molex Mini-Fit Jr contact tools ................................................................................................ 123
• Molex Mini-Fit Sr contact tools................................................................................................ 124
• Torx screwdriver ..................................................................................................................... 125
• Wire strip tool.......................................................................................................................... 125
• Crimp tool for wire end-sleeves (0,08 mm² - 16 mm²) ............................................................ 126
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Replacing boards and/or assemblies
General
Replacement When a board or assembly is defective, proceed as follows:

process 1. Send a request for a ‘RMA’-number to your local CSR-office.
2. Your local CSR-office will send you an RMA-number.
3. Dismount the defective board or assembly according to the respective procedure described in this
chapter.
4. Fill in the RMA-form. See RMA (Return Merchandise Authorization) [92].
5. E-mail the filled-in RMA-form to BUP_return@picanol.be.
Always fill in the e-mail subject as follows: RMA <RMA_number>.
6. Send the defective board or assembly to your local CSR-office.

Always mention the RMA number when sending the defective boards or assemblies!
7. After you received the new board or assembly, replace it according to the respective procedure
described in this chapter.
RMA (Return Merchandise Authorization)
Form To return a defective board or assembly the RMA-form must be filled in correctly. The different entries of
the form are explained below:
Form Illustration (example)
1) Name defective board or assembly: .....................(A)
2) BE number defective board or assembly: ............(B)
3) Serial number defective board or assembly: ........(C)
See: Board naming [24].
4) Problem description: .............................................(D)
5) Machine serial number and the CSF file: .............(E) B
6) Error number and error description or if possible a
bitmap of the info screen: ............................................(F)
A
D. Describe the problem, what happened, when did it E. Write down the serial number of the
happen, how did it happen. machine (see the identification plate on the
right-hand side of the machine) and the name
of the CSF-file (see CSF (Customer System
File) [115]).
92 / 134 Service EN170410N

Form Illustration (example)
F.
1. Go to the info screen.

2. Take a screen capture. See: Screen capture [117].
3. Take a CSF. See: CSF (Customer System File) [115].
4. Take a LOG. See: Machine log [116].
Replacing the assem. NG_LDEC
Removing the Proceed as follows to remove the assem. NG_LDEC:

assem. NG_LDEC 1. Switch off the power supply.
2. Wait at least 3 minutes and open the rear side of the control box. See: Power Panel side [30] of the
control box.
3. Latch the power panel. See: Latching the Power panel [55].
4. Disconnect the connectors on the NG_LDEC.
5. Remove the assem. NG_LDEC.
For any further operations on the NG_LDEC, place the NG_LDEC in a dust-free environment. Dust
between the power modules and the heat sink will damage the modules.
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Fitting the assem. 1. Fit the new assem. NG_LDEC into its position.
NG_LDEC
2. Reconnect all connectors on the NG_LDEC.

3. Remove the fixation tool.
4. Close the main control box.
Replacing the EBMM

Removing the Proceed as follows to remove the EBMM:
EBMM Always replace both EBMM boards. If one board is defective, the other board will also be
damaged.
1. Remove the NG_LDEC, see: Replacing the assem. NG_LDEC [93].
2. Remove the cover of the NG_LDEC.
3. Loosen the bolts “A” of both EBMM boards and remove the boards.
A A
Fitting the EBMM Proceed as follows to fit the EBMM boards:

boards Always replace both EBMM boards. If one board is defective, the other board will also be
damaged.
1. Fit the EBMM boards and tighten the bolts “A” (1,4 Nm).
A A
94 / 134 Service EN170410N

2. Mount the cover.
3. Fit the assem. NG_LDEC. 

See: Fitting the assem. NG_LDEC [94].
Replacing the OBMM

Removing the Proceed as follows to remove the OBMM:
OBMM The procedure below applies to both OBMM boards.
1. Remove the NG_LDEC.

See: Replacing the assem. NG_LDEC [93].
2. Remove the cover of the NG_LDEC.
3. Disconnect the flat cable from the OBMM.
4. Loosen the bolts “B” and remove the EBMM board.
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5. Remove the bolts “C” from the OBMM board.
6. Remove the 8 bolts “D” from the power modules.
7. Remove the OBMM board

8. Remove the cooling paste from the heat sink and from the OBMM power module.
Fitting the OBMM Proceed as follows to fit the OBMM board:

The procedure below applies to both OBMM boards.
1. Evenly apply cooling paste onto the heat sink.

Spread the cooling paste with a spatula.
2. Fit the OBMM board and hand tighten the bolts “C”.
3. Tighten the 8 bolts “D” of the power modules.

Tighten the bolts in diagonal order. Tighten first to 2 Nm, afterwards to 4 Nm.
1 6 3 8
5 2 7 4
96 / 134 Service EN170410N

4. Tighten the bolts “C” (1,4 Nm).
5. Connect the flat cable to the OBMM board.
6. Fit the EBMM board and tighten the bolts “B” (1,4 Nm).
7. Remount the cover.
8. Put the LDEC back and restore all connections.

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Replacing the MMRB
Removing the Proceed as follows to remove the MMRB board from the NG_LDEC:
MMRB 1. Remove the assem. NG_LDEC panel from the control box.
See: Replacing the assem. NG_LDEC [93].
2. Remove the cover.
3. Disconnect both flat cables from the MMRB board “A”.

A A
4. Loosen the bolts “B” of both EBMM boards and remove the boards.
B B
5. Loosen the bolts “C” of the MMCU board and remove the board.
6. Remove the bolts “D” from the MMRB board.
98 / 134 Service EN170410N

7. Remove the bolts “E” of the power modules and remove the MMRB board.
8. Remove the cooling paste from the heat sink and from the MMRB power module.
Fitting the MMRB 1. Evenly apply cooling paste onto the heat sink.
Spread the cooling paste with a spatula.
2. Fit the new MMRB board and finger-tighten the bolts “D”.
3. Tighten the 4 bolts “E” of the power modules.

Tighten the bolts in diagonal order. First tighten to 2 Nm, afterwards to 4 Nm.
1 4
3 2
4. Tighten the bolts “D” of the MMRB (1,4 Nm).
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5. Connect both flat cables “A” to the MMRB.
A A
6. Fit the MMCU board and tighten the bolts “C” (0,6 Nm).
7. Fit both EBMM boards and tighten the bolts “B” (1,4 Nm).
B B
8. Remount the cover.
9. Restore all connections and reconnect the LDEC panel. 

100 / 134 Service EN170410N

Removing and mounting boards from the rack
Removing Proceed as follows to remove a board from the rack:

1. Switch off the power supply.
Wait at least 3 minutes before continuing the procedure.
2. Open the Front [28] of the control box.

3. Remove the upper and lower holding plates “A” of the rack:
A B
Be sure to loosen the correct bolts “B”:
4. Remove all cables from the board (if present).

5. Push the board hooks from the desired board a little to the side to unlock them:
Push the board hooks in the direction of the arrow as shown in the illustration below:
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6. Tilt the board hooks and remove the board from the rack:
Mounting Proceed as follows to mount a board in the rack:

1. Insert the board in the corresponding rack position (see: Rack position [32].)
Make sure the board is properly inserted and completely plugged in.
2. Lock the board hooks.
3. Mount the holding plates “A”:
4. Reconnect all cables (if applicable)

5. Close the control box and switch on the main power.
102 / 134 Service EN170410N

Replacing the assem. SRDD
Remarks
Always replace the complete assembly.
Never remove the board from the heat sink.
Unpacking Proceed as follows to unpack the assem. SRDD:

Do not cut or damage the plastic foil.
1. Open the box and lift the assem. SRDD by pulling both cardboard handles
2. Flip both long sides upwards.
3. Remove the assem. SRDD from the package.
Packing To pack the assem. SRDD, carry out the Unpacking [103]-procedure in reverse.
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Removing Proceed as follows to remove the assem. SRDD:
1. Switch off the power supply.
Wait 3 minutes before continuing the procedure
2. Latch the power panel using the fixation tool “A”.
A A
3. Disconnect the connectors on the SRDD.

4. Remove the assem. SRDD:
Replace only the assem. SRDD
that is damaged.
5. Unpack the new assem. SRDD. See Unpacking [103].

6. Pack the old assem. SRDD. See Packing [103].
For any further operations on the SRDD, place the SRDD in a dust-free environment. Dust
between the power modules and the heat sink will damage the modules.
7. Mount the new assem. SRDD.
104 / 134 Service EN170410N

Replacing the CBFSB
Tools To replace the CBFSB you will need the following:

• Torx Tx20and Tx8 screwdrivers, (See Torx screwdriver [125]);
• Upgrade package (UBB1-file), see Upgrade package [113];
• Masterstick or USB-stick, see Masterstick (BE316654) [119] and USB-stick (N1038701) [119];
• Spare CBFSB board.
The CBFSB contains a unique identification number that has to be linked with the options for a
given machine serial number. Replacing the CBFSB will require a new upgrade package, when
you install this board into a specific machine.
Software request When replacing the CBFSB board, the “CBFSB board exchange: software request form” must be filled
form in. After sending this form to the Picanol Service Engineer, you will receive an upgrade package.
The following illustration shows the software request form:
A
B
C
D
E
F
A. Customer name B. Email account customer

C. Machine serial number D. Serial number original CBFSB
E. BE-number new CBFSB F. Serial number new CBFSB
See: Board naming [24]
.
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Replacing Proceed as follows to replace the CBFSB:
1. Fill in the ‘CBFSB board exchange: software request form’ to get the correct upgrade package
(ubb1-file). See Software request form [105].
2. Turn off the machine, and open the Front [28] of The Control Box (CB) [25].
3. Write down the location of each board in the rack:
4. Remove all boards from the rack. See Removing and mounting boards from the rack [101].
5. Remove the original CBFSB from the rack and install the new CBFSB:
6. Remount all boards in the rack.

Check with your notes (see step 3) for the correct location of the boards.
7. Turn on the power and wait until the following message appears on the PDP:
8. Choose ‘CBFSB’ (‘A’) and press <Confirm> (‘B’).

The following message appears:
9. Install the upgrade package. See Upgrade package [113].
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Replacing the CBMP
Ways to replace the There are 2 ways to replace the CBMP:

CBMP • Quick CBMP replacement [107] (replace the board, keep the existing SD-card)
• Full CBMP replacement [108] (replace the board and load new software, configuration and
settings)
Tools To replace the CBFSB you will need the following:

• Torx TX20 screwdriver, see Torx screwdriver [125];
• Upgrade package (UBB1-file), see Upgrade package [113];
• Masterstick or USB-stick, see Masterstick (BE316654) [119] and USB-stick (N1038701) [119];
• Spare CBMP board;
• Manometer.
Quick CBMP Proceed as follows to execute a quick replacement of the CBMP:

replacement 1. Turn off the machine, and open the Front [28] of The Control Box (CB) [25].
2. Remove the SD-card of the new CBMP.
3. Remove the original CBMP from the rack, see Removing and mounting boards from the rack [101].
4. Remove the SD-card of the original CBMP.
5. Place the original SD-card in the new CBMP.
6. Place the new CBMP in the rack.
2
4+5 3
7. Turn on the power and wait until the following message appears on the PDP:
8. Choose ‘CBFSB’ (‘A’) and press <Confirm> (‘B’).
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Full CBMP Proceed as follows to execute a full replacement of the CBMP:
replacement 1. Copy the following data:
• Style file. See chapter ‘Terminal > Service > Explorer > Copy files or folders’;
• CSF, see CSF (Customer System File) [115];
• Machine logging, see: Machine log [116]
2. Turn off the machine, and open the Front [28] of The Control Box (CB) [25].
3. Remove the original CBMP from the rack, see Removing and mounting boards from the rack [101].
4. Place the new CBMP.
5. Turn on the power, and wait until the following message appears on the PDP:
6. Choose ‘CBMP (‘A’) and press <Confirm> (‘B’).

7. Insert the USB-stick in the PDP and install the upgrade package. See Installing Software [113].
8. Set the correct password using the Masterstick (BE316654) [119].
9. Restore the styles-file or enter all settings manually.
10. Perform the following actions:
• Warp beam change procedure (including the zero adjustment of the warp tension sensor);
• EPR calibration. See chapter ‘Insertion > Air preparation settings’.
• CAM box/dobby: position of the first frame. See chapter “Shed > The outside cam motion” or
“Shed > The dobby”.
• E-leno configuration.
3 7+8+9+10 replace software, configuration and

settings
108 / 134 Service EN170410N

Replacing the PDP
Unpacking Proceed as follows to unpack the PDP from its package:

Do not cut or damage the plastic foil.
1. Open the box and lift the PDP by pulling both cardboard handles
2. Flip both long sides upwards
3. Remove the PDP from the package.
Packing To pack the PDP, carry out the Unpacking [109]-procedure in reverse
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Removing Proceed as follows to remove the PDP:
1. Switch off the main power supply (main switch QM):
Wait 3 minutes before continuing the procedure.
2. Loosen the bolts “A” and remove the cover on the left-hand side of the machine:
A
3. Loosen the bolts “B” and remove the bolts “C”:

Lift the PDP and block it by placing a screwdriver in the hole “D” to remove the bolts “C”.
B
C
4. Bring down the PDP and tilt the PDP towards weaver’s side.
5. Disconnect the cables from the PDP:
Disconnect the cable from the cable plug or cable tie on the PDP-side.
6. Remove the assem. PDP:

1
Mounting To mount the PDP, carry out the Removing [110]-procedure in reverse.
110 / 134 Service EN170410N

Replacing the protection foil on the assem.PDP_9inch
Preparation Proceed as follows to mount the protection foil on a PDP2.

1. Place the foil in the correct orientation with the big flap on the left-hand side.
2. Bend the corners by hand.
Do not bend the big and small flap at the bottom of the foil.
3. Remove the protection foil on the back side.
Mounting 1. Mount the bottom side by bending the foil and slip the flaps under the housing.
USB
2. Mount the upper side by bending the foil in the other direction.
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Result The following illustration shows a correctly mounted protection foil.
112 / 134 Service EN170410N

Software
Installing Software
When The upgrade package is needed when you want to:

• upgrade the software to a more recent version;
• replace the CBMP board;
• replace the CBFSB board;
• modify the machine configuration.
Upgrade package The upgrade package is a file with the extension .ubb1.
Tools A USB-stick or Masterstick is required. See USB-stick (N1038701) [119] or Masterstick

(BE316654) [119].
Overview The following illustration shows the overview of the software installation:
Installation Proceed as follows to install the software:

1. Download the upgrade package from the Picanol SFTP server via https://sftp.picanolgroup.com.
Enter your user name and password to login to the SFTP server.
Picanol automatically gives you a user account when sending you an upgrade package.
The .ubb1-file is approximately 100Mb. Downloading the .ubb1-file can take more than 10
minutes in case of slow Internet connection.
2. Copy the ubb1-upgrade package in the “software”-folder on the USB-stick.
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3. Insert the USB-stick in the PDP and select the upgrade package:
Confirm the installation of the ‘.ubb1’-file by clicking the -button.
Press the information button to see more information about which machines the software
was designed for.
A full installation of the upgrade package can take about 15 minutes.
4. Press the “OK” button to start the software installation.
Log file When the software is installed, a log file will automatically be generated.
The UBB_log file:

• is located in the log directory of your USB stick
• has the following syntax: ubb_log_<machine serial number>_<date>_<time>.zip
114 / 134 Service EN170410N

CSF (Customer System File)
What The CSF is a snapshot from the current configuration.
CSF has the following syntax: csf_<machine serial number>_<date>_<time>.zip
Generating Proceed as follows to save a data overview in a .zip-file:

1. Place an USB stick in the PDP.
2. Generate the .zip-file:
Access Screen
<System>
<Overview>
<CSF=>USB>
3. Remember the generated file name:
4. Remove the USB-stick from the PDP.

The CSF is located in the ‘CSF’-directory of the USB-stick.
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Machine log
What A machine log is a file that records events that occur over an amount of time.
Machine log has the following syntax: log_machine_<machine serial number>_<date>_<time>.zip
Generating Proceed as follows to save a data overview in a .zip-file:

1. Place an USB stick in the PDP.
2. Generate the .zip-file:
Access Screen
<Tools>
<Expert functions>
<Mc log2USB>
3. Remove the USB-stick from the PDP.

The machine log is located in the ‘Log’-directory of the USB-stick.
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Screen capture
Introduction The PDP can be used to create screen captures. The terminal puts the screen captures on the USB
memory stick.
Screen without Follow these steps to create a screen capture of a screen without pop-up:
pop-up 1. Plug in the USB Memory Stick on the terminal.
2. Press the empty area “A” in the top bar of the PDP.
If the screen capture function has not been enabled yet, a pop-up appears in which the function
can be enabled. Enable the function and press the empty area “A” again. 
The PDP makes a screen capture. A pop-up appears on the screen if the screen capture is
ready.
Screen with pop-up Follow these steps to create a screen capture of a screen with a pop-up:
1. Plug in the USB Memory Stick on the terminal.
2. Go to the following screen and press “Screen capture”:
Access Screen
3. Press “Screen capture ON (delay)” and enter a delay. E.g. 15 s.

4. Go to the screen which you want to create a screen capture of (but without the pop-up).
5. Press the empty area “A” in the top bar and go to the screen with the pop-up within the set delay. 
A
A counter is counting down. The terminal makes a screen capture on 0. A pop-up appears on the
screen if the screen capture is ready.
Only on certain On certain screens a screen capture can also be created as follows:
screens 1. Plug in the USB Memory Stick on the terminal.
2. Press . E.g.:
Access Screen
If the screen capture function has not been enabled yet, a pop-up appears in which the function
can be enabled. Enable the function and press again. 
The terminal makes a screen capture. A pop-up appears on the screen if the screen capture is
ready.
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Fuses
Marking
Example The following table describes the fuse marking:
T 3,15A H 250V
A B C D
A. Fuse characteristic [118] B. Maximum current
C. Fuse breaking capacity [118] D. Maximum voltage
.
Fuse characteristic The following table describes the fuse characteristics:

Fuse characteristic Description
FF Very fast acting
F Fast acting
M Medium acting
T Slow acting
TT Very slow acting
Fuse breaking The following table describes the fuse breaking capacity:
capacity Fuse breaking capacity Description
L Low breaking capacity
H High breaking capacity
Fuse details
Electrical wiring For more information about the fuses, see chapter: ‘Electrical wiring’.
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Tools
Masterstick (BE316654)
Function The masterstick is a special USB-stick delivered by Picanol with the following functions:
• Granting full access to the machine settings by opening the lock on the PDP;
• Allowing to change the password on the PDP
The standard password is always “1111”.
The password can only be changed using the masterstick.
For daily access to the PDP, use the password system to unlock the PDP instead of the
masterstick.
Formatting the masterstick will cause a loss of all the functions of the masterstick.
Changing the Proceed as follows to change the password on the PDP:

password 1. Insert the masterstick in the PDP
2. Enter a new password in the ‘Access control’ screen.
After entering the new password, the terminal will ask to confirm it. Re-enter
the new password to confirm.
USB-stick (N1038701)
Function The usb-stick is a data carrier that makes use of the Universal Serial Bus interface and can be used for
data exchange with the PDP.
Only use Picanol USB-sticks. Other USB-sticks can cause damage or will not work properly.
The USB-stick can be used for the following applications:

• creating CSF files, see CSF (Customer System File) [115];
• saving CSF files, see CSF (Customer System File) [115];
• installing an upgrade package, see Software [113];
• making screen captures, see Screen capture [117].
Formatting the Proceed as follows to format the USB-stick:

USB-stick Access Screen
Formatting the USB-stick by any other means than via the PDP will make the USB-stick
unrecognizable for the PDP.
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F-contact tools
F-contact extractor The table below shows the extraction tool and the F-contact connector:
Extraction tool Connector
N1023004
Proceed as follows to extract a wire:
Push the extraction tool into the connector as shown on the illustration above. When the extraction
tool hits the end of the connector, lift the extraction tool a little and pull out the wire from the
connector.
F-contact crimp
tool
N1023020
FC2
FC3
.
F-contact number Position F-contact crimp tool

• N1013143 (0,14mm² - 0,56mm²) FC2
• N1013144 (0,50mm² - 1,50mm²) FC3
.
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Burndy (TRIM TRIO) contact tools
Burndy (TRIM The table below shows 2 possible extraction tools and the Burndy (TRIM TRIO) contact connector:
TRIO) extraction Extraction tool Connector
tool N1023005
or
N1023022
Burndy (TRIM
TRIO) contact
N1023021
crimp tool
Used Burndy (TRIM TRIO) contact numbers

• N1013517 female (0,50mm² - 1,50mm²)
• N1013518 male (0,50mm² - 1,50mm²)
• N1013527 female (0,32mm² - 0,50mm²)
• N1013528 male (0,32mm² - 0,50mm²)
• N1013631 male (0,12mm² - 0,25mm²)
.
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D-sub contact tools
D-sub extraction The table below shows the extraction tool and the D-sub contact connector:
tool Extraction tool Connector
N1023023
D-sub contact
crimp tool
N1023019
D-sub contact number Position D-sub crimp tool

• N1013571 (female)
0,20mm² - 0,56mm²
• N1013587 (male)
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Molex Mini-Fit Jr contact tools
Molex Mini-Fit Jr The illustration below shows the Molex Mini-Fit Jr extraction tool.
extraction tool
N1023026
Molex Mini-Fit Jr
crimp tool
N1023025
Used Molex Mini-Fit Jr contact numbers

• N1013614 female (0,20mm² - 0,80mm²)
• N1013682 female (1,30mm²)
• N1013698 male (0,20mm² - 0,80mm²)
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Molex Mini-Fit Sr contact tools
Molex Mini-Fit Sr Proceed as follows to extract a wire:

extraction tool N1023013
Molex Mini-Fit Sr Not available.

crimp tool
124 / 134 Service EN170410N

Torx screwdriver
Torx screwdriver Use a Torx tool to replace parts in the control box.
A
A. BA800736, magnetic screwdriver

B. Torx bit:
• BA800734: Tx8 x 1/4”
• BA800735: Tx20 x 1/4”
Wire strip tool

Wire strip tool
N1023024
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Crimp tool for wire end-sleeves (0,08 mm² - 16 mm²)
Crimp tool for wire

end-sleeves
N1023015
Used end-sleeves
Number Wire section info
• N1013535 0,50 mm² white end-sleeve
• N1013646 0,50 mm² end-sleeve, non insulated
• B44058 0,75 mm² - 1,00 mm² red end-sleeve
• B44518 0,75 mm² - 1,00 mm² end-sleeve, non insulated
• B44059 1,50 mm² black end-sleeve
• B44060 2,50 mm² grey end-sleeve
• N1013649 2,50 mm² end-sleeve, non insulated
• N1013575 4,00 mm² orange end-sleeve
• N1013576 6,00 mm² green end-sleeve
• N1013632 10,00 mm² brown end-sleeve
Turn the button “A” on:

• 10°, for wire section 0,08 mm² until 10 mm².
• 16°, only for wire section of 16 mm².
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Electrical Wiring
General
Contents • General ................................................................................................................................... 127

• TPVN ...................................................................................................................................... 127
• Cable identification ................................................................................................................. 128
• Diagrams ................................................................................................................................ 129
• Color coding wires .................................................................................................................. 129
• Cable number ......................................................................................................................... 130
• Shielded wire connections ...................................................................................................... 131
TPVN
Location The title page of the ‘Electrical Wiring’-section shows the TPVN number. The wiring section is specific
for all machines with this TPVN number.
The illustration belows shows an example of a TPVN number:
EN170410N Electrical Wiring 127 / 134

132
On machine side The TPVN number can be found on the right-hand side of the machine:
In case of machines equipped with Quick Style Change, be sure to use the number on the
machine side and not on the Quick Style Change side.
Cable identification
Cable label Every cable has a label with information about the cable.
The illustration below shows a cable label and the information on it:
A
B
C
A. Cable number B. Cable description
C. BE number
.
128 / 134 Electrical Wiring EN170410N

Diagrams
Description The following table describes the diagrams in the wiring section:
C
D
A. Cable number and cable description B. Cable wires

C. Connector cable side D. Connector print side
.
Color coding wires
See: Wire abbreviations [8].

132
Cable number
Standard A standard cable number consists of the letter “W” followed by a three digit number. E.g. W015.
numbering
Different sections When a cable has different sections, the cable number ends with a letter. E.g. W104A and W104B.
The “A”-cable is always connected in the control box.
W104a W104B
B C
A. Control box B. Board

C. Device
.
Split cables When a cable is split up in two or more ends, the cable number ends with a digit. E.g. W129A is split up
in W129B1 and W129B2.
A
W129B1
C
W129a
B
W129B2
D
A. Control Box B. Board

C. Device D. Device
.
2000 and higher Cable numbers starting from W2000 are reserved for single wires or wire units.

Shielded wire connections
Rack The following illustration shows the shielded wire connections on the rack:
X_SH15
Power panel The following illustration shows the shielded wire connections on the power panel:
X_SH20
X_SH24
X_SH25
X_SH27
Cable bundle The following illustration shows the shielded wire connections in the cable bundle:
X_SH02
X_SH01

132
Resolver housing The following illustration shows the shielded wire connection on the resolver housing:
X_SH74

Abbreviations
A
ABSD Airjet Board Sensors and Devices BlueBox air insertion board
B
BK BlacK Black
BN BrowN Brown
BN/BK BrowN/BlacK Brown with black rings
BN/BU BrowN/BlUe Brown with blue rings
BN/GN BrowN/GreeN Brown with green rings
BN/RD BrowN/ReD Brown with red rings
BR BRake Brake
BU BlUe Blue
C
CBMP Common Board Main Processor BlueBox main processor board
D
DEN Drive ENable Drive enable signal
DTTH DeTection THermal Thermal detection
DTWTCAL DeTection Warp Tension CALibration Calibration signal for the warp tension
E
ELO_RHS Electronic Let_Off Right-Hand Side Electronic let off right-hand side
EPR Electronic Pressure Regulator Electronic pressure regulator
EPR_MN Electronic Pressure Regulator_Main Nozzle Main nozzle pressure regulator
EPR_RN Electronic Pressure Regulator_Relay Nozzles Electronic pressure regulator for the relay nozzles
ES_CB Emergency Stop Control Box Emergency stop located on the control box
ES_LHS Emergency Stop Left-Hand Side Emergency stop on the left-hand side
ES_RHS Emergency Stop Right-Hand Side Emergency stop on the right-hand side
ES_RRHS Emergency Stop Rear Right-Hand Side Emergency stop on the rear right-hand side
ETU Electronic Take Up Electronic take up system
F
FDCB Filling Detection Control Box PICAN control box for the filling detectors
FPGA Field Programmable Gate Array Integrated circuit with programmable logic
G
GN GreeN Green
GN/BK GreeN/BlacK Green with black rings
GN/BU GreeN/BlUe Green with blue rings
GN/RD GreeN/ReD Green with red rings
GY GreY Grey
GY/BN GreY/BrowN Grey with brown rings
GY/BU GreY/BlUe Grey with bleu rings
GY/GN GreY/GreeN Grey with green rings
GY/PK GreY/PinK Grey with pink rings
H
HS_RX Hand Safety Receiver Receiver from the optical safety device
HS_TX Hand Safety Transmitter Sender from the optical safety device
M
MID Machine IDentification number Identification number of the machine
MMCU Main Motor Control Unit Main motor control board
MMRB Main Motor Rectifier Board Rectifier board for the main motor
MPS Main Power Supply Main power supply board
O
OBMM Output Board Main Motor Power board main motor
P
PB Push Buttons Push buttons
PBFA Push Buttons Fancy Push buttons for the fancy
PBLO Push Buttons Let-Off Push buttons for the let-off
PBPTHR Push Button Pull THRough Push button pull through
PBPWRON Push Button PoWeR ON Power on button
PDP Picanol DisPlay Picanol display
PK PinK Pink
PK/BN PinK/BrowN Pink with brown rings
PK/GN PinK/GreeN Pink with green rings
PRW PReWinder Prewinder
EN120110N Abbreviations 133 / 134

Original setting manual - TecDoc@picanol.be 134
PX ProXimity sensor Proximity sensor
PX-FA-SFTY ProXimity sensor FAncy SaFeTY Proximity sensor fancy safety
PX_LVL_OFF ProXimity sensor LeVeLing OFF Proximity sensor levelling off
R
RD ReD Red
RD/BU ReD/BlUe Red with blue rings
RMA Request Merchandise Authorisation Form with information about a defective board or
assembly
RS ReSolver Resolver
S
SRDD Switch Reluctance Dual Drive BlueBox auxiliary motor control board
V
VT VioleT Violet
W
WH WHite White
WH/BK WHite/BlacK White with black rings
WH/BU WHite/BlUe White with blue rings
WH/GN WHite/GreeN White with green rings
WH/GY WHite/GreY White with grey rings
WH/PK WHite/PinK White with pink rings
WH/RD WHite/ReD White with red rings
WH/YE WHite/YelloW White with yellow rings
WL Warning Lights Warning lights
WL-LHS Warning Lights - Left-Hand Side Warning lights on the left-hand side
WL-RHS Warning Lights - Right-Hand Side Warning lights on the right-hand side
Y
YE YEllow Yellow
YE/BK YEllow/BlacK Yellow with black rings
YE/BN YEllow/BrowN Yellow with brown rings
YE/BU YEllow/BlUe Yellow with blue rings
YE/GY YEllow/GreY Yellow with grey rings
YE/PK YEllow/PinK Yellow with pink rings
YE/RD YEllow/ReD Yellow with red rings
YWGR Yellow Green earth wire Yellow-green tinted earth wire
134 / 134 Abbreviations EN120110N

Original setting manual - TecDoc@picanol.be

01 A18 Electronic Control System

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Ypres - Belgium

Pictographs, wire abbreviations and safety devices ..................................................................... 7

• Power supply cable specifications .................................................................................................12

Control system and machine drive .....................................................................................................16

Overview of the weaving machine ......................................................................................................22

• Division of the weaving machine ...................................................................................................22

The Control Box (CB) ................................................................................................................. 25

• Overview of the control box ...........................................................................................................26

Mains entry ............................................................................................................................................48

High voltage part...................................................................................................................................51

• MPS-2 (Main Power Supply) .........................................................................................................56

Devices on the machine ............................................................................................................. 67

• Installing Software .......................................................................................................................113

• Masterstick (BE316654) ..............................................................................................................119

Electrical Wiring ........................................................................................................................ 127

Abbreviations ............................................................................................................................ 133

2 Sections The electronic part of the manual is divided into 2 sections:

The electronic control system

The Electronic Wiring System

EN170410N Introduction 5 / 134

6 / 134 Introduction EN170410N

Liability Provides information about the legal liability.

EN170410N Pictographs, wire abbreviations and safety devices 7 / 134

Colored wires The following table gives an overview of the abbreviations

Earth wire The following table gives an overview of the abbreviations.

8 / 134 Pictographs, wire abbreviations and safety devices EN170410N

• This is a red button on a yellow background.

Safety light grid

• Is located over the pressure roll.

POWER ON • Power circuits are turned on.

EN170410N Pictographs, wire abbreviations and safety devices 9 / 134

10 / 134 Pictographs, wire abbreviations and safety devices EN170410N

Control system and machine drive ............................................................................................... 16

Overview of the weaving machine ................................................................................................ 22

EN170411N General 11 / 134

Contents • Load demands [12]

General conditions • Stability of the power supply

• Power consumption at cold start

• Conditions at machine start-up

12 / 134 General EN170411N

EN170411N General 13 / 134

50 70* 50* 35* 25 25 16 16 16 16 10 10 10 10 10 6

Supply cable protections

Leak current The machine control has no leak current protection.

14 / 134 General EN170411N

EN170411N General 15 / 134

Block diagram The following illustration shows the principle:

A. Input signal from the PX_ref B. Signal to the VPF

The safety system combines software and hardware protection.

16 / 134 General EN170411N

motor switch Function

Control system of the main motor control box

Stator coils • Contains 8 stator coils (4 double coils).

Main motor test See chapter: the Drive’-section.

EN170411N General 17 / 134

Machine stopped When the machine is stopped, it is held motionless by a brake.

Heatsink The following components are fitted against the heatsink:

18 / 134 General EN170411N

Process The illustration below shows the pickfinding process:

1. Weaving --> Pickfinding A. Peg

Weaving (driving the machine)

Process The illustration below shows the weaving process:

1. Pickfinding --> Weaving A. Peg

• The peg holding the sley gear is disengaged.