ECO PULSARS I-DLS

INSTRUCTIONS TRANSLATED FROM THE ORIGINAL LANGUAGE

MANUAL FOR USE AND MAINTENANCE

SERIAL NO.

MANUAL CODE :

11645.0035.0/2

MANUAL REVISION :

04

PUBLICATION DATE :

01/11/2016

© Any reproduction of this document, by any means, without the prior written permission of Savio S.p.A. is forbidden.
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SAVIO MACCHINE TESSILI S.p.A. - 33170 PORDENONE Italy - Via Udine,

105 - Tel. 04343971 - Fax. 0434 21951 / 0434 397393

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INTRODUCTION

Modification table

Chapters Revision Date Drafter:

0 01 01/11/2016 Badiali Roberto

1 00 01/05/2015 Moras Luca

2 02 01/11/2016 Badiali Roberto

3 01 26/01/2016 Tweddle

4 01 01/11/2016 Badiali Roberto

5 02 01/11/2016 Moras Luca

6 01 26/01/2016 Tweddle

9 00 01/05/2015 Moras Luca

10 04 01/11/2016 Badiali Roberto

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INDEX

0 PREMISE
1 WARNINGS AND GENERAL INFORMATIONS
2 MACHINE GENERAL INFORMATION
3 TRANSPORTATION AND HANDLING
4 INSTALLATION
5 MACHINE UNIT INFORMATION, USE INSTRUCTIONS AND MAINTENANCE
6 OF MACHINE START AND STOP
9 DISMANTLING AND WASTE DISPOSAL
10 APPENDIXES

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0 - PREMISE

Modification table
Revision Date Drafter: Revision Date Drafter:
01 01/11/2016 Badiali Roberto

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INDEX :

0.1 PREMISE ................................................................................................................................... 3

0.2 CONSULTING THE MANUAL .................................................................................................... 4
0.3 LIABILITY ................................................................................................................................... 5
0.4 COPYRIGHT .............................................................................................................................. 6
0.5 KEEPING THE MANUAL ........................................................................................................... 6
0.6 DOCUMENTATION PROVIDED WITH THE MACHINE ............................................................. 6

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0.1 PREMISE

USE

This documentation contains all the technical information concerning ECO PULSARS I-DLS for the winding of
discontinuous fibre yarns.

ATTENTION!
Any other use is considered improper and hence not conforming and the manufacturer declines
all liabilities.

Furthermore, this manual contains all the information to ensure the best use of the machine as well as all the
instructions and suggestions for a correct maintenance.
By reading this manual through carefully and consulting it when required the user will be able to obtain the best
machine performance and maintain the highest levels of machine safety and reliability for a long time.

ATTENTION!
It is up to the Customer to instruct his staff on accident risks, operator safety devices, noise
emission risks and the general accident prevention rules and regulations as foreseen by
international guidelines and national laws in the country the machines are used in.

However, the machine should be used exclusively by qualified operators who must strictly observe all the technical
and accident prevention rules given in this manual.
It is the user’s duty to ensure that the machine is only used under completely safe conditions for people, animals
and things.

EEC DIRECTIVES
The machine is designed and made in accordance with the following Community Directives:
 2006/42/EC, concerning the unification of member States’ laws on
machinery
 2014/35/UE and relative amendments, concerning the unification of member States’ laws
regarding electrical material to be used within certain voltage limits;
 2014/30/UE and relative amendments, concerning the unification of member States’ laws
regarding electromagnetic compatibility;

This manual is property of SAVIO. Any right of reproduction in whole or in part is reserved.

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0.2 CONSULTING THE MANUAL

The aim of the manual, written in chapters, is to:

 assist the user during the entire “life cycle” of the product;
 organically group the information for specific professional people.

PROFESSIONAL FIGURES
 the technician in charge of plant configuration and the “take-up product” quality, who we shall call
“TECHNICIAN OR TECHNOLOGIST” and to whom chapter 6 is dedicated;
 the person in charge of running the machine, who we shall call "OPERATOR" and to whom chapter 7 is
dedicated;
 the technician authorised by the Customer and qualified to service the machine, who we shall call
“MAINTENANCE ENGINEER” and to whom chapter 8 is dedicated.
Note: checks and maintenance work on the electrical installation must be carried out by
a qualified electrician.

To this end we wish to call your attention to the EEC directive 89/391, Section II, articles 10 and 12 (corresponding
in Italy to Law 626/96, Section VI, articles 21 and 22) that specifies the employer’s responsibility to inform and train
workers on the subject of safety and health.

OPTIONAL DEVICES
You will find paragraphs relative to the optional devices in the various chapters, regardless of the configuration of
the machine.
These paragraphs are marked with [OPT].

GLOSSARY
Technical terms used in this manual that could be difficult to understand and/or translated, are explained in
paragraph 3.

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0.3 LIABILITY

The instructions for use provided with the machine take into account the experience and knowledge that SAVIO
has accumulated to date.
The instructions for use are updated to the date shown in the index of each chapter. The edition corresponds to the
revision index of the chapter (IRD). Each new edition substitutes and cancels all previous editions.

SAVIO declines all responsibility for harm to people and animals and damage to things caused by:
 an improper use of the machine;
 inexperience, imprudence or negligence;
 manoeuvring errors;
 non compliance of the instructions given in the manual;
 repairs that have not been expertly done and the substitution of spare parts different from those
specified in the manual (assembly and use of non original spare parts and accessories
could also negatively influence machine operation);

All responsibility is declined for damages caused by unauthorised transformations and modifications carried out by
the user or Customer.

 unauthorised modifications or work;

 poor maintenance;
 faults in the supply of electricity or other energy sources (pneumatic, hydraulic, etc.);
 the use of the machine by unauthorised personnel;
 the failure to apply the standards of safety, hygiene and health at the work place.

It is the Customer’s responsibility to find and choose the most adequate and suitable category of IPGs (Individual
Protective Gear).

The mentioning of third party products is for information purposes only and does not constitute a commitment or
recommendation.
SAVIO is under no liability regarding the performance or use of such products.

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0.4 COPYRIGHT

This Manual is for the exclusive use of authorised personnel and/or personnel trained by the Customer. It may only
be given to third parties after written authorisation has been given by SAVIO.

0.5 KEEPING THE MANUAL

The manual must be kept in perfect condition all the time the machine is used, right up until it is demolished. Hence
it must be kept in a place where it can be accessed immediately for consultation in the case of doubt or each time
the circumstances so require.
If the machine is transferred, sold, hired or in any other way loaned out, all its documentation and the manual must
go with it.

0.6 DOCUMENTATION PROVIDED WITH THE MACHINE

The manual, together with the wiring, pneumatic and installation diagrams and the manuals of use and
maintenance of systems not designed by SAVIO (see the clearing, blower/aspirator, splicer systems, etc.), as well
as the spare parts catalogue, is kept inside a case provided with the machine.

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1 - WARNINGS AND GENERAL INFORMATIONS

Modification table
Revision Date Drafter: Revision Date Drafter:

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INDEX :

1.1 MANUFACTURER IDENTIFICATION DATA .............................................................................. 3

1.2 GENERAL SAFETY PROVISIONS ............................................................................................ 4
1.2.1 CHARACTERISTICS OF THE PEOPLE ASSIGNED TO THE USE OF THE MACHINE .................. 5
1.2.2 TECHNICAL SERVICE SAFETY INFORMATION .............................................................................. 6
1.2.3 SUMMARY OF THE INDIVIDUAL PROTECTIVE GEAR (IPG) TO BE WORN/USED IN ALL
THE MACHINE’S LIFE PHASES ........................................................................................................ 7
1.2.4 LIFTING AND HANDLING SAFETY MEASURES .............................................................................. 9
1.2.5 SAFETY MEASURES FOR INSTALLER .......................................................................................... 10
1.2.6 USE SAFETY MEASURES ............................................................................................................... 11
1.2.7 MAINTENANCE SAFETY MEASURES ............................................................................................ 13
1.3 SYMBOLS USED IN THE MANUAL ......................................................................................... 15
1.4 SAFETY SIGNS AND SYMBOLS ON THE MACHINE ............................................................. 17
1.5 GLOSSARY ............................................................................................................................. 20
1.6 FORESEEABLE INCORRECT USE ......................................................................................... 22
1.7 RESIDUAL RISKS.................................................................................................................... 23
1.7.1 WINDING UNIT ................................................................................................................................. 24
1.7.2 MACHINE BODY............................................................................................................................... 27
1.7.3 DOFFING TROLLEY UNIT .............................................................................................................. 31
1.7.4 HEADSTOCK .................................................................................................................................... 33
1.7.5 CONE FEEDING UNIT...................................................................................................................... 35
1.7.6 BOBBIN PREPARING DEVICE ........................................................................................................ 37
1.7.7 TUBE CLEANER ............................................................................................................................... 41
1.7.8 RESIDUAL RISK GENERAL ............................................................................................................. 45
1.8 INSTALLATION, INSPECTION, WARRANTY .......................................................................... 46
1.9 MODIFICATIONS ..................................................................................................................... 47
1.10 REQUESTS FOR ASSISTANCE AND SPARE PARTS............................................................ 47

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1.1 MANUFACTURER IDENTIFICATION DATA

The identification data of the machine is shown on the plate attached to the headstock as shown in the figure
below.

ATTENTION!
Do not remove, tamper with or render illegible the “CE” mark on the machine.
Please refer to the information given on the “CE” machine plate for any communication with the
manufacturer (for spare parts, etc.). When the machine is being demolished the CE mark must
be destroyed.

USE ALL INFORMATION HEREIN GIVEN ONLY FOR THE

MACHINE WITH THE SPECIFIC SERIAL NUMBER (1).

MANUFACTURER: SAVIO Macchine Tessili

33170 PORDENONE (Italy) −Via Udine n° 105
tel. 39 0434 3971
fax 39 0434 397393
e−mail : [email protected] − internet: www.saviospa.it

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1.2 GENERAL SAFETY PROVISIONS

PREMISE

This chapter is dedicated to the OPERATOR and for anyone who is in charge of starting the machine, its routine
operation and stopping.

ATTENTION!
To ensure the machine works properly under safe conditions the authorised operators should
take note of what is written here before starting any work on the machine and strictly follow the
instructions.

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1.2.1 CHARACTERISTICS OF THE PEOPLE ASSIGNED TO THE USE OF THE MACHINE

The Customer must ensure that the people assigned to the routine use of the machine are adequately trained and
prove to be skilful in carrying out their jobs, taking care of their own safety as well as that of others.
On the basis of the type of task, the operators shall be suitably instructed also as regards machine functioning to
ensure correct use and control and to guarantee efficiency.

GENERIC WORKER
Unskilled worker, able to perform simple tasks following the instructions of qualified technicians.

OPERATOR / USER
1st level machine operator (Qualification level 0.1)
Unskilled workers who do not posses specialised skills and are only able to perform simple tasks,
i.e., operating the machine through the controls located on the push button panel, loading and
unloading of the materials used during maintenance and cleaning operations with ACTIVATED
guards.
INFORMED PERSON
2nd level machine operator (Qualification level 0.2)
Qualified personnel who can perform the tasks required for qualification level 0.1 and who can also
perform monitoring, adjustment and control tasks on the production line.
TRAINED, QUALIFIED AND SPECIALISED PERSON
Mechanical maintenance engineer (Qualification level 1)
Qualified engineer, able to operate the machine under normal conditions, to intervene on the
mechanical parts in order to perform all necessary adjustments, maintenance and repairs.
This person is not usually qualified to intervene on electrical systems.
TRAINED, QUALIFIED AND SPECIALISED PERSON
Electrical maintenance engineer (Qualification level 2)
Qualified engineer, able to operate the machine under normal conditions and in charge of all
interventions, adjustments, maintenance and repairs on the electrical parts.
This person is able to operate in electrical cabinets and shunt boxes while the machine is powered
ON.
MATERIAL HANDLING AND LIFTING EQUIPMENT OPERATOR
Qualified personnel who is able to use material and machine handling and lifting equipment
(carefully following the manufacturer's instructions supplied with the machine) on the company's
premises, in compliance with the laws in force in the country where the machine is used.
TECHNICAL ASSISTANCE PERSONNEL
Manufacturer's engineer (Qualification level 3)
Qualified engineer able to operate the machine under normal or faulty conditions, provided by the
manufacturer to perform complex tasks and inspections as agreed with the user.
SAFETY MANAGER
Qualified and trained engineer in charge of workplace safety measures.

ATTENTION!
All tasks that need to be performed by an operator with a specific qualification level as
described in this manual can be performed by an operator with a higher qualification level but
they cannot be performed by an operator with a lower qualification level.

If required, SAVIO offers a number of specific training courses to train the Customer's personnel to use, control and
perform maintenance operations on the machine. For more detailed information, please contact SAVIO technical
assistance centre.

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1.2.2 TECHNICAL SERVICE SAFETY INFORMATION

SAVIO employs qualified personnel to guarantee that inspections, repairs and training meet the highest standards.

Customers are reminded that any alterations made by the user, without the prior written permission of
SAVIO will immediately void the WARRANTY and cancel any liability on part of SAVIO for damages caused
by a faulty product, especially when such alterations are made to safety devices, reducing their
effectiveness.

Unauthorised alterations and installation of non-genuine spare parts on the machine may cause dangerous
situations,
especially when non-genuine spare parts or spare parts different from those recommended by SAVIO are used as
"SAFETY COMPONENTS".
Replacing parts that are defined as SAFETY COMPONENTS with non-genuine spare parts or with parts having
different features may affect the safety of the machine.
In order to ensure the correct and safe functioning of all machine parts and to avoid voiding the WARRANTY,
SAVIO recommends the use of genuine spare parts at all times.
To purchase/order spare parts follow the recommendations in the spare part catalogue supplied by SAVIO upon
delivery of the machine and included in the documentation provided with the machine.

Only our engineers or engineers from our network of authorised ASSISTANCE CENTRES are authorised to carry
out repairs on our machines. Please contact our Assistance Centre or one of our authorised centres.
Extra-ordinary assistance is provided by SAVIO or by persons authorised by SAVIO. It is the Customer's
responsibility to make sure that any emergency interventions carried out by their own engineers are done safely
and by qualified personnel.

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1.2.3 SUMMARY OF THE INDIVIDUAL PROTECTIVE GEAR (IPG) TO BE WORN/USED IN ALL THE
MACHINE’S LIFE PHASES

The IPGs (Individual Protective Gear) are summarised in the following table; they are to be worn/used during all the
working phases of the machine (for each phase it is compulsory to wear IPGs) and/or place them at the operators’
disposal).

It is the Customer’s responsibility to find and choose the most adequate and suitable category of IPGs (in
accordance with current laws in force in the Customer's country regarding “Accident Prevention at the Work
Place”).

Protective Safety Goggles Ear Face Helmet Protective

PHASE Gloves
clothing footwear Glasses protection mask hard hat heardgear

Transportation
Handling
Unpacking
Assembly
Ordinary use
Adjustments
Cleaning
Maintenance
Disassembly
Demolition

Legend:

ENVISAGED IPGs

IPGs AVAILABLE

NOT ENVISAGED IPGs

The IPGs used must comply with the EEC Directive 89/686, corresponding in Italy to Leg. D. 475/92, and they must
comply with local health and safety laws in force where the machine is installed.

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Working phases description of the machine:

PHASE DESCRIPTION

Transportation This entails transferring the machine from one place to another using specific equipment

Handling This entails loading and unloading the machine from the equipment used to transport it, as well
as
moving it inside the factory

Unpacking This entails removing all the materials used for packing the machine

Assembly This entails all the assembly jobs to prepare the machine for
setting up

Ordinary use This is the use for which the machine has been designed (or which is deemed usual) in relation
to its project, construction and function

Adjustments This entails the adjustment, setting up and calibration of all the devices that have to be adapted
to the normal, envisaged functioning condition

Cleaning This entails removing dust, oil and machining residuals that could compromise the proper
working order and use of the machine as well as the health and safety
of the operator

Maintenance This entails routine checking of machine parts that can be subject to wear and tear or that may
need replacing

Disassembly This entails part or total disassembly of the machine for any reason

Demolition This entails the final removal of all machine parts resulting from the final
dismantling operation, to allow recycling of the
components according to the procedures established by current laws

ATTENTION!
While the machine is running normally it is forbidden to wear protective gloves as they could get
caught in its moving parts.

Remember that the sound level the operators are exposed to each day should be evaluated in compliance with the
standards of the European Community and the laws of the country where the machine is installed (as established
by the EEC directive 86/188 - Board Directive dated 12th May 1986 on the subject of protecting workers against
risks deriving from exposure to noise during work, corresponding in Italy to Leg.D. 277/91).
A first idea of the noise risk can be gleaned from point 9, Chapter 1.

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1.2.4 LIFTING AND HANDLING SAFETY MEASURES

The machine must be lifted and handled exclusively with the equipment and methods
described in the relevant chapter and in compliance with local laws.

Transport, installation and disassembly must be carried out only by personnel with the
necessary technical competence and experience in each of the fields involved.

The presence of an assistant is required to help with transport manoeuvres and during
the installation or removal of large or heavy parts.
The assistant must oversee such operations and make sure that no encumbrance can
hinder the process.

Take all precautions recommended by current health and safety laws in order to
prevent possible harm to people or damage to things.

No person shall stand near an overhead load or within the operating range of the
crane, the elevator trolley or other equipment used to lift and transport the machine.

All transit lanes in the factory where the machine is installed must be kept free from
any obstacle that may cause jolting of the elevator trolley or the crane.

The load must always be safely secured to a load-bearing element of the lifting and
handling equipment, to prevent the load itself from moving or shifting.

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1.2.5 SAFETY MEASURES FOR INSTALLER
The work area must be adequately lighted and equipped with compressed air and power
outlets. The power outlet must be located in a protected position and equipped with a knife
switch.

The machine's electrical connection to the mains and its preliminary inspection must be
carried out by a qualified electrician with a proven experience in the field and through the
use of adequate tools.

All subsequent interventions on the electrical system must be carried out only by qualified
technical personnel with a proven experience in the field.

The earthing system must be checked and approved by a qualified installer through the use
of specific tools.

The space required for operation around the machine must be free from obstacles, clean
and well-lighted at all times.

The work area must be adequately cordoned off to prevent the operator from being hit by
any transportation or handling equipment during machine operation.

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1.2.6 USE SAFETY MEASURES

The instruction manual of each machine must always be kept near the work area.

The operator must have all the prerequisites required for the operation of a complex
machine.

The operator must not be disturbed or distracted in any way while during the machine's
operating cycle.

The machine start-up sequence must be performed as indicated in this instruction

manual.

Do not enter the machine's work area during the machine's operating cycle.

Do not place your hands or other limbs near or inside the machine's moving parts, live
parts or the electrical cabinet.

Do not modify the programmed parameters to obtain results other than those
established during the machine's designing and installation phase.

Never exceed the machine's maximum production limit.

Organise the material to be processed in a convenient way, so that it does not obstacle
the operating cycle.

Before starting the machine, check the work area for any potential hazards.
If working in the dark, use all available lights making sure that they operate correctly.
Report any blown bulb and replace it immediately.

Before starting the machine, make sure that nobody is standing in the operating area
and no maintenance operations are being carried out.

Maintain adequate visibility in the operating or work area at all times.

Report any faults of particular systems to the maintenance engineers.

When the machine is in operation, it is absolutely forbidden to open the fixed guards
before stopping the machine.

During a pause in the operating cycle and in case of long pauses, set the main switch to
0 (Zero) and lock it.

Concentrate and take all safety measures before carrying out any operation on the
machine.

Unfortunately, as numerous accidents have shown, some objects worn by workers may
cause severe injury. Please remove bracelets, watches and rings before starting to
work.

Wrap the sleeves of your work clothes carefully around your wrists and button them up

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in a safe way.

Users are recommended to remove any clothes or personal items that may get caught
in the machine's moving parts before starting to use the machine.

Users must wear protective clothes, shoes and equipment at all times while using the
machine, in compliance with local health and safety laws.

Do not feed into the machine any material that the machine is not designed to process.

Before starting the machine make sure that no foreign matter has been placed on top of
or inside it.

If, during the operating cycle, the machine stops for any reason that can only be solved
by accessing the electrical cabinet, proceed to set the main switch to 0 (Zero) and lock
it. Report the fault and the conditions in which it has arisen to the factory and production
line manager.

The operator must always check the correct functioning of the emergency controls by
activating them directly.

Before starting the machine, make sure that nobody is carrying out maintenance
operations or cleaning the machine.

The operator must never use the machine to perform different tasks from those for
which it is designed and that are illustrated in this manual.

The machine must always be used according to the methods, times and places
specified in the standards of good practice and laws of all countries, even when a
country lacks legislation for that specific field.

Only authorised operators with a proven experience in this kind of tasks are allowed to
operate on the electric board.

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1.2.7 MAINTENANCE SAFETY MEASURES

Do not allow unauthorised persons to carry out repairs or maintenance operations.

Use thick gloves in compliance with the laws of the country where the machine is
installed. The gloves used to handle the parts being processed must not decrease hand
sensitivity and grip.

Do not lubricate, repair or adjust the setting of a machine while it is in operation, unless
it is expressly requested by the instructions and maintenance manual, to avoid getting
caught in the machine's moving parts.

Stop the machine according to the instructions provided in this manual before
lubricating or intervening on the machine.

Every time it is necessary to disassemble or install machine parts, these must be lifted
with suitable devices, chosen according to the load they will need to bear.

Transfer the load on adequate support means immediately.

Do not work under or near machine equipment or on parts that have not been secured
adequately.

To prevent damage, keep personnel away from the equipment or machine parts when
these are lifted.

Due to the presence of flammable fluids, it is absolutely forbidden to use matches,

cigarette lighters or torches as light sources while operating on the machine.

When carrying out repairs in areas that are not accessible from the ground, use ladders
or safety platforms compliant with local or national laws to reach the work area.

Carry out all repairs and maintenance operations with care.

ATTENTION!
Do not use abrasive materials or substances to clean the parts in Plexiglas.

ATTENTION!
When cleaning the machine with compressed air it is compulsory to wear protective glasses and
a mask to protect your lungs, paying particular attention that splinters and dust raised by the
compressed air do not hit other people.

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ATTENTION!
Do not use compressed air to clean people or clothes.

ATTENTION!
Do not use compressed air to clean electrical or electronic equipment: it could damage the
electrical components.

ATTENTION!
Dispose of the cleaning product residuals correctly. Do not contaminate the environment
with them.

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1.3 SYMBOLS USED IN THE MANUAL

The following table lists the symbols used in the manual as well as their meaning.

SYMBOL MEANING

Read the use and maintenance manual before using and/or doing any work on the machine.

Pay particular attention to what is indicated.

Damage is possible to the machine or to the product being processed.

Machine main switched, locked in the “0” (Zero) position.

Existing hazards, how to behave to comply with the safety standards, procedures that must be
followed scrupulously.

Electrocution hazard.

Forbidden to touch with your hands or any other part of your body.

Emergency push button.

Adjustments.

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Lubricating.

Maintenance frequency (given in hours)

Understanding figure numeration xyy/z:

x : chapter
yyy: progressive numeration
z : position of the item indicated
Understanding table numeration xtt:
x : chapter
tt: progressive numeration
Understanding page numeration x/pp:
x : chapter
pp: progressive numeration

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1.4 SAFETY SIGNS AND SYMBOLS ON THE MACHINE

The following table lists the safety signs and symbols on the machine as well as their meaning.

SIGNAL MEANING
HAZARD
SIGNS: ATTENTION
GENERIC HAZARD

Please consult the instruction manual before doing anything on the

machine.

ELECTROCUTION HAZARD.
Existing hazards: live parts/devices; it is located outside casings or guards
where it is not obvious that there are live parts/devices.

ATTENTION
DRAGGING HAZARD.

ATTENTION
DRAGGING HAZARD.
Do not open or remove the panel while parts are moving (belt driven
pulleys).

ATTENTION
DRAGGING HAZARD.
Do not remove the cover with moving parts (gears).

ATTENTION
PRICKING HAZARD

ATTENTION
SHEARING/CRUSHING HAZARD
In some cases this is accompanied by written examples.

Before restarting the machine (START) make sure there are no people
exposed to hazards near the mobile devices.

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SIGNAL MEANING
FORBIDDEN
SIGNS:
DO NOT CLIMB ON THE LIFTING DEVICE

DO NOT STAND AND/OR WALK IN THE LIFTING DEVICE’S

MANOEUVRING AREA

DO NOT TOUCH

DO NOT OIL, LUBRICATE, REPAIR OR ADJUST MOVING PARTS.

DO NOT REMOVE THE SAFETY DEVICES

DO NOT GO NEAR THE MACHINE WITH FLAPPING CLOTHS,

TIES OR SHOES.

COMPULSORY
SIGNS:
IT IS COMPULSORY TO WEAR SAFETY GLOVES

IT IS COMPULSORY TO WEAR HEAD PROTECTION GEAR

OBSTACLE SIGNALS OBSTACLES AND HAZARDOUS AREAS

SIGNS: SIGNALS INDICATING THE RISK OF BUMPING INTO
OBSTACLES

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INFORMATION
SIGN: SIGNAL THAT INDICATES THE HOPPER STATION’S BIN
ELEVATOR IS OVERLOADED. MAX. 260 KG.

ATTENTION!
Do not remove or render illegible the safety, danger, forbidden or compulsory signs on the
machine.

ATTENTION!
It is forbidden to affix any signs or plates that could undermine the safety of the machine and
people.

When starting, repairing or simply moving near the machine, it is of fundamental

importance to pay the utmost attention to the information contained in the plates
attached to the it.
Users must make sure that the plates are legible.
Worn-out plates can be replaced. Ask the manufacturer's ASSISTANCE CENTRE for a
complete kit, indicating the relative code.

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1.5 GLOSSARY

Stretch A quantity of yarn wound around a bobbin by the up and down travel of the spinning
frame’s ring trolley.

Booster Device to reduce bobbin unwinding tension. It is mounted on the bottom unwinding
unit.

C.A.P. Acronym for Computer Aided Winding. It identifies an electronic modulation system
used in making up the winding.

Ribbon / Ribboning Overlapping of several coils in the same point due to synchronisation between the
rotation speed of the winding and the grooved roller.

Winding Build Up Representative index of the increase in winding diameter compared to the length of
yarn taken up.

Template Device used to make one or more adjustments.

Unwind To wind the yarn tidily in a ball, unwinding it from the hank.

IPG Individual Protective Gear.

P.C.F. Acronym for Production Correction Factor. It is a correction index used in calculating
machine production.

Jaws Assembly of metal extractor plates and of rubber plates installed on the cleaner
supports.

Ispector Control An industrial PC (IPC) used to set and acquire data and to monitor the whole winding
process.

Leq Average value of the sound pressure levels the operator is subject to when working.

Modulation "Anti-ribboning" method used to continuously vary the drive ratio between the grooved
roll and the take-up winding, its purpose being to avoid synchronisation phenomena.

Nep A yarn defect.

ON / OFF Identifies a modulation system realised with continuous accelerations and

decelerations of the grooved roll.

Exposed person Anyone who is partly or totally in a hazardous situation.

Yarn accompanying A device to move the yarn between two fixed positions.
lever
Pusher strut Pushing device operating on the tube tip, to make the yarn waste stripping cycle
possible.

Reserve Winding of yarn at the base of the winding cone.

R.L. Acronym for Red Light; it identifies winding unit stops once the
maximum number of permitted cycle repetitions is reached.

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Wrap Winding of yarn around a rotating part of the machine.

Balloon breaker A device applied to bobbin unwinding to limit yarn tension.

Extractor plates Extractor plates Pair of metal or rubber devices which actually strip the yarn from the
tube body.

Section A part of the machine consisting of “x” winding units.

Slip C. Slip Coefficient; it is a correction index used to compensate for any slips between
winding and cylinder during winding metering.

Underwinding Winding of several coils of yarn on the tube-bobbin base.

Splicer A yarn splicing device.

Axial displacement Continuous displacement of the winding with respect to the cylinder’s longitudinal
axis.

Clearer Electronic device that intercepts yarn defects.

Yarn count Ratio between yarn length and corresponding mass.

Twinsplicer ® An exclusive SAVIO mechanical yarn splicer for neat and high resistant splicing.

Hopper Chute used for bobbin transfer by falling.

Winding unit A basic machine element, its job being to perform the technological function.

Vacuometer An instrument for measuring pressures lower than atmospheric pressure.

VSS Acronym for Variable Speed System. It is equivalent to a controlled reduction in

winding speed when the unwinding bobbins are finished.

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1.6 FORESEEABLE INCORRECT USE

Any use different from that specified in this manual is considered incorrect.
While the machine is running, it is forbidden to carry out other work considered incorrect and which could, generally
speaking, lead to risks for the safety of the workers and damage the machine.

SAVIO shall not be held responsible for damages caused by incorrect use: the risk is the Customer’s alone.

The following cases of incorrect behaviour can be foreseen by the operators (and are consequently forbidden):

 The extraction of one or more winding units before disconnecting the machine from the power source;
 Cleaning and/or removing lint from the winding units while they are working;
 Using the machine with cones different to those specified in the manual or using bobbin tubes in an
unacceptable condition;
 Using the machine with the protections out of place;
 Using the machine while the keys to close the guards are still in their locks;
 The operators (qualified, authorised and trained people) are not using the IPGs.

ATTENTION!
It is forbidden to act as described above.

ATTENTION!
Do not remove or render illegible the safety, danger, forbidden or compulsory signs on the
machine

ATTENTION!
Do not remove or tamper with the machine’s protections.

ATTENTION!
Do not deposit combustible or inflammable materials near the machine or any other material that
is incompatible or has nothing to do with the process.

ATTENTION!
Do not use the machine with materials different to those specified in the manual.

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1.7 RESIDUAL RISKS

PREMISE

Correct use of the winder includes complying with all the operating and routine maintenance conditions.
We wish to sensitise each person to the use of the machine, asking them to give their
maximum co-operation to make sure there is no chance of critical operating situations arising in the area that could
lead to serious hazards without the necessary measures of prevention and protection being taken.

While the machine is running, avoid:

 prolonged exposure to noise;
 inhalation of residual winding dust when cleaning the machine;
 inhalation of residual dust from brake wear when cleaning the machine.

ATTENTION!
Do not approach the machine holding objects, like yarn for instance, that could wind around its
rotating parts.

In actual fact some parts of the machine, having to perform a purely technological function, cannot be suitably
shielded which means there are residual risks for the operator.

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1.7.1 WINDING UNIT

STARTING

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REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF RESIDUAL

RISK
1 Winding rotating Winding exiting from the winding cradle Abrasion
2 Winding rotating Contact between hand and rotating winding Abrasion
3 Fall-stop and yarn Finger fitting between grooved roll and side yarn Crushing
guide cylinder guide
4 Cylinder and winding Hand fitting between cylinder and winding chute Dragging and jamming
chute blade blade if there is no winding and in case of manual or
automatic cycle start
5 Arm support Winding cradle fall on hand Shearing
6 Winding chute and Hand shearing between arm support and winding Shearing
arm support chute
8 Winding cradle Finger fitting between winding cradle support and Crushing
arm height adjustment screw
9 Movable nozzle Impact of body parts, in particular face, with winding Impact
thread nozzle
10 Movable nozzle Impact of the upper limbs with bobbin thread nozzle Impact
11 Scissors Finger point cutting with scissors and knotter Cutting
chamber
12 Clearer knife Finger point cutting with clearer knife Cutting
13 Compressed air pipes Compressed air ejection from clearer area blowers, Ejection and inhalation
Jointair, pre-clearer, unthreading, due to compressed
air line disconnection
14 Yarn's path Yarn's path Contact between fingers/hand and Cutting
yarn's path

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MAINTENANCE

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS TYPE OF RESIDUAL

SITUATION RISK
15 Nozzle control belt Contact between hand and winding yarn bobbin yarn nozzle
nozzle, bobbin yarn nozzle control belt Crushing and
Jamming
16 Cycle control boxes Contact with electric components inside the Electrocution
cycle control boxes

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1.7.2 MACHINE BODY

STARTING

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL
RISK
1 Peg conveyor belt Contact of fingers/hands with peg conveyor belts Abrasion
4 Travelling blower working Impact of the operator with travelling blower sleeves Crushing
area
5 Travelling blower rails Finger crushing on travelling blower rails Crushing
6 Compressed air pirns Compressed air ejection for various pirn detachment Ejection
from the relevant system
7 Peg-locking piston Contact of the fingers with the peg-locking piston and Crushing
fixed guards, in unwinding position
8 Bobbin change levers Contact of fingers/hand between bobbin change levers Crushing
and fixed guards

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TAIL PICK-UP ON SECTIONS (MACHINE BODY)

STARTING

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL RISK
1 Tail pick-up electrical Contact of the head with sheets of the search electrical
equipment equipment compartment
Electrocution,
compartment
Crushing and
2 Live centre Hand on movable components of the peg tailstock on tail
snatching
pick-up stations
3 Tail pick-up unit Hand on tail pick-up foot on tail pick-up stations
4 Scissors Fingers on scissors on tail pick-up stations Cutting
5 Peg conveyor belt Finger fitting between return pulleys and peg conveyor
belt Crushing and
10 Peg rotation group Fingers between pulleys of peg rotation group and fingers snatching
on transfer disc grooves
11 Tail cutting station Fingers on control lever and underwinding tail cutting Cutting
blade

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SECTION (MACHINE BODY)
MAINTENANCE

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF RESIDUAL

RISK
2 Winding unloading belt Contact between hand and winding unloading belt Abrasion
returns
5 Compressed air lines Compressed air ejection for various pirn detachment Ejection
from the relevant system
6 Electric channel along Contact with parts of the electric channel Electrocution
the machine body

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TAIL PICK-UP ON SECTIONS (MACHINE BODY)
MAINTENANCE

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL RISK
6 Electric equipment Contact with electrical equipment
7 Motor supply cables. Contact with motor supply cables Crushing,
8 Solenoid valve group Compressed air ejection for various pirn detachment snatching,
from the relevant system Ejection,
9 Stops and shunters groups Fingers on stops and shunters of the tail pick-up Electrocution
station

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1.7.3 DOFFING TROLLEY UNIT

STARTING

RE HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

F. RESIDUAL
RISK
17 Trolley and supporting Upper limbs in the area where the trolley moves from one Shearing and
structure, top part of the winding unit to the other. impact.
machine.
18 Movable parts outside the Upper limbs in the operating area of the winding doffing Crushing.
trolley. cycle.
19 Operating area of the Contact with the operator dwelling in the operating area of
trolley. the trolley.
The operator, dwelling in the operating area under the trolley,
stands up when the trolley is passing.
To avoid or reduce the hazard, the following are available:
(a) moving and stationary trolley
Anti-impact side photocells: detect the presence of any
obstacles in the area
stopping the movement motor. The trolley remains stationary
until the photocell is deactivated, and it is free to move in the
opposite direction. Crushing,
Safety side levers and emergency stop: the side levers are snatching,
connected to the red emergency push-button. If at least one dragging and
of the levers is activated, the power supply is cut off and the jamming.
pneumatic emergency brake is activated, stopping the
movement of the trolley. To restart the trolley, follow the reset
procedure.
When the trolley is stationary the 2 systems mentioned above
(anti-impact side photocells and safety side levers) remain
activated.
(c) area under the trolley
It is not possible to monitor the area under the trolley with a
specific safety system, therefore a plate has been attached to
warn operators dwelling under the trolley about the hazard.

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MAINTENANCE

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF RESIDUAL

RISK
7 Movable part units Upper limbs (hand) fitting in the internal parts of the Crushing, snatching and
movable units. dragging.
8 Doffing trolley If a maintenance operation requires the extraction of Loss of stability and
the doffing trolley from the machine body, carry out crushing.
this operation with care to prevent the trolley itself from
coming off the anti-tilt guides and falling.
9 Electronic cards and Danger of electrocution with guards not in place and Electrocution.
electric panel. electric insulation fault.
10 Trolley connection Danger of electrocution with guards not in place and Electrocution.
chain electric cable electric insulation fault.

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1.7.4 HEADSTOCK

MAINTENANCE

REF. HAZARDOUS DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

AREA RESIDUAL
RISK
13 Electric equipment Contact with electric equipment with safety devices not in place.
14 Voltage transformer Danger of electrocution with guards not in place and electric
area insulation fault.
15 Motor supply Contact with worn/damaged motor supply cables.
cables.

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REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL
RISK
16 Tube conveyor belt Contact of the upper limbs between the pinions and the
control chains and between the rollers and the belt, with Crushing and
safety devices not in place. shearing
17 Motor supply cables. Contact with worn/damaged motor supply cables.

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1.7.5 CONE FEEDING UNIT

STARTING

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS TYPE OF RESIDUAL

SITUATION RISK
20 Cone holder chain. Contact of the upper limbs with the cone holder
chain. Crushing and shearing.
21 Cone holding stakes. Contact with the cone holding stakes.

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MAINTENANCE

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF RESIDUAL

RISK
3 Chain control belt Hand between cone-holding chain control belt and
pulleys
4 Return pulleys Hand between return pulleys and cone delivery belt Crushing, shearing
5 Cone feeder Instability of the complete group and electrocution
6 Electric equipment Contact with electric panel
7 Motor supply cables. Contact with motor supply cables

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1.7.6 BOBBIN PREPARING DEVICE

STARTING

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF RESIDUAL

RISK
1 Peg belt return groups Finger fitting between return pulleys and conveyor
belt Crushing, Snatching and
2 Preparing device Contact with electrical equipment Electrocution
electrical equipment
7 Drum Contact with moving parts

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(BOBBIN PREPARING DEVICE) BACK-UP STATION
STARTING

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF RESIDUAL

RISK
1 Tail pick-up electric Contact of the head with sheets of the search
Electrocution
equipment compartment electrical equipment compartment
2 Live centre Hand on movable components of the peg tailstock
on tail pick-up stations Crushing, Snatching
3 Tail pick-up unit Hand on tail pick-up foot on tail pick-up stations
4 Scissors Fingers on scissors on tail pick-up stations Cutting
5 Peg conveyor belt Finger fitting between return pulleys and peg
conveyor belt Crushing, Snatching
10 Peg rotation group Fingers between pulleys of the peg rotation group

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MAINTENANCE

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL RISK
1 Peg belt return groups Finger fitting between return pulleys and conveyor belt
2 Preparing device Contact with electrical equipment
Crushing,
electrical equipment
Ejection,
5 Bobbin and tube belts Finger fitting between pulleys and conveyor belt
Snatching
6 Solenoid valve group Blast of compressed to detach different tubes from the
Electrocution
relevant system
7 Motor supply cables. Contact with motor supply cables

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(BOBBIN PREPARING DEVICE) BACK-UP STATION
MAINTENANCE

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL RISK
1 Electric equipment Contact with electrical equipment
Electrocution
2 Motor supply cables. Contact with motor supply cables
3 Solenoid valve group Compressed air ejection for various pirn detachment
Ejection
from the relevant system
4 Stops and shunters Fingers on stops and shunters of the tail pick-up Crushing
groups station

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1.7.7 TUBE CLEANER

STARTING

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REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL
RISK
1 Electrical equipment Finger fitting in the electric board lower side (ratiomotor
compartment encoder)
2 Cleaner rack Finger fitting between rack and ratiomotor
3 Peg lifting trolley Hand fitting between peg lifting trolley and supporting bracket
of the front pneumatic cylinders while lifting and lowering
4 Peg lifting trolley Hand fitting between peg lifting trolley and blow group Crushing,
5 Peg lifting trolley Hand fitting between peg lifting trolley and base plate snatching,
electric shock,
6 Jaws sliding slot Finger fitting in the jaws sliding slot (right, left) while closing
electrocution
7 Jaws sliding slot Finger fitting in the jaws sliding slot (right, left) while opening
8 Jaws Hand fitting between the jaws while closing
9 Jaws Hand fitting between point and jaws while peg lifting
10 Tube gripper Hand fitting between tube gripper and basic plate
11 Peg gripper Finger fitting between peg gripper and peg
12 Economizer slot Finger fitting in the economizer sliding slot

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MAINTENANCE

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REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF

RESIDUAL
RISK
1 Electrical equipment Finger fitting in the electric board lower side (ratiomotor
compartment encoder)
2 Cleaner rack Finger fitting between rack and ratiomotor
3 Peg lifting trolley Hand fitting between peg lifting trolley and supporting bracket
of the front pneumatic cylinders while lifting and lowering
4 Peg lifting trolley Hand fitting between peg lifting trolley and blow group Crushing,
5 Peg lifting trolley Hand fitting between peg lifting trolley and base plate snatching,
electric shock,
6 Jaws sliding slot Finger fitting in the jaws sliding slot (right, left) while closing
electrocution
7 Jaws sliding slot Finger fitting in the jaws sliding slot (right, left) while opening
8 Jaws Hand fitting between the jaws while closing
9 Jaws Hand fitting between point and jaws while peg lifting
10 Tube gripper Hand fitting between tube gripper and basic plate
11 Peg gripper Finger fitting between peg gripper and peg
12 Economizer slot Finger fitting in the economizer sliding slot
13 Pneumatic system unit Compressed air ejection for various fitting detachment from Ejection
the relevant system
14 Peg belt return group Finger fitting between return and conveyor belt Crushing and
snatching

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1.7.8 RESIDUAL RISK GENERAL

REF. HAZARDOUS AREA DESCRIPTION OF THE HAZARDOUS SITUATION TYPE OF RESIDUAL

RISK
Contact with noisy parts without any suitable
1 General machine Noise
acoustic protection
Inhalation of residual winding dust during cleaning
2 General machine Dust inhalation
operation;
Inhalation of residual dust from brake wear during
3 General machine Dust inhalation
cleaning operation
Crushing, snatching,
4 General machine Safety device faults shearing, electric shock
and electrocution

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1.8 INSTALLATION, INSPECTION, WARRANTY

INSTALLATION The installation and final inspection of the machine shall be carried out by the manufacturer.
At the end of these operations the Customer will be given a “DELIVERY CERTIFICATE” which symbolises
acceptance of the total supply the moment it is signed.

The manufacturer guarantees that its machines are in proper working order and free from faults and defects.
Unless stipulated otherwise in the contract, the warranty is valid for 12 months starting from the date installation is
finished and, in all cases, from the date the customer signs for delivery on the delivery certificate.
The warranty is limited to the repair and replacement of faulty parts, excluding consumables and failures caused by
overloading, inexperience in using the machine, negligence and non compliance with the instructions given in this
manual.

NOTE: for more information please consult the “General Conditions of Sale” enclosed with the contract.
Any different conditions, stipulated when the contract is drawn up, shall prevail over those mentioned above.

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1.9 MODIFICATIONS

Any alterations the Customer makes to the machine must be authorised beforehand by the manufacturer; to the
contrary the warranty will no longer be considered valid.

ATTENTION!
The manufacturer declines all responsibility for harm to people or damage to things caused by
any unauthorised alterations.
It is absolutely forbidden to modify the installed software.

1.10 REQUESTS FOR ASSISTANCE AND SPARE PARTS

To request the assistance of Savio specialised personnel, contact the Customer assistance centre directly at the
following numbers:

Phone: 39 0434 397276

Fax: 39 0434 397292
web site: www.saviospa.it
e−mail : [email protected] − internet: www.saviospa.it

For spare parts please consult the Catalogue provided with the machine, following the instructions given for
ordering:

Phone: 39 0434 397239

Fax: 39 0434 397314
web site: www.saviospa.it
e−mail : [email protected] − internet: www.saviospa.it

ATTENTION!
The Customer should only use original Savio parts.
If other spare parts are used it is at the Customer’s risk and the manufacturer declines all
responsibility.

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Page left blank intentionally

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2 - MACHINE GENERAL INFORMATION

Modification table
Revision Date Drafter: Revision Date Drafter:
01 26/01/2016 Badiali Roberto

02 01/11/201 Badiali Roberto

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INDEX :

2.1 TECHNICAL DATA .................................................................................................................... 3

2.1.1 MACHINE WARNINGS AND GENERAL CHARACTERISTICS ......................................................... 3
2.1.2 MACHINE DIMENSIONS .................................................................................................................... 7
2.1.3 MATERIAL WARNINGS AND GENERAL CHARACTERISTICS ....................................................... 8
2.1.3.1 TUBE AND BOBBIN FEATURES ............................................................................................. 8
2.1.3.2 TAKING-UP CONES ............................................................................................................... 11
2.1.3.3 GROOVED WINDING DRUMS............................................................................................... 15
2.1.3.4 WARNING FOR GROOVED WINDING DRUMS ................................................................... 17
2.1.4 MACHINE NOISE.............................................................................................................................. 18

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2.1 TECHNICAL DATA
2.1.1 MACHINE WARNINGS AND GENERAL CHARACTERISTICS

The table below contains the machine technical data and features.

Description Config. OPT optional devices

Machine Presett. Application
Machine model ECO PULSARS I-DLS for connection to spinning As
machines: preferre
bobbin automatic loader for one batch d
Machine RIGHT version: As
with control headstock positioned on the machine body right side preferre
d
Machine LEFT version: As
with control headstock positioned on the machine body left side preferre
d
Number of winding units that can be installed: from 20 to 72, by
steps of 2
Configuration 62, 66 and 68 are not available
1 search from 20 to 40 units; 2 searches from 32 to 72, 3 searches
70-72
Workable yarns:
Discontinuous fibre, staple and woollen yarns
Working range:
Counts from Nm 1/3.5 to thinner ones
Feeding bobbins:
As
- Length from 180 to 280 mm and other tube heights, “PNS” on
preferre
request upon SAVIO approval
d
- 32 to 67 mm diameter
Collection windings: As
- Taper 0° - 1°05' - 3°30' - 3°51' - 4°20' - 5°57' - 9°15' preferre
d
Collection speed: As
400 to 2200 m/min with continuous rating preferre
d

HEADSTOCK

CHARACTERISTIC DESCRIPTION Config. Optional OPT

Machine Presett. Application
Technological air discharge :
the air in the winding units is filtered and discharged into the room,
without overpressure and with low temperature increase.
NOTE: underground or overhead ducts dedicated only to the
headstock are not necessary

Dust and lint anti-static discharge in separate bins

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MACHINE BODY

CHARACTERISTIC DESCRIPTION Config. Optional OPT

Machine Presett. Application
Machine cleaning devices: YES Dust suction
As
- With travelling blower. system
preferred
- With travelling blower and suction system of dust in unwinding.
Lighting on machine body. [OPT]

WINDING UNIT

CHARACTERISTIC DESCRIPTION Config. Optional OPT

Machine Presett. Application
Grooved winding drum: YES
- in special cast iron of various types (see paragraph 2.1.3.3)
Anti-creasing modulation:
- ON-OFF type (cylinder rotation speed variation) set for C.A.P. As YES C.A.P. type
type preferred
- C.A.P. type (variation of winding transfer point on the cylinder).
Axial movement of dyeing winding cradle. [OPT]
Instant lifting and braking of the winding, separate from drum
braking
CLEARERS:
As
- USTER – QUANTUM 3.
preferred
- LOEPFE – ZENIT.
Sensor to detect unwinding yarn tension.
Pre-clearer:
- adjustable width on 4 positions.
Yarn tensioner:
- with one tension section.
Waxing unit:
[OPT]
- at interference.
Probe that detects the wax is about to finish. [OPT]
Balloon breaker tension reducer with anti-kink device.

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CHARACTERISTIC DESCRIPTION Config. Optional OPT
Machine Presett. Application
Splicer:
- Savio splicer

- Jointair 895
- Jointair 8951 and water supply system
- Jointair 692 and water supply and discharge system.
- Heatsplicer 4982. As
- Twinsplicer. preferred
- Mechanical knotter (upon request).

- Finishing presettings
Adjustments on a single winding unit:
Waxing extent, pre-clearer width, splice characteristics for
Twinsplicer, Knotter.
Winding taper increase.
As
. Mechanical with ON-OFF modulation 0°÷ 5°.
preferred
Electronic with C.A.P. 0°÷3°.
Automatic check of the wound thread meterage by laser. [OPT] C.A.M. type
Counter-weighing adjustable on single winding unit. [OPT] C.A.D. type
Steady cleaning device for the clearers.
[OPT]
TO PNS

WINDING DOFFING

CHARACTERISTIC DESCRIPTION Config. Optional OPT

Machine Presett. Application
Doffing:
As
- automatic with 1 trolley. YES 2 trolleys
preferred
- automatic with 2 trolleys.
Take-up cone feeding:
- automatic centralised, 1 magazine placed on the headstock. As
- automatic centralised, 2 magazines placed on the headstock. preferred
- Individual by means of a cradle placed on each winding unit.
Winding unloading belt: As
- single headstock sense. preferred

BOBBIN PREPARING DEVICE

CHARACTERISTIC DESCRIPTION Config. Optional OPT

Machine Presett. Application
- preparing device with Back-Up station As
YES
- tail pick-up units on sections 1, 2 or 3 preferred
Tube cleaner. [OPT]

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INSTALLED ELECTRIC POWER

Installed power is the sum of all the rating plate nominal powers of the various motors.
The following table indicates the power installed for the various ECO PULSARS I-DLS models according to
machine length.
The values refer to the following machine configurations: ECO PULSARS I-DLS.
To find the installed powers of differently configured machines, the values indicated in the table have to be:
a) added if they are relative to the optional applications the machine can be equipped with (e.g.: winding unloading
belt towards the tail end, fourth peg conveyor belt etc.)
b) subtracted if they are relative to applications not present.

(1) = With 2 centralized magazines, 2 doffing carriages, 1 yarn PLANT POWER (kW) (1)
end finder, package conveyor belt, waste yarn collector, NUMBER OF WINDING HEADS
bobin hopper 20-28 29-36 37-48 49-56 57-64 65-72
BASE POWER PLANT 16,28 19,35 25,27 29,00 32,73 36,47
DUST REMOVAL 50,5 Watt/spindle
HEAT SPLICER 23 Watt/spindle
LIGHTING 10,5 Watt/spindle
SAVIO BELT BLOWER 2,2
ELECTROJET 2,29
ADDITIONAL YARN END FINDER 1,40
ADDITIONAL BOBBIN HOPPER 2,75

COMPRESSED AIR CONSUMPTION

The compressed air consumption depends on the function of the single winding units and the bobbin preparing
devices fitted on the machine.
All values are reported in the specific paragraphs of the units mentioned above.

TECHNOLOGICAL AIR DISCHARGE

For the amount of air flow (m 3/h) discharged by the machine, in order to dimension the room air treatment, with a
ΔT = 4,5°C, see the diagram below.

Normal suction
Air flow (m3/h)
3 research

2 research

1 research

Number of winding heads

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2.1.2 MACHINE DIMENSIONS

The overall dimensions of the machine can be found in the technical data sheets in paragraph 10 APPENDIXES.

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2.1.3 MATERIAL WARNINGS AND GENERAL CHARACTERISTICS
2.1.3.1 TUBE AND BOBBIN FEATURES

TUBE FEEDING

TUBE LENGTH
The bobbin tube length L must be included in a range 180 ÷ 280 mm, with possibility of extension up to 310 mm
(upon SAVIO approval), exclusively for ECO PULSARS I-DLS version.
The tolerances are defined by the UNI−ISO 368 Standards.

TUBE DIAMETERS
The base inside diameter d2 must remain within a range of 17 ÷ 36 mm.
The hole d3 should be at least 8 mm.
The diameter d1 should be within the range: 14 ÷ 28 mm.
The tube nose must have one of the 4 following configurations.
Nose diameter (d1) should be at least 1 mm bigger than diameter (d2) to stop one tube slipping inside another.

USED MATERIAL
The material used to make the tubes should be good quality, preferably in 6-6 polyamide loaded with fibreglass or
Bakelite cardboard with a ring nut on the bottom and nose so it cannot deform when loaded.
Cardboard and disposable cardboard tubes are advised against.

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WARNINGS
The tubes should not be deformed, crushed, nicked and, above all, there should be no scaling or
deformations on the base or nose.
Tubes utilised simultaneously in the loader, that is, part of the same lot, should all be the same size.

In case of stretched yarns (LYCRA), in order to avoid tail coming out of the tube, it is necessary to use tubes
whose best shape is described in the following figure.
Regardless of its length, the geometry of the tube end must be accurately respected.

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Tubes used for ECO PULSARS I-DLS with tube cleaner shall not have deep grooves in Zone 1 as per DIN ISO 368,
(i.e. at tube bottom) since this would prevent cleaner correct operation.

For tube bottom end, the following types of surface are recommended:
- microrifling having a max. depth of 0.04 and pitch 0.5 mm
- orange-peel finish surface with Ra 6.3-12.5
- dimpled or napped surface
Rifling, with max depth of 0.12 mm and pitch 5 mm, is generally not recommended (especially with strong yarns like
Polyester, Kevlar, etc.), unless groove bottom parts are duly radiussed.

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2.1.3.2 TAKING-UP CONES

CARDBOARD CONES

The nose can either be straight (B) or inverted (A), to increase rigidity.
The most widely used surface finishes are scraping and felting.

The main features are:

 - rigidity is important for this type of cone;

 the diameter of the inverted nose should be within the tolerances and limits given in Table 103;
 it is essential that the inside corner at the base of the cone be rounded while
the characteristic notch (for the reserve) on many types of cone, is not essential; however it is
acceptable provided it does not undermine cone strength;
 The external finish of the cone should reach the edge of the cone base and include
the inside of the circular lowering so as to facilitate reserve conservation.
12 mm of the internal surface must be free from riflings (C);

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PLASTIC CONES

There can be many different surface finishes but mechanical brushing on a slightly rifled surface is preferable.
The features of the cardboard tubes are also valid for plastic cones but perfectly straight cones are recommended
without the relief ring, sometimes found at the base of the tube (D), as it hinders reserve formation.

CONES FOR DYEING AND STEAMING

They are normally in perforated plastic; It is important that the perforated area be within the package (E) winding
limits.
The external finish should be a fine molding pitch microrifling.
Composition material should be inert so as to guarantee an indeformable plastic at high working temperatures or
pressures and impermeability to dye bath colours, etc.

110 ÷ 150 mm CONES FOR PER DIRECT TWISTING

These cones are used in the direct feeding of two-for-one twisters with two single-yarn
overlapping packages (F).
As regards the external finish we recommend fine brushing on a microrifling surface.

ATTENTION!
If cardboard cones are used which do not comply with the description above, or if they are
flattened, the speed must absolutely be reduced, with the tube empty, by means of parameter 12
“New package initial speed” (see paragraph ISPECTOR CONTROL).

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2.1.3.3 GROOVED WINDING DRUMS

The following table gives the characteristics of the cylinders to use depending on package use, yarn type and
relevant count.

DEFINED FEATURES OUTCAM CYLINDER

COUNT Cone Features
PACKAGE YARN Winding Drive Conicity
conicity Helix Helix Notes
USE TYPE Description Range traverse Diam. C/L increase
revs pitch
Medium and 5°57’
coarse counts
Nm
Yarns with 152 4°20’ 94 2 PV L NO
5÷20
slippage twisted 3°51’
yarns 3°30’
5°57’
Acrylic Medium-fine Nm 4°20’
152 94 2 PV L
counts 20÷60 3°51’
3°30’
YES
5°57’
Fine-extra fine Nm 4°20’
152 94 2 PV L
counts 60÷100 3°51’
3°30’ -
5°57’(*)
Medium and
Nm 4°20’
coarse counts 152 94 2 PV L NO
5÷60 3°51’
twisted yarns
3°30’
Medium-fine 5°57’
counts with
Wool
slippage fine 4°20’
Knitting
and extra fine Nm 3°51’
Warping 152 94 2 PV L YES/NO
counts medium 30÷100
Weaving
and coarse
3°30’
counts twisted
yarns
Particularly 5°57’(*)
Wool difficult yarn 4°20’
Nm
Acrylic blends 152 3°51’ 94 2 PV L NO
5÷100
Blends (slippage,
3°30’
hairiness, etc.)
5°57’
Ne 4°20’ -
Medium counts 152 94 2 PV L YES
10÷30 3°51’
Cotton
3°30’
100%
5°57’ (*)
Blends
Medium-fine Ne 4°20’
152 94 2.5 PV L YES
counts 30÷90 3°51’
3°30’
5°57’
Wool Coarse-medium-
Nm 4°20’
Acrylic fine counts 152 94 2 PV L YES/NO -
5÷60 3°51’
Blends twisted yarns
3°30’

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DEFINED FEATURES OUTCAM CYLINDER
COUNT Features
PACKAGE Winding Cone Drive Conicity
YARN TYPE Helix Helix Notes
USE Description Range Traverse conicity Diam. C/L increase
revs pitch
Coarse 5°57’
and 4°20’
medium Ne 3°51’
152 94 2 PV L YES/NO
counts 5÷30
twisted 3°30’
Cotton
yarns
Knitting bleds/cott
5°57’
Warping viscose
Medium- Ne 4°20’
Weaving synthetic 152 94 2.5 PV L YES
fine counts 30÷80 3°51’
short staple
3°30’
5°57’
Extra fine 4°20’
Ne > 80 147 87 3 PMV L YES
counts
3°51’

5°57’ (*)
4°20’ L
Wool acrylic All 3°51’
Dyeing 152 85 / 90 2 PC NO (2)
cotton blends counts 0°
Biko C
(PNS)
5°57’ (*)
4°20’ 94 L
Knitting Wool acrylic All
150 3°51’ 2 PC YES (1)
(Dyeing) cotton blends counts
Biko
93 / 98 C
(PNS)
5°57’ (*)
4°20’
3°51’ 94 2 PC L
3°30’
Direct All 150 1°05’ (3)
All yarns NO
twisting counts 0° Ø 68 (4)
L
0° Ø 54
93 / 98 2 PC
Biko
C
(PNS)
110 1°30’ 98 / 93 1.5 PC C
5°57’ (*)
4°20’
3°51’ 94 2 PC L
Dyeing Cotton
3°30’
(knitting blends/cotton All (3)
150 1°05’ NO/YES
warping acrylic counts (4)
0° Ø 68 L
weaving) blends/acrylic
0° Ø 54
93 / 98 2 PC
Biko C
(PNS)

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Note:
1 – The right solution is using for dyeing and knitting, but mainly for knitting, except for cone 5°57’ (dyeing).
2 – The outside diameter of the 0°cones must beat least 66 mm.
3 − The outside diameter of the 0°cones must beat least 58 mm.
4 – In the case of a machine with electronic modulation (C.A.P.), if both 0° and 1° 05’ cones are to be taken-up, a
98/93 diameter cylinder with a 150 mm winding traverse must be used.

(*) not recommended.

N.B. Thechoice of modulation (antiribboning) is made according to the main use of the packages.
For knitting/warping modulation should be chosen excluding the 0° take-up.
For dyeing prefer axial displacement (as it allows higher speeds of the 85/90 diameter)

Legend:
PV = Drum with variable pitch helix
PC = Drum with constant pitch helix
PMV = Drum with an average variable pitch
C = Drive with centre belt
L = Drive without edge (slow start)

2.1.3.4 WARNING FOR GROOVED WINDING DRUMS

The grooved winding drums are made of cast iron covered with a layer of nickel-hard, and their life span normally is
extremely long.
It is noted, however, that in the case of use of:
- Flax yarns , wet or dry spinned, particularly dirty;
- polyester yarns dyed, in a such a way to present abrasive features;
- acrylic yarns dyed, in such a way to present abrasive features.
The drums life span is shortened considerably and it is necessary to provide for their replacement in time.

We recommend the following preliminary point:

1) for flax yarn wet, perform an adequate preliminary process of cleaning of the fibers and dissolve the natural
cements, and a bleaching that makes the fibers more elastic and soft, before spinning and winding.
2) for the polyester yarn dyed, choose fiber from polymerization and appropriate dyes.
a. It is not recommended to exceed with the polymerization with the aim to obtain higher molecular weights. In
these cases it is frequent the formation of unwanted compounds (oligomers), and if the subsequent dyeing
process is done without using appropriate dispersant, the oligomers are deposited on the outer surface of
the fibers significantly increasing and the abrasiveness and the friction coefficient of the yarn, arriving up to
μ = 0.34, considering good values μ = 0.20, mean values μ = 0.22, and just enough values μ = 0.25.
3) For acrylic dyed yarn, use appropriate processes of dyeing which does not leave on the fibers an excess of
abrasive additives.

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2.1.4 MACHINE NOISE

INTRODUCTION

Below the measurements of the equivalent sound pressure levels of the winder are given, the latter being designed
and made employing the best technological solutions to reduce the sound power level at source.

TEST PROCEDURE

The measurements were taken in compliance with the following standard:

the International ISO 9902-1-2 standard (2014):

“Textile machinery - Noise test code - Part1: Common requirements - Part2: Spinning preparatory and spinning
machinery”.

OPERATING CONDITIONS

CONDITIONS MODEL: ECO PULSARS I-DLS

No. Units 32
Winding traverse 152 mm
Splicer Jointair 895
Travelling blower YES
Air discharge from packaging units In the room
Processed material 100% cotton Ne 30
Winding speed 1400 m/min
Suction vacuum 32-42 mbar
Jointair working pressure 6,5 bar

MEASUREMENT RESULTS

The equivalent sound pressure level LAeq mean is 83 dB (A), detected on a single machine operating in the
conditions described above.

ATTENTION!
If the machine is installed on reverberating premises or where there are other noise sources and
the “daily personal sound exposure level” is higher than 80 dB(A), there is a noise risk for the
operator. In this case the Customer must provide personal protection for the operator (such as
ear plugs) in accordance with the laws in force in his country on the subject of “Prevention of
accidents at the work place”.

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3 - TRANSPORTATION AND HANDLING

Modification table
Revision Date Drafter: Revision Date Drafter:
01 26/01/2016 Tweddle

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INDEX :

3.1 TYPE OF PACKING ................................................................................................................... 3

3.2 PACKAGE DIMENSIONS .......................................................................................................... 4
3.3 PACKING HANDLING DIAGRAMS ............................................................................................ 5
3.3.1 PACKING FOR THE HEADSTOCK .................................................................................................... 6
3.3.2 PACKING FOR MACHINE BODY....................................................................................................... 6
3.3.3 PACKING FOR THE PREPARING DEVICE....................................................................................... 7
3.3.4 PACKING FOR THE HOPPER STATION .......................................................................................... 8
3.3.5 CARDBOARD BOXES OR WOODEN CRATES ON PALLETS ......................................................... 9
3.4 INSTRUCTIONS FOR HANDLING AND OPENING PACKS UNDER SAFE CONDITIONS ..... 10
3.4.1 HANDLING MEANS .......................................................................................................................... 11
3.4.2 MACHINE PACK STORAGE ............................................................................................................ 13
3.4.3 PACK OPENING ............................................................................................................................... 14

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3.1 TYPE OF PACKING

The ECO PULSARS I-DLS winder is supplied with one of the following packing types, upon specific request by the
Customer:

 on frames
 on wooden cages
 on ”overseas” cases

PACKING ON A FRAME

It is made of a wooden pallet or frame - fastened to a platform in the same material and acting as base - and of a
wooden cage on the sides.

PACKING ON WOODEN CAGES

It is made of a wooden pallet or frame - fastened to a platform in the same material and acting as base - and of a
wooden cage on the sides.

The machine’s section is held rigidly in position on the base with straps and protected with polyethylene.

PACKING ON "OVERSEAS" CASES

It is made of a wooden pallet or frame - fastened to a platform in the same material and acting as base - and of a
wooden cage closed on the sides and top.
The machine’s section is held rigidly in position on the base with straps and protected with a wrapping coupled with
a rarefied atmosphere barrier.

NOTES

 All packings described are completed with wooden or cardboard boxes positioned on pallets for the smaller
units as illustrated in detail in paragraph 2.
 If the overseas packing is chosen, the remaining packings in boxes will also have the barrier protection.
 Unless otherwise stipulated in the contract, the manufacturer guarantees the protection (only for those
machines with barrier protection) of parts subject to corrosion for 6 months starting from the date of
packing.

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3.2 PACKAGE DIMENSIONS

In order to facilitate identification, handling and unpacking of the packs, the following table gives the types, sizes
and contents.

WEIGHT (kg) DIMENSIONS

CONTENTS No. TYPE NOTES
Gross Net AxBxH (cm)
Control headstock 1 800 760 Frame 190x120x155 (1)
Machine section 10 units 1150 1040 334x115x165
Machine section 8 units (1) 923 835 Cage 270x115x165
Machine section 6 units 692 625 206x115x165
Search section (1) 192 180 Blade 73x110x142
Bobbin preparing device 1 325 230 Cage 184x108x185
Automation trolley (2) 140 110 Box 85x85x118
Cone magazine (2) 162 141 Gage 280x75x56
Travelling blower Savio by Magitex 1 82 66 83x76x56
(1) Example of
Savio by Magitex system tracks and Box
1 720 663 350x80x52 a machine
machine parts
with 48 units
Electrojet travelling blower
Box
Electrojet system tracks
Material for assembling the machine Cage
Material for assembling the machine Blade
Material for assembling the machine (1) (1) (1) (1)
Material for assembling the machine Box
Material for assembling the machine
(1) : according to machine length and configuration;
(2) : 1 or 2 according to machine configuration.

NOTES

The dimensions of packs must be interpreted as indicated in paragraph 3.

For each pack, the weight is basically centred.

The documentation provided with the machine, including the "Manual for Use and Maintenance", installation
diagrams and spare parts catalogue, can be found in the boxes marked with a "red stamp".

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3.3 PACKING HANDLING DIAGRAMS

Indicated below are the packing diagrams for the control headstock, the machine element (in the case of packing
on a frame), the preparer, the hopper station and the packing diagrams for the remaining packs (cardboard boxes
or wooden crates) on pallets.

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3.3.1 PACKING FOR THE HEADSTOCK

Side lifting only from the side opposite the package unloading belt board.

Handling side

3.3.2 PACKING FOR MACHINE BODY

Load basically centred.

Handling side

ATTENTION!
On the back of the machine sections are installed service tie rods, which must be kept and used
again, if necessary, to handle the machine sections themselves.

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3.3.3 PACKING FOR THE PREPARING DEVICE
Load basically centred.

Handling side

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3.3.4 PACKING FOR THE HOPPER STATION

Load is not centred on the long sides, and centred on the short sides.
Pack can be lifted only from the long sides.

Handling side

NOTES:
 THE FORKS, WHOSE MINIMUM LENGTH MUST BE AT LEAST 1200MM, MUST REACH THE
OPPOSITE CROSSBAR.
 FOR HANDLING THE MACHINE INSIDE THE FACTORY, PLACE THE FORKS AS SHOWN IN THE
FIGURE: ONE UNDER THE AUXILIARY BARS (1), THE OTHER UNDER THE LONGITUDINAL BARS OF
THE STRUCTURE.

ATTENTION!
The auxiliary bars (1) must be kept and used again whenever the machine is moved.

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3.3.5 CARDBOARD BOXES OR WOODEN CRATES ON PALLETS

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3.4 INSTRUCTIONS FOR HANDLING AND OPENING PACKS UNDER SAFE CONDITIONS

ATTENTION!
Before any handling of the packs can be done, first check for symbols on the outer wrapping.

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3.4.1 HANDLING MEANS

Use a fork lift truck for handling with a minimum capacity “Q” = 1500 Kg, at a minimum distance “C” = 500 mm, as
illustrated in the figure.

ATTENTION!
The person driving the lift truck should be skilled in this job, according to the laws in force in the
country where the machine is installed. Packs on a frame or pallet should always be picked up
with the forks placed centrally on the longest side.

When loading and unloading, verbal and hand signals are necessary as prescribed in the EEC directive 92/58
regarding minimum health and/or safety at the work place which, in Italy, is included in the Legislative Decree no.
493 of 14/08/1996.
In non-EEC countries comply with the norms in force in the machine installation country and relevant provisions.

ATTENTION!
The person loading and unloading the packs must wear suitable IPG (individual protective gear).

ATTENTION!
The shipping agent must make sure that the load is positioned and anchored properly to the
transportation means.

ATTENTION!
When loading and unloading it is forbidden to stand under hanging loads.
Only authorised personnel are allowed to access the work area.

ATTENTION!
To lift machine parts it is forbidden to anchor to mobile or delicate parts like the casing,
raceways, pneumatic parts, etc.

ATTENTION!
When handling it is forbidden to stand under hanging loads and only authorised personnel is
allowed to enter the work area.
It is compulsory to wear work overalls, safety footwear, protective headgear and gloves.

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ATTENTION!
The Customer must comply with the contents of the EEC Directive 89/391 Section II, article 10,
which in Italy in included in Leg.D. 626/94 (and subsequent amendments) on the subject of
“Supply contract or work contract".

ATTENTION!
The control headstock and all machine components should be handled and transported avoiding
knocks and/or damage: FRAGILE.

ATTENTION!
Failure to apply the above procedures can result in a residual risk of crushing.

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3.4.2 MACHINE PACK STORAGE

The packs that make up the machine should be stored and kept under cover, protected against the damp, in a non-
corrosive environment, free from vibrations and where the temperature is between 0 and 40 °C. The floor of the
place where the machine is to be stored must be perfectly horizontal so as to avoid deforming the machine or
damaging the supporting feet.

ATTENTION!
Do not store packs on top of each other.

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3.4.3 PACK OPENING

ATTENTION!
This operation must be performed by qualified personnel, having proven experience and
previously duly trained.

ATTENTION!
While performing this operation, all personal protection must be worn, in compliance with the
laws in force in the country where the machine is installed.

OPENING When the machine is delivered check that the packing and/or components are all sound. If that is not the
case, notify the shipping agent immediately and also inform SAVIO.

ATTENTION!
Cut the straps with scissors made for cutting thick material. As the straps are pulled very tight
pay particular attention when cutting them as they could fly back and hit the operator or anyone
else nearby. Take great care not to damage the materials when removing them from the boxes or
pallets.

ATTENTION!
When unpacking do not stand on the packs. The operator should wear suitable protective gear
(e.g. gloves, safety shoes, work overalls, etc.).

ATTENTION!
The packing materials (pallets, cardboard boxes, etc.) must be disposed of by authorised
companies, complying with the laws in force in the country where the machine is being used.

ATTENTION!
Failure to apply the above procedures can result in a residual risk of crushing.

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Modification table
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INDEX :

4.1 REQUIRED ENVIRONMENTAL CONDITIONS .......................................................................... 3

4.1.1 ELECTRICAL CONNECTION ............................................................................................................. 4
4.1.2 COMPRESSED AIR CONNECTION .................................................................................................. 5
4.2 INSTALLING THE MACHINES................................................................................................... 6
4.3 TEST .......................................................................................................................................... 7

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4.1 REQUIRED ENVIRONMENTAL CONDITIONS

The following are the customer’s responsibilities, unless specific contract conditions have been stipulated:

 Before the machine is installed check that the building’s bearing structures (floor, etc.) are able to withstand
the weight of the machine (in terms of safety). (Use the technical data sheets in Paragraph 10
"Appendixes")
The maximum loads bearing on each supporting foot are given in the installation diagrams in Paragraph 10
"Appendixes".
The surface on which the machines stand, including the area between the supporting feet, must be
perfectly level and even and, above all, must have none of the building’s expansion joints.
If the area is slightly uneven, the machine can be levelled by adjusting its feet.
The maximum adjustment value is 40 mm;

 While waiting for Savio’s assembly experts to arrive, the packages must be kept on dry, covered premises.
A mechanic and electrician must be placed at the disposal of each Savio assembler.
Also arrange for a handling means as specified in chapter 3, where more information is also given about
packings and handling;

 Check the condition of the packaging and report any damage found immediately to the manufacturer;

 Arrange the material at the place of installation;

 Prepare the connection to the electrical and compressed air outlets in the position indicated in Paragraph
10 "Appendixes", and verify the operating values given in Paragraph 4 "Installation";

 Have ready, for the complete Final Inspection of the machine, yarns with the same characteristics indicated
in the order confirmation’s technical list.

ATTENTION!
Ensure the correct environmental conditions to safeguard the health and hygiene of each
“exposed person”.

Air conditions are affected by the raw materials processed and by technological requirements.
As a guide, optimum environmental conditions are:

 temperature : 22 ÷ 27 °C
 relative humidity (R.H.) : 50 ÷ 70 %.

CHANGING THE AIR

The number of air changes needed for the winding departments depends on:
 how hot the departments are normally,
 the temperature required,
 the degree of dustiness produced by the process,
 the need to eliminate pollution between yarns of different compositions being processed simultaneously.

Except for special circumstances, 20 changes of air/hour are considered reasonable.

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4.1.1 ELECTRICAL CONNECTION

PREMISE

The electrical connection of the machine is carried out by engineers employed by the manufacturer, SAVIO. In
order to facilitate this operation, the Customer is asked to follow the instructions for the connection to the factory's
electrical system and the indications contained in the technical data sheets in Paragraph 10 "Appendixes"

POWER SUPPLY

The Customer must dimension the machines’ connection cable to suit his own system in compliance with
the standards IEC 204-1, CEI 44-5, EN
60204−1.

APPROXIMATE CABLE CROSS SECTION

up to 40 A → 10 mm 2 from 85 to 100 A → 35 mm 2
from 45 to 55 A → 16 mm 2 from 105 to 115 A → 50 mm 2
from 60 to 80 A → 25 mm 2 130 A → 70 mm 2

Moreover, the factory plant should allow for compliance with the following characteristics:

 tolerance on power voltage at machine inlet: ±10%,

 tolerance on power frequency: ± 2%;
 The earthing system should comply with the standards of the country of installation, and should at least
comply with the IEC 60364-5-54 standard; the value of the resistance between the earth protection line and
the earth should be no higher than 20 Ohm;
 if the power cable comes out of the ground, it should be at least 2000 mm long,
 the voltage pulses should last no longer than 1 ms with a voltage peak no higher than double the supply
voltage’s nominal value.

ATTENTION!
The electrical and electronic components are dimensioned to ensure correct operation up to a
height of 1000 metres a.s.l.; in the case of higher altitudes, these components should be re-
examined in relation to the installation height.

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4.1.2 COMPRESSED AIR CONNECTION

PREMISE

The compressed air connection of the machine is carried out by engineers employed by the manufacturer, SAVIO.
In order to facilitate this operation, the Customer is asked to follow the instructions for the connection to the
factory's compressed air system and the indications contained in the technical data sheets in Paragraph 10
"Appendixes"

COMPRESSED AIR SUPPLY

The figure below indicates the required specifications of the supply pipe.

Supply pipe specifications:

Øe = 3/4” GAS
To avoid faults due to pressure drops, the
length of the pipe must be less than 5 metres (longer
pipes will need to have a
larger diameter).

The compressed air supply pipes should slant 0.5% in the direction of the air flow, while the branches should be
made so the water can flow towards the steam traps.

The compressed air must be cooled and filtered and at the use must be free of liquid water, oil aerosol and solid
impurities, as for class 3.4.3 of ISO 8573-1: 2010 , therefore:
- solid impurities: <= 5 µ with concentration <= 5 mg/normal cubic meter
- water pressure dewpoint: <= 3°C. If the distribution network arrives from external site, the
compressed air in the network should have water pressure dewpoint -20°C
- oil content : <= 1 mg/normal cubic meter

Supply pressure:
 minimum: 600 kPa (6 bar)
 maximum: 750 kPa (7.5 bar)
Should pressure drop below 550 kPa (5.5 bar) the “minimum pressure switch” will turn the machine off
automatically. Different minimum pressures can be set via the pressure switch to safeguard the minimum Jointair
splicing pressure with air splicers but maximum supply pressures must never be set any higher than 750 kPa (7.5
bar).

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4.2 INSTALLING THE MACHINES

Installation of the machines shall be done by and is the responsibility of Savio whose personnel shall be helped by
people placed at their disposal by the Customer, as specified in chapter 1, paragraph 4.

The following has to be done prior to installing and mounting the machine:

 the working area must be cordoned off and marked with the appropriate safety signs;
 customer personnel is not allowed TO access the work areas unless expressly
authorised by SAVIO.

SAVIO qualified personnel together with the Customer’s authorised personnel shall carry out the following:

 check the packs and relative materials making sure none are missing and they are all sound;
 check the machine’s installation area, paying particular attention to floor evenness;
 arrangement on site, alignment, levelling and connecting the various machine sections;
 mount the travelling blower;
 wiring of the electricity supply lines to the factory’s plant, prepared by the Customer;
 pneumatic circuit connection;
 a general machine check;
 check conformance of the mains voltage and frequency with those given in this manual and on
the rating plates of the machine’s electric motors;
 check that all guards and safety devices are in place and working properly;
 . machine start up and commissioning.

ATTENTION!
The above jobs must only be done when the machine is still and the machine’s main switch is
locked in the “O” (Zero) position.

ATTENTION!
The people mounting the machine must be qualified and
equipped with safety shoes, gloves and suitable tools and suitable auxiliary means.

ATTENTION!
Work on electric equipment must be carried out by a qualified electrician. .

ATTENTION!
Do not make any alterations to the parts supplied with the machine. Any parts that are lost
or broken should be replaced with original parts.

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4.3 TEST

Once the machine has been mounted and started, Savio personnel will carry out a functional and technological test
on it.
When this has been done, the Customer will be given a “DELIVERY CERTIFICATE” which symbolises acceptance
of the total supply the moment it is signed (see also chapter 1.8, paragraph 1.).
The document also has a space where the Customer can write down any comments or complaints.

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5 - MACHINE UNIT INFORMATION, USE INSTRUCTIONS

AND MAINTENANCE

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02 01/11/2016 Badiali Roberto

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INDEX :

5.0 PREMISE ................................................................................................................................... 8

5.1 HEADSTOCK ............................................................................................................................. 9
5.1.1 TECHNICAL DESCRIPTION .............................................................................................................. 9
5.1.1.1 MAIN SWITCH ........................................................................................................................ 11
5.1.1.2 CONTROL POSITION ............................................................................................................ 12
5.1.1.2.1 HEADSTOCK CONTROL PANEL ......................................................................................................... 13
5.1.1.2.2 COMPARTMENT CLEARERS .............................................................................................................. 14
5.1.1.4 PNEUMATIC PANEL .............................................................................................................. 15
5.1.1.5 PEG TRANSPORT BELT CONTROL UNIT ........................................................................... 16
5.1.1.6 PACKAGE UNLOADING BELT UNIT ..................................................................................... 17
5.1.1.7 ELECTRIC EQUIPMENT ........................................................................................................ 18
5.1.2 TECHNICAL DATA ........................................................................................................................... 19
5.1.3 ADJUSTMENTS ................................................................................................................................ 20
5.1.3.1 PACKAGE UNLOADING BELT .............................................................................................. 21
5.1.3.2 PEG CONVEYOR BELTS....................................................................................................... 23
5.1.4 USE INSTRUCTIONS ....................................................................................................................... 25
5.1.5.1 MAIN SUCTION FILTER CLEANING ..................................................................................... 26
5.1.5.2 ELECTRIC COMPONENT COOLING GRIDS CLEANING .................................................... 27
5.1.5.3 PACKAGE UNLOADING BELT ROLLER CLEANING ........................................................... 29
5.1.5.4 MAIN SUCTION ROTOR CLEANING .................................................................................... 30
5.1.5.5 PEG CONVEYOR BELT BRUSH CLEANING ........................................................................ 31
5.1.5.6 PEG CONVEYOR BELT UNIT CLEANING ............................................................................ 33
5.1.5.7 COMPRESSED AIR SYSTEM FILTER CLEANING ............................................................... 34
5.2 MACHINE BODY...................................................................................................................... 38
5.2.1 TECHNICAL DESCRIPTION ............................................................................................................ 38
5.2.1.1 DUST AND WASTE TRANSFER TOWARDS THE HEADSTOCK ........................................ 38
5.2.1.2 PNEUMATIC PLANT DISTRIBUTION .................................................................................... 38
5.2.1.3 PEG CONVEYOR BELTS....................................................................................................... 39
5.2.1.4 PACKAGE UNLOADING BELT .............................................................................................. 40
5.2.1.5 BOBBIN LOADER PEGS ........................................................................................................ 41
5.2.1.6 TOP STRUCTURE .................................................................................................................. 42
5.2.2 TECHNICAL DATA ........................................................................................................................... 43
5.2.3 ADJUSTMENTS ................................................................................................................................ 44
5.2.3.1 BOBBIN HOLDER PEG ADJUSTMENTS AND CONFIGURATION ...................................... 45
5.2.4 USE INSTRUCTIONS ....................................................................................................................... 45
5.2.5 MAINTENANCE ................................................................................................................................ 46
5.2.5.1 MACHINE BODY GENERAL CLEANING ............................................................................... 47
5.3 WINDING UNIT ........................................................................................................................ 51
5.3.1 TECHNICAL DESCRIPTION ............................................................................................................ 51
5.3.1.1 COLLECTION UNIT ................................................................................................................ 54
5.3.1.1.1 PACKAGE CRADLE ............................................................................................................................. 55
5.3.1.1.2 MODULATION SYSTEMS .................................................................................................................... 56
5.3.1.1.3 AXIAL DISPLACEMENT [OPT] ............................................................................................................. 57
5.3.1.1.4 COUNTER-WEIGHING AND INSTANT LIFTING ................................................................................. 58
5.3.1.1.5 NOZZLE-PACKAGE DISTANCE COMPENSATOR.............................................................................. 59
5.3.1.1.6 PACKAGE UNLOAD CHUTE ................................................................................................................ 60
5.3.1.1.7 GROOVED ROLL AND SIDE YARN GUIDE ........................................................................................ 60
5.3.1.1.8 COLLECTION UNIT FRONT ................................................................................................................. 61
5.3.1.2 PACKAGE TAIL SUCTION UNIT, WAXING UNIT AND CLEARER ....................................... 62
5.3.1.2.1 TENSOR AND ANTI-WRAP DEVICE ................................................................................................... 63

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5.3.1.2.2 CLEARER ..............................................................................................................................................63
5.3.1.2.3 PACKAGE YARN SUCTION ..................................................................................................................64
5.3.1.2.4 WAXING UNIT [OPT] .............................................................................................................................65
5.3.1.3 SPLICING UNIT ...................................................................................................................... 66
5.3.1.4 FEELER KNIFE YARN TENSIONER BOBBIN TAIL SUCTION UNIT ................................... 67
5.3.1.4.1 KNIFE ....................................................................................................................................................68
5.3.1.4.2 PRE-CLEARER .....................................................................................................................................69
5.3.1.4.3 BOBBIN TAIL SUCTION NOZZLE .........................................................................................................70
5.3.1.4.4 YARN TENSIONER ...............................................................................................................................71
5.3.1.4.5 YARN FEELER AND UNWINDER .........................................................................................................72
5.3.1.5 BOBBIN FEEDING AND CHANGE UNIT ............................................................................... 73
5.3.1.6 PACKAGING UNIT SUCTION UNIT ...................................................................................... 74
5.3.1.7 UNREELING ASSISTED GROUP (OTP) ............................................................................... 77
5.3.2 TECHNICAL DATA ........................................................................................................................... 79
5.3.2.1 WINDING UNIT COMPRESSED AIR CONSUMPTION ......................................................... 79
5.3.2.2 PACKAGING UNIT EXTRACTION TROLLEY DIMENSIONS AND WEIGHTS [OPT] .......... 79
5.3.3 ADJUSTMENTS................................................................................................................................ 80
5.3.3.1MODULATION SYSTEMS ...................................................................................................... 81
5.3.3.2CONES TO COLLECT, CYLINDER AND YARN DEPOSIT ................................................... 83
5.3.3.3YARN DEPOSITING AREA ON THE TAKE-UP CONE AND PARALLELISM
BETWEEN THE TAKE-UP CONE AND GROOVED ROLLER .............................................. 84
5.3.3.4 TAPER INCREASE ................................................................................................................. 88
5.3.3.5 INSTANT CRADLE LIFTING .................................................................................................. 89
5.3.3.6 NOZZLE-PACKAGE DISTANCE COMPENSATOR .............................................................. 90
5.3.3.7 PACKAGE SUCTION NOZZLE CONTROL UNIT .................................................................. 91
5.3.3.8 CLEARER ............................................................................................................................... 92
5.3.3.9 PACKAGE YARN SUCTION NOZZLE ................................................................................... 93
5.3.3.10 PACKAGE ASPIRATION NOZZLE ........................................................................................ 95
5.3.3.11 WAXING UNIT ........................................................................................................................ 96
5.3.3.12 KNIFE...................................................................................................................................... 97
5.3.3.13 BOTTOM UNWINDER UNIT .................................................................................................. 98
5.3.3.14 PRE-CLEARER OPENING ..................................................................................................... 99
5.3.3.15 BOBBIN YARN NOZZLE CONTROL UNIT .......................................................................... 100
5.3.3.16 BOBBIN CHANGE UNIT ....................................................................................................... 101
5.3.5 MAINTENANCE .............................................................................................................................. 103
5.3.5.1 PACKAGING UNIT GENERAL CLEANING ......................................................................... 104
5.3.6 TWINSPLICER® - A MECHANICAL SPLICING SYSTEM ............................................................. 109
5.3.6.1 MAIN TWINSPLICER UNITS ............................................................................................... 110
5.3.6.1.1 WATER SUPPLY FOR WATER-SPLICER® .......................................................................................112
5.3.6.2 TWINSPLICER® ADJUSTMENTS - A MECHANICAL SPLICING SYSTEM ....................... 113
5.3.6.3 TWINSPLICER® OPERATING CYCLE - A MECHANICAL SPLICING SYSTEM ............... 114
5.3.6.4 TWINSPLICER® MAINTENANCE - A MECHANICAL SPLICING SYSTEM ....................... 115
5.3.6.4.1 MAINTENANCE PROGRAMME ..........................................................................................................115
5.3.6.4.2 INTERVENTION AND MAINTENANCE PHASES ...............................................................................118
5.3.6.4.3 PREVENTIVE CHECKS ......................................................................................................................121
5.3.6.4.4 DISASSEMBLY ....................................................................................................................................122
5.3.6.4.5 ASSEMBLY INSTRUCTIONS ..............................................................................................................129
5.3.6.4.6 FAULTS, CAUSES AND REMEDIES ..................................................................................................134
5.3.6.4.7 CLEANING WATER FILTER FOR WATER-SPLICER® ......................................................................136
5.4 CONNECTION BELTS TO THE SPINNING FRAME.............................................................. 137
5.4.1 TECHNICAL DESCRIPTION .......................................................................................................... 137
5.4.1.1 CONNECTION BELT UNIT TO THE SPINNING FRAME .................................................... 137
5.4.1.2 BOBBIN TRANSFER BELT UNIT ........................................................................................ 138
5.4.1.3 TUBE TRANSFER BELT UNIT............................................................................................. 139
5.4.2 TECHNICAL DATA ......................................................................................................................... 140
5.4.3 ADJUSTMENTS.............................................................................................................................. 141

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5.4.4 USE INSTRUCTIONS ..................................................................................................................... 142

5.4.5 MAINTENANCE .............................................................................................................................. 144
5.5 CLEANER BACK-UP PREPARING DEVICE.......................................................................... 145
5.5.1 TECHNICAL DESCRIPTION .......................................................................................................... 145
5.5.1.1 CLEANER BACK-UP PREPARING DEVICE ....................................................................... 145
5.5.1.2 PEG TRANSPORT ............................................................................................................... 147
5.5.1.3 TUBE BOBBIN FEELER STATION ...................................................................................... 149
5.5.1.4 DIRTY-CLEAN TUBE FEELER STATION ............................................................................ 151
5.5.1.5 TECHNOLOGICAL WASTE BELTS ..................................................................................... 153
5.5.1.6 TUBE LOADERS [OTP] ........................................................................................................ 154
5.5.1.7 STATION UNDER INCANNO ............................................................................................... 155
5.5.1.7.2 GROUP MOBILE TAILSTOCK ............................................................................................................ 157
5.5.1.7.3 TAIL PICK-UP GROUP ....................................................................................................................... 158
5.5.1.7.4 BOBBIN TAIL SUCTION NOZZLE ...................................................................................................... 159
5.5.1.7.5 YARN CHECKING AND CUTTING UNIT ............................................................................................ 160
5.5.1.7.6 GROUP UNDER DECEPTION ........................................................................................................... 161
5.5.1.8 TUBE CLEANER [OPT] ........................................................................................................ 162
5.5.1.8.1 FEEDING UNIT ................................................................................................................................... 163
5.5.1.8.2 POSITIONING AND STRIPPING UNIT............................................................................................... 164
5.5.1.8.3 PUSHER UNIT .................................................................................................................................... 165
5.5.1.8.4 DISCHARGE UNIT.............................................................................................................................. 166
5.5.1.8.5 PNEUMATIC PLANT........................................................................................................................... 167
5.5.2 TECHNICAL DATA ......................................................................................................................... 168
5.5.2.1 BOBBIN PREPARER COMPRESSED AIR CONSUMPTION .............................................. 168
5.5.2.2 TUBE CLEANER TECHNICAL DATA .................................................................................. 169
5.5.2.3 TUBE CLEANER MATERIAL TECHNICAL DATA ............................................................... 170
5.5.3 ADJUSTMENTS .............................................................................................................................. 172
5.5.3.1 CONVEYOR BELT TENSIONING ........................................................................................ 172
5.5.3.1.1 PORTABLE PUSH BUTTON PANEL TO CONTROL BELTS ............................................................. 172
5.5.3.3 DIRTY-CLEAN TUBE FEELER STATION ............................................................................ 174
5.5.3.4 GROUP MOBILE TAILSTOCK ............................................................................................. 175
5.5.3.5 BOBBIN TAIL SUCTION NOZZLE ....................................................................................... 176
5.5.3.6 SEARCH GROUP STARTED ON ROLL .............................................................................. 177
5.5.3.7 GROUP UNDER DECEPTION ............................................................................................. 178
5.5.4 USE INSTRUCTIONS ..................................................................................................................... 179
5.5.4.1 PREPARER BOBBIN RECOVERY ...................................................................................... 179
5.5.4.2 DISPOSAL OF TUBES WITH YARN RESIDUES ................................................................ 180
5.5.4.3 BOBBIN PREPARER CONTROL STATION ........................................................................ 181
5.5.4.4 BOBBIN PREPARING DEVICE ALARMS ............................................................................ 182
5.5.4.5 CLEANER CONTROL STATION [OPT] ............................................................................... 183
5.5.4.5.1 TUBE CLEANER ALARMS RESET .................................................................................................... 184
5.5.5 MAINTENANCE .............................................................................................................................. 187
5.5.5.1 BOBBIN PREPARER GENERAL CLEANING ...................................................................... 188
5.5.5.2 TUBE CLEANER MAINTENANCE ....................................................................................... 193
5.5.5.2.1 STRUT REPLACEMENT THRUST ..................................................................................................... 195
5.5.5.2.2 CHANGING THE EXTRACTOR PLATES ........................................................................................... 196
5.5.5.2.2.1 ADJUSTING EXTRACTOR PLATE STROKE ................................................................. 197
5.5.5.2.3 ADJUSTING THE PEG LOCK LEVER ................................................................................................ 198
5.5.5.2.4 POSITION OF THE STRIPPING AREA CONTROL PHOTOCELL ..................................................... 199
5.5.5.2.5 POSITION OF THE CYCLE SENSOR ................................................................................................ 200
5.5.5.2.6 POSITION OF THE CLEANING BLOW .............................................................................................. 201
5.5.5.2.7 POSITION OF THE ECONOMISER GATE VALVE ............................................................................ 202
5.5.5.2.8 POSITION OF THE SAFETY SWITCHES .......................................................................................... 203
5.5.5.2.9 ADJUSTING THE YARN CUTTING BLADE ....................................................................................... 204
5.6 BOBBIN TAIL SEARCH UNIT ON SECTIONS ....................................................................... 205
5.6.1 TECHNICAL DESCRIPTION .......................................................................................................... 205

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5.6.1.1 BOBBIN TAIL PICK-UP STATION ....................................................................................... 205
5.6.1.2 PEG ROTATING UNIT ......................................................................................................... 207
5.6.1.3 LIVE CENTRE UNIT ............................................................................................................. 208
5.6.1.4 BOBBIN TAIL PICK-UP LEVER UNIT .................................................................................. 209
5.6.1.5 GROUP INTAKE SUCTION ROLL TOP COP AND CONTROL WIRE EXTRACT .............. 210
5.6.1.6 GROUP THREAD TRIMMING EXTRACT ............................................................................ 211
5.6.1.7 BOBBIN TAIL THREADING UNIT ........................................................................................ 212
5.6.1.8 LEVER POSITIONING PLATE AND BREAK TAIL .............................................................. 213
5.6.1.9 GROUP DISK TRANSPORTER ........................................................................................... 214
5.6.2 TECHNICAL DATA ......................................................................................................................... 215
5.6.3 ADJUSTMENTS.............................................................................................................................. 216
5.6.3.1 SETTING TAILSTOCK MOBILE ........................................................................................... 217
5.6.3.2 SETTING GROUP INTAKE COP ......................................................................................... 218
5.6.3.3 ADJUSTMENT LEVER START SEARCH HANK COP ........................................................ 219
5.6.3.4 SETTING GROUP INSERTION THE BEGINNING HANK COP .......................................... 221
5.6.3.5 ADJUSTMENT LEVER POSITIONING PLATE AND BREAK TAIL ..................................... 222
5.6.4 USE INSTRUCTIONS ..................................................................................................................... 223
5.6.5 MAINTENANCE .............................................................................................................................. 224
5.6.5.1 GENERAL CLEANING GROUP RESEARCH BRANCH ROLL TOP COP .......................... 225
5.7 PACKAGE CONE MAGAZINE [OPT] ..................................................................................... 228
5.7.1 TECHNICAL DESCRIPTION .......................................................................................................... 228
5.7.2 TECHNICAL DATA ......................................................................................................................... 230
5.7.3 ADJUSTMENTS.............................................................................................................................. 231
5.7.3.1 CONE EJECTOR LEVER ..................................................................................................... 232
5.7.3.2 APPROACHING DEVICE(ONLY FOR CONES WITH A L < 155 mm) ................................ 233
5.7.3.3 CONE HOLDER SUPPORTS ............................................................................................... 234
5.7.3.4 CONE HOLDER CHAIN ....................................................................................................... 235
5.7.3.5 CONE CONVEYOR BELT .................................................................................................... 237
5.7.3.6 PROBE POSITION ............................................................................................................... 240
5.7.4 USE INSTRUCTIONS ..................................................................................................................... 241
5.7.4.1 CONTROL PANEL ................................................................................................................ 241
5.7.4.2 SPLICING CYCLE ................................................................................................................ 242
5.7.4.2.1 LOADING OF CONES ONTO A TROLLEY “WITH ON-BOARD TUBE RESERVE” ............................242
5.7.4.2.2 LOADING OF CONES ONTO A TROLLEY “WITHOUT ON-BOARD RESERVE” ...............................243
5.7.4.3 HOW TO LOAD CONES....................................................................................................... 244
5.7.4.4 ALARMS ............................................................................................................................... 245
5.7.5 MAINTENANCE .............................................................................................................................. 246
5.7.5.1 PACKAGE CONE MAGAZINE GENERAL CLEANING ....................................................... 247
5.8 AUTOMATION TROLLEY ...................................................................................................... 249
5.8.1 TECHNICAL DESCRIPTION .......................................................................................................... 249
5.8.1.1 TUBE PICK-UP AND DELIVERY GROUP ........................................................................... 256
5.8.1.2 CLAMPING GROUP, CUTTING, DELIVERY OF YARN ...................................................... 257
5.8.1.3 BUFFER YARN INSERTION GROUP .................................................................................. 258
5.8.2 TECHNICAL DATA ......................................................................................................................... 259
5.8.3 ADJUSTMENTS.............................................................................................................................. 260
5.8.3.1 PRELIMINARY INSPECTION AND ADJUSTMENTS .......................................................... 261
5.8.3.2 TROLLEY PRECISE POSITIONING .................................................................................... 263
5.8.3.3 TUBE PICK-UP AND DELIVERY GROUP ........................................................................... 265
5.8.3.4 TUBE GRIPPING AND DELIVERY CONTROL GROUP ADJUSTMENT ............................ 269
5.8.3.5 YARN CLAMPING GROUP ADJUSTMENT ......................................................................... 271
5.8.3.6 BUFFER GROUP ADJUSTMENT ........................................................................................ 274

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5.8.3.7 TUBE, BASKET VERSION TROLLEY SEPARATOR ADJUSTMENT ................................. 277

5.8.3.8 TUBE HOLDING BASKET ADJUSTMENT ........................................................................... 279
5.8.3.9 TUBE PRESENCE PHOTOCELL CALIBRATION ADJUSTMENT ...................................... 280
5.8.3.10ADJUSTMENT OF TUBE UNIT ON BELT AND BASKET TROLLEY - VERSION WITH
CONE MAGAZINE ................................................................................................................ 281
5.7.3.7 ADJUSTING THE TUBE UNIT ON BELT AND BASKET TROLLEY - VERSION WITH
CONE MAGAZINE ................................................................................................................ 281
5.8.3.11 TUBE GRIPPING ADJUSTMENT FOR RH MACHINE ........................................................ 283
5.8.3.12 TUBE GRIPPING ADJUSTMENT FOR LH MACHINE ......................................................... 284
5.7.3.9 ADJUSTING THE TUBE PICK-UP ADJUSTMENT FOR LH MACHINE ........................................ 284
5.8.3.13 BRAKE GROUP ADJUSTMENT........................................................................................... 286
5.8.3.14 PNEUMATIC PLANT ADJUSTMENT ................................................................................... 287
5.8.3.15 PROCEDURE FOR ADJUSTING THE SIDE PHOTOCELLS .............................................. 289
5.8.4 USE INSTRUCTIONS ..................................................................................................................... 290
5.8.4.1 OPERATING LOGIC ............................................................................................................. 290
5.8.4.1.1 FORWARDING OF TROLLEY TOWARDS WINDING UNIT ............................................................... 290
5.8.4.1.2 CYCLE WITH INDIVIDUAL CONE MAGAZINE .................................................................................. 290
5.8.4.1.3 DOFFING CYCLE ............................................................................................................................... 291
5.8.4.1.4 PACKAGE UNLOADING CYCLE ........................................................................................................ 291
5.8.4.1.5 LOT STARTING CYCLE ..................................................................................................................... 291
5.8.4.2 MAIN INDICATORS .............................................................................................................. 292
5.8.4.2.1 SELECTION OF THE WORKING PROGRAM (MANUAL CONTROLS OR AUTOMATIC CYCLE) ... 293
5.8.4.2.2 AUTOMATIC CYCLE .......................................................................................................................... 294
5.8.4.2.3 MANUAL CYCLE ................................................................................................................................ 294
5.8.4.2.4 TROLLEY IN ALARM .......................................................................................................................... 295
5.8.4.2.5 ALARMS RESETTING PROCEDURES .............................................................................................. 298
5.8.4.2.6 EMERGENCY TROLLEY .................................................................................................................... 298
5.8.4.2.7 TROLLEY IN BASKET VERSION ....................................................................................................... 299
5.8.5 MAINTENANCE .............................................................................................................................. 300
5.8.5.1 AUTOMATION TROLLEY GENERAL CLEANING ............................................................... 301
5.9 MOBILE SUCTION AND CLEAN UNIT .................................................................................. 305
5.9.1 TECHNICAL DESCRIPTION .......................................................................................................... 305
5.9.1.1 MOBILE BLOWING AND SUCTION SAVIO BELT BLOWER .............................................. 305
5.9.1.2 MOBILE BLOWING AND SUCTION ELECTROJET [OPT] .................................................. 307
5.9.1.3 REVERSE DEVICE [OPT] .................................................................................................... 308
5.9.1.4 OBSTACLE DETECTION SYSTEMS [OPT] ........................................................................ 309
5.9.1.4.1 OBSTACLE DETECTION SYSTEM SAVIO BELT BLOWER [OPT] ................................................... 309
5.9.1.5 OUTFEED SYSTEMS ........................................................................................................... 310
5.9.1.5.1 OUTFEED SYSTEM FOR SAVIO BELT BLOWER ............................................................................ 310
5.9.2 TECHNICAL DATA ......................................................................................................................... 311
5.9.3 ADJUSTMENTS .............................................................................................................................. 312
5.9.4 USE INSTRUCTIONS ..................................................................................................................... 313
5.9.5 MAINTENANCE .............................................................................................................................. 315
5.9.5.1 LUBRICATION ...................................................................................................................... 317
5.9.5.2 SCHEDULED MAINTENANCE SHALL INCLUDE INSPECTION OF THE FOLLOWING
PARTS .................................................................................................................................. 318
5.9.5.2.1 MONTHLY MAINTENANCE ................................................................................................................ 319
5.9.5.2.2 SIX-MONTHLY MAINTENANCE ......................................................................................................... 320
5.9.5.2.3 MAINTENANCE EVERY YEAR .......................................................................................................... 321
5.9.5.3 FAULTS, CAUSES AND REMEDIES ................................................................................... 322

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5.11 ISPECTOR CONTROL (VER. 2.0) ......................................................................................... 324

5.11.1 TECHNICAL DESCRIPTION .......................................................................................................... 324
5.12 MAINTENANCE PROGRAMME............................................................................................. 408

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5.0 PREMISE

The ECO PULSARS I-DLS winder is a machine for winding yarns wound on bobbins sent from the spinning frame.

The machine comprises:

1) Headstock housing the electric equipment, the technological bobbin distribution controls and collecting lint;
2) Transport and distribution system of bobbins and tubes from the preparer device to the packaging unit
and vice versa;
3) Machine body , to support the packaging units, doffing units and machine cleaning units, divided into 6 or 8
or 10 packaging unit bearing elements;
4) Packaging unit to treat the yarn to be made into packages;
5) Bobbin preparer to provide the bobbins on the transport pegs, and controlling pegs coming from the
machine;
6) Control station for adjusting the machine services;
7) Group of connection to the spinning machine for feeding the spools and the return of the tubes;
8) Cone magazine to house the take-up cone reserve; this device can be substituted by single cone-holder
cradles for each packaging unit;
9) Doffing trolley to remove the complete packages and position a new take-up cone;
10) Cleaning unit for cleaning the machine with a travelling blower and aspirator unit;
11) Inspector Control to adjust the machine functions.
to provide the spools on the plate of transport, and the management of the plates coming from the machine

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5.1 HEADSTOCK
5.1.1 TECHNICAL DESCRIPTION

The control headstock is available in two versions:

- for machines with automatic bobbin load (E and IDLS)
- for machines with manual bobbin load (M and L)

In all machine models, the headstock includes the machine control electric components, the dust and lint
evacuation unit with the relevant filters that do not need maintenance, the control unit for the package unloading
belt, the electric and pneumatic control panels, and, in case of ECO PULSARS M/L, also the clearer control unit
and the Ispector Control controlling the winder.
The headstock includes the groups below that are described below:

1 front control panel for machine start, stop, emergency and reset
2 side control panel for package and lint unloading
3 front electric equipment with motor guards and controls
4 rear electric equipment for machine section and 310 Volt supply unit
5 machine handle - main switch
6 electronic proportional adjusters, driven by the Ispector Control for counter-weighing and splicer
7 310 Volt supply main transformer, 110 Volt auxiliary transformer, inductor, autotransformer
8 side channel suction unit (high pressure) for lint suction from heads
9 lint double cyclone filter with discharge in the bin without the need to stop the machine
10 dust single cyclone filter with discharge in the bin without the need to stop the machine
11 compressed air supply unit with filter
12 package unloading belt ratiomotor
13. peg conveyor belt ratiomotors
14 waste evacuation duct (lint and dust suction)
15 lint discharge door
16 dust discharge door
17 cleaning unit for tubes featuring yarn residues

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5.1.1.1 MAIN SWITCH

The main handle switch (1) allows cutting the power to the machine and working on the electric equipment.

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5.1.1.2 CONTROL POSITION

Located on the control headstock, it is composed of the following elements:

1) main control panel (see 5.1.1.2.1);
2) clearer compartment (see 5.1.1.2.2);
3) Pneumatic panel.

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5.1.1.2.1 HEADSTOCK CONTROL PANEL

The control panel on the headstock front side consists of:

1) Machine emergency red mushroom-head push-button

2) Machine START white push-button
3) Machine STOP black push-button
4) Alarm RESET backlighted blue push-button

The control panel under the package unloading belt exit consists of:
1) white package unloading belt start push-button
2) white backlighted push-button to start dust and lint discharge in the bin.

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5.1.1.2.2 COMPARTMENT CLEARERS

The control card for the clearers or relevant control unit is installed in this compartment. For ECO PULSARS I-DLS
and other models, it is located at the end of the machine in the Ispector Control compartment on the last section.
Fort the ECO PULSARS I-DLS version M/L model, it is placed in a compartment over the headstock.

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5.1.1.4 PNEUMATIC PANEL

It is composed of three electronic proportional adjusters managed by the Ispector Control, perfectly fitted and
tightened and accessible by opening the rear door next to the sections. The adjustment is set on the Ispector
Control on which also the actual pressure is displayed. The adjusters have the following functions:

 counter-weighing the package cradle

 air splicer supply pressure
 package braking

A pressure switch is assembled on an electric proportional adjuster in order to ensure that the machine is supplied
with the suitable pressure for each above-mentioned function.
If the pressure lowers below the set value the machine stops automatically.

A vacuometer detects the value of the side channel suction unit vacuum which will also be displayed on the
Ispector Control.

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5.1.1.5 PEG TRANSPORT BELT CONTROL UNIT

Placed on the headstock base, their function is to control peg movement belts.
They consist of:
 Drive motor (1);
 Aligning cam (2);
 Rubber-coated driving pulley (3);
 Belt support fastening screws (4);
 Belt tensioning motor guide (5);
 Transmission roller (6);
 Belt guide block (7);
 Screw device to tension the belt (8).

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5.1.1.6 PACKAGE UNLOADING BELT UNIT

It is located in the machine rear side and drives the belt transporting the packages from the packaging units to the
collection point in the headstock.
This unit comprises:
 PACKAGE UNLOADING BELT (1);
 Ratiomotor with driving roller (2);
 Belt transfer control panel (3);
 Stop sensor for the belt control roller after the unload (4);
 reflection photocell for the belt transfer stop with package in unload position (5);
 Roller metal insert (6)
 Photocell reflection mirror (7).

The PACKAGE UNLOADING BELT lays on the board and winds on the motor-driven roller that delivers the
package to the headstock end. The package dims the photocell which stops the belt.

After the package has been removed by the operator, the photocell gives the consent for the re-start of the belt to
deliver further packages and so on.

When the roller stop sensor has counted a preset number of turns, the belt
stops finally.

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5.1.1.7 ELECTRIC EQUIPMENT

The electric equipment compartments are closed respectively by the front (1) and rear (2) doors, closed with two
locks.

ATTENTION!
Such doors can be opened and the electric equipment can be accessed exclusively
by expert personnel suitably trained in "electric equipment according to IP 20"
protection class. Failure to apply the above procedures can lead to residual
electrocution risk.

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5.1.2 TECHNICAL DATA

PREMISE

Since no special specifications are available for the headstock, all its technical data are included in the machine
overall specifications.

Please consult chapter 2 of this manual.

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5.1.3 ADJUSTMENTS

INTRODUCTION

This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety, by reading and appropriately
consulting this paragraph.

ATTENTION!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

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5.1.3.1 PACKAGE UNLOADING BELT

TENSIONING

Tightening the package unloading belt is tightened following the procedure described below:

 mark the belt (when slack) with two references, 2000 mm away from each other (distance A);
 tighten the belt by turning the screws (1) until there are about 15 mm between the transmission roller (2)
and the side (3), distance C.
On this occasion also check centring of the belt in relation to the driving and idle rollers;
 Check the value of the distance A, effected previously.
The new resulting value (distance A) must be equivalent to 2014 mm, that is, corresponding to a tightening
of 0.7%.

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CENTRING

To centre the PACKAGE UNLOADING BELT proceed as follows:

 Remove the motor protection guard (1);

 Working from the top slightly loosen the 4 screws (2) securing the ratiomotor support to the base structure;
 Turn the bolt (3) in order to orient the entire motor-pulley support with respect to the to the pin (4) so that
the belt travels on the centreline of the driving roller;
 Make sure that the roller stop probe (5) switches correctly next to the metal insert (6) placed on the roller.

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5.1.3.2 PEG CONVEYOR BELTS

TENSIONING

The peg conveyor belts have different tension values, depending on the type of use they are subject to.
The following figure summarises - according to the application - the required tightening percentage value.

LEFT MACHINE

Headstock Preparer

RIGHT MACHINE

Preparer Headstock

CONVEYOR
% TENSIONING
BELTS
1 0.4
2 0.4
3 0.4

The belts are tightened in the following way:

4) mark the belt (when slack) with two references, 2000 mm away from each other (distance A);
5) tension the belt through the worm screw rotating clockwise (8).
To do this, the screws (4) fastening the motor support to the headstock base must have been previously
loosened;
6) check the value of distance A effected previously.
The new resulting value (distance A1) must include the required tightening percentage value.

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CENTRING

Belt distance from the edges of the driving and idle pulleys must be the same; for this reason they are both
equipped with devices that make it possible to alter their position.
Generally, centring of the belt requires just one intervention on the control unit’s pulley.
Centring of the belt in relation to the driving pulley (4) can be modified by turning the screw with eccentric (3), that
causes the slanting angle of the entire support (4) to change and the belt to move sideways.
Centring of the belt in relation to the transmission roller (5), located at the end of the machine body (area where the
pegs enter and leave from the preparer), can be modified by turning the screws (6) that will cause the roller axis to
slant.
The roller (7) is an element that guides the belt and requires no adjustments.

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5.1.4 USE INSTRUCTIONS

PREMISE

Since no special headstock use instructions are available, this document includes use instructions for the
headstock, as for all machine components.

Please consult chapter 6 of this manual.

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5.1.5.1 MAIN SUCTION FILTER CLEANING

ATTENTION!
The double and single cyclone filter must be cleaned with the machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear
as required by the local health and safety laws in force where the machine is
installed and complying with provisions under 1.2 "GENERAL SAFETY
PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Manual tools,
Visual check of the cyclone filter. Suction
8000 activation of possible residue and cleaning Personal protection
of internal surface with a damp cloth. equipment as required by the
laws of the country where the
machine is installed

Compressed air system

(gentle blow),
Disassembly of single cyclone filter cover,
8 visual check of mesh filter and cleaning Personal protection
using downwards blowing equipment as required by the
laws of the country where the
machine is installed

ATTENTION!
Failure to comply with the above procedures leads to residual risks of dust
inhalation.

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5.1.5.2 ELECTRIC COMPONENT COOLING GRIDS CLEANING

ATTENTION!
Grids must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Compressed air system
(gentle blow),
Cleaning the cooling grilles of electric
8
material housings in the headstock Personal protection
equipment as required by the
laws of the country where the
machine is installed

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Clean all grids (1) and filters (2) of the headstock from the outside removing the accumulated dust; then open the
fixed guards and blow compressed air inside-out.

ATTENTION!
Failure to comply with the above procedures leads to residual risks of dust
inhalation.

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5.1.5.3 PACKAGE UNLOADING BELT ROLLER CLEANING

ATTENTION!
The unload driving and transmission roller cleaning must be carried out with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator.
Personal protection
Cleaning of package unloading belt driving equipment as required by the
150 and idle rollers and belt control motor laws of the country where the
cooling fans. machine is installed.
Compressed air system
(gentle blow).

SERVICE INTERVAL every 150 hours

Remove any coils of yarn from the driving and transmission rollers and clean all groups from any impurities.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and dust inhalation remains.

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5.1.5.4 MAIN SUCTION ROTOR CLEANING

ATTENTION!
The side channel suction rotor must be cleaned with the machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear
as required by the local health and safety laws in force where the machine is
installed and complying with provisions under 1.2 "GENERAL SAFETY
PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

NOTE: Usually it is not necessary to clean

the side channel suction unit inside.
If suction is not enough, first check the
vacuum value indicated on the Aspirator,
vacuometer, then check that waste
Manual tools,
evacuation duct seals all along the
8000 machine are in their seats and operating Personal protection
properly. equipment as required by the
laws of the country where the
If vacuum is still low, it is necessary to
machine is installed
disassemble and clean the side channel
suction unit: while doing so, carefully follow
the instructions indicated by the
manufacturer in the machine documents.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and dust
inhalation remains.

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5.1.5.5 PEG CONVEYOR BELT BRUSH CLEANING

ATTENTION!
Peg conveyor belt brushes must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator.
Manual tools,
Pegs conveyor belt top and bottom
24 Personal protection
brushes cleaning
equipment as required by the
laws of the country where the
machine is installed

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SERVICE INTERVAL every 4 hours

Both in the front and rear side clean the belt cleaning brushes.
Loosen the retaining screws (1) and remove the fixed guard
(2).
Release the spring (3), lower the brush support and remove
the upper (4) and lower (5) brush.
Clean the brushes from residual lint and refit them, fastening
the unit with spring (1).
Check brush efficiency, renew them if necessary.

ATTENTION!
Failure to apply the above procedures, a
residual risk of snatching and dust inhalation
remains.

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5.1.5.6 PEG CONVEYOR BELT UNIT CLEANING

ATTENTION!
The pegs conveyor belt unit cleaning must be carried out at machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Manual tools,
Cleaning of peg conveyor belts control
150 Personal protection
ratiomotors, drive and transmission rollers
equipment as required by the
laws of the country where the
machine is installed

SERVICE INTERVAL every 150 hours

Cleaning of the control ratiomotor groups (1) for peg conveyor belt, driving and transmission rollers (2), and
nozzles-tubes for peg belts dust suction.
After cleaning, check alignment and centring of the peg conveyor belts; refer to paragraph 5.1.3.2 if necessary.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and dust inhalation remains.

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5.1.5.7 COMPRESSED AIR SYSTEM FILTER CLEANING

ATTENTION!
The filter must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

(gentle blow),
750 Compressed air system filter cleaning Personal protection
@TO_004@
equipment as required by the
laws of the country where the
machine is installed

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SERVICE INTERVAL every 750 hours

Pull knob (1) and discharge condensate from the compressed air filter (2).
Remove the container (3) and the filtering cartridge, then clean with compressed air; if the cartridge does not clean
properly after several cleaning operations replace it.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and dust inhalation remains.

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5.1.5.8 37 kVA TRANSFORMER REPLACEMENT

To replace the 37kVA transformer, in column version, proceed as follows:

1 - Turn off the machine using the main switch;

2 - Lock the main switch with a padlock to put the machine in safe conditions;
3 - Remove transformer access guards;
4 - Disconnect cables from Transformer terminal board;
5 - Remove transformer fastening screws;
6 - Remove the gate unit under the lint separator (1);

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ATTENTION!
Use lifting equipment and transport systems for handling suitable to the weight to be supported.
Transformer total weight is kg. 240.

7 - Use the eyebolts (3) available in the lower part of the transformer to slide it.
8 - Slide the transformer until it gets out and lay it on the trolley;

ATTENTION!
Be careful not to damage the radiator and the other internal parts (2).

9 - Install the new transformer by inserting it into the compartment.

ATTENTION!
Be careful not to damage the radiator and the other internal parts (2).

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5.2 MACHINE BODY

5.2.1 TECHNICAL DESCRIPTION

The purpose of the machine body is to:

1. support the packaging units and from one to three tail pick-up stations;
2. distribute the technological air from the headstock to the various peripheral units;
3. distribute the pneumatic supply to the different peripherals;
4. distribute power supply from the headstock to the various peripheral units;
5. transport the packages from the preparer to the pick-up stations and then to the packaging units;
6. return the empty tubes to the preparer;
7. convey the packages produced by the various units to be unloaded;
8. support the doffing trolley and travelling blower.

5.2.1.1 DUST AND WASTE TRANSFER TOWARDS THE HEADSTOCK

Lints and dust collected by the packaging units, the preparing device and tail pick-up units on sections are collected
by the waste evacuation duct placed under the sections and conveyed towards headstock filters which separate
lints from dust.

Every packaging unit, the preparing device and the tail pick-up units on the sections are equipped with a specific
independent suction device that provides the necessary suction.

5.2.1.2 PNEUMATIC PLANT DISTRIBUTION

Connection of the machine to the centralised pneumatic unit is done upstream from the feeding filter located in the
headstock.
The filter’s task is to trap any impurities there may be in the air.

The pneumatic system along the machine consists of:

 a steady pressure circuit (dry air) used to feed the solenoid valves on the unit, adjusting reduction gears for
the variable pressure circuits and the preparer air lubricating unit;
 two variable pressure circuits (with pressure reduction gears on the pneumatic unit panel), to feed the air
splicer and the package cradle counterweight piston (dry air).

If the pressure lowers below 550 KPa (5.5 bar), the min. pressure switch automatically stops the machine.
The pressure switch detects the line value in the circuit with steady pressure, at the entry of the adjustment
reducers (counter-weighing, splicer).
If the power supply fails, a solenoid valve interrupts the compressed air supply to the line of the splicers in order not
to change its functioning.

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5.2.1.3 PEG CONVEYOR BELTS

Pegs coming from the preparer are conveyed to the 1st search station through the 2nd belt and to the 2nd or 3rd
search station (if present) through the 1st belt.
The pegs from each tail search are addressed to the single packaging units fed by that tail search.
Indeed, the machine can be divided in two to max. three sections, each one fed by its own tail search.
Belts 1 and 2 are behind the machine whereas belt 3 is in front of the machine and conveys the return pegs
unloaded by the packaging unit to the preparer.
The belts are featured by a numbering, as shown in the scheme:

LEFT MACHINE

RIGHT MACHINE

A: HEADSTOCK
B: PREPARER

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5.2.1.4 PACKAGE UNLOADING BELT

The doffing trolley deposits the packages produced by the packaging units on the
package conveyor belt which is behind the heads.

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5.2.1.5 BOBBIN LOADER PEGS

The bobbin movement system along the winder is aided by a peg support by means of which the bobbins are
distributed to the machine units.
The single peg is composed of a supporting and driving disk.
Peg is supplied with the pin suitable for the tube stated by customer in the sale transactions.

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5.2.1.6 TOP STRUCTURE

Its job is to sustain the doffing trolley and travelling blower with the relative sliding guides and chain holder ducts,
the cone feeding belt to the doffing trolley and the cone baskets.

It consists of the following parts:

1. Supporting post;
2. Doffing trolley guides;
3. Chain holder duct;
4. Cone feeding belt;
5. Support for the machine illuminating lights;
6. Travelling blower guides support;
7. Travelling blower guide.

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5.2.2 TECHNICAL DATA

PREMISE

Since no special specifications are available for machine body, all its technical data are included in the machine
overall specifications.

Please consult chapter 2 of this manual.

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5.2.3 ADJUSTMENTS

PREMISE

This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety, by reading and appropriately
consulting this paragraph.

ATTENTION!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

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5.2.3.1 BOBBIN HOLDER PEG ADJUSTMENTS AND CONFIGURATION

Peg requires no adjustments since the spinning frame manufacturer or Savio supplies it already fit for the diameter
of tube to be processed.

IMPORTANT:
The use of Lycra yarns, it is necessary that the bobbin tube end is as described in chapter 2.

5.2.4 USE INSTRUCTIONS

PREMISE

Since no special machine body use instructions are available, this document includes use instructions for the
machine body, as for all machine components.

Please consult chapter 6 of this manual.

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5.2.5 MAINTENANCE

PREMISE

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Only a qualified electrician is allowed to work on the electrical equipment.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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5.2.5.1 MACHINE BODY GENERAL CLEANING

ATTENTION!
The machine body must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Personal protection
8 Peg conveyor belt brush cleaning equipment as required by the
laws of the country where the
machine is installed

PEG CONVEYOR BELT BRUSH CLEANING

SERVICE INTERVAL every 8 hours
Both in the front and rear side, as well as in the intermediate part of the machine it is necessary to clean the belt
cleaning brushes.
Release the spring (1), lower the brush support and remove the upper (2) and lower (3) brush.
Clean the brushes from residual lint and refit them, fastening the unit with spring (1).
Check brush efficiency, renew them if necessary.

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator.
Personal protection
150 Peg cleaning equipment as required by the
laws of the country where the
machine is installed

PEG CLEANING
SERVICE INTERVAL every 150 hours
Remove and clean the peg from any yarn coils.

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Manual tools,
Personal protection
8000 Check peg integrity equipment as required by the
laws of the country where the
machine is installed.

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PEG CLEANING
SERVICE INTERVAL every 8000 hours
Make sure the hollow section for tail threading is not obstructed and has no deformations (it must be straight) and
check its integrity.
Change peg if worn or damaged.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and dust inhalation
remains.

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Manual tools,
Securing the cables on electrical Personal protection
8000 equipment as required by the
equipment and motors
laws of the country where the
machine is installed

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Hand Tools and warnings

shown in paragraph charge
OPERATIONS NOT ORDINARY below.
0 Replacement and Handling of electronic Personal protection as
boards required by the rules in force
in the country of installation
of the machine.

EXTRAORDINARY MAINTENANCE

WARNING

PRECAUTIONS WHEN CHANGING AND HANDLING THE ELECTRONIC CARDS

- The cards must be removed or changed when the winder is not powered.
- CMOS printed circuits are also used on the cards that can be damaged by static discharges from the operator.
- Before handling the cards, discharge to earth such static discharges by touching an unpainted, earthed
metal surface with both hands (for instance, the winding unit box).
- When plugging in or removing cards or when plugging in connectors, do not bend or deform the cards especially
if they are big.
- Do not remove the connectors by pulling on the cables.
- If there are jumpers or selection dip switches on the card remember to restore setting of the card replaced.

After the cards have been replaced in :

- winding unit (CPU board)
- headstock (excluding the centralized power supply)
- bobbin loader, yarn end finders, hopper station
- doffing trolley
- update the software following the procedures described in chapter 5 : “Software update” or “Teleload” in the
paragraph dedicated to the Ispector Control.

WARNING
Failure to heed the instructions above, there remains a residual risk of entanglement and
electrocution.

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5.3 WINDING UNIT
5.3.1 TECHNICAL DESCRIPTION

The packaging unit performs the main technological functions of the machine, that is:
- it transforms the yarn package: in fact, yarn is taken from several initial bobbins and wound on one final
package so the yarn can continue its utilisation cycle,
- it eliminates dimensional defects and impurities from the yarn,
- it carries out yarn splicing to restore its continuity.

The packaging unit does not consist of a box containing different yarn packaging and control groups but it is made
of multifunctional units, independent from one another and connected to an "S" support structure suitable to
support multifunctional units and service parts to the packaging units all along the machine.
The multifunctional units are the following:
- Collection unit 1, composed of the package cradle and by the yarn guide cylinder
- Package tail suction unit 2, waxing unit and clearer
- Splicing unit 3
- Bobbin tail suction unit 4, yarn tensioner, knife, yarn feeler and unwinder
- Bobbin feeding and change unit 5
- Packaging unit suction unit 6

The service parts of the packaging units are connected to support structure S:
- Package unloading belt 7
- Compressed air supply lines 8
- Waste evacuation duct 9
- Bobbin conveyor belts 10
- Unwound bobbin unloading belts 11
- Electric supply channel 12

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S support structure consists of:

- Two sheet metal support shoulders 13 which support a series of components indicated later
- A "C"-shaped bar 14 which supports packaging unit multifunctional units
- Two shoulder connection bars 15 and 16
- Two transversal supports 17 connected to the shoulders and supporting bed slides 18 and 19 of the bobbin
unloading and feeding belts

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The shoulders 13 support:
- two posts 20 supporting the upper structures which at the same time support
- doffing trolley sliding guides 21
- cone basket support guides 22 (or cone delivery belt guides 23)
- doffing trolley feeding chain guide 24
- travelling blower support anchorages 25

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5.3.1.1 COLLECTION UNIT

The winding head collection unit supports and contains the parts expressly involved in making the package.
The multifunctional unit comprises the following subunits or functions:
- package cradle 1;
- axial displacement 2 [OPT] ;
- centres 3 and 4
- package brake 5, package speed and centre opening 6 sensor ;
- counterweighing and instant lifting 7 ;
- nozzle-package distance compensator 8 ;
- grooved roll and side yarn guide 9 ;
- CAP 10 modulation check [OPT]
- package unload chute 11 ;
- control of length with laser system 12 ;
- counterweight control proportional valve 13
- check electronic equipment 14
- taper increase lever 15
- front 16

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5.3.1.1.1 PACKAGE CRADLE

Its job is to sustain the take-up package and keep it in position.

The unit, with reference to the following figures, is composed of: live centre 1, fixed centre 2, lint anti-winding
guards 3, package brake 4, package speed and centre opening probe 5, package taper increase device 6, centre
cover 7 with signalling devices.
- The centres are used to fit and hold in place the different types of take-up cones as required. They are
interchangeable according to taper and dimensions of the tube to fit. The fixed centre has a guard 3 that
protects it from lint winding.
- The live centre opening is performed by touching centre opening sensor 5 by hand and its purpose is to doff
the package from the arm and insert a new cone. The centre is pneumatically opened and stays open as long
as sensor 5 is touched.
- Package brake 4, behind the live centre, brakes the package before starting the splicing cycle. Braking is by
means of a pair of jaws that act on the external support surface of the live centre after the package has been
lifted off the drum by the instant lifting device.
- The package speed probe 5 detects package rotation speed and checks that the package has stopped at the
beginning of the splicing cycle.
- The purpose of the package taper increase is to provide the package with additional tapering. This is done
either with a mechanical system (graduated vernier scale/lever 6) in the base version or electronically [OPT].
- On the live centre cover front side 7 are located the red LED for signalling unit faults and the light blue LED for
signalling package in doffing phase

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5.3.1.1.2 MODULATION SYSTEMS

The purpose of package cradle modulation is to vary the drive ratio between package and grooved roll in order to
avoid superimposed coils of yarn forming.
With the [OPT] CAD version, modulation movement is given by a stepping motor (1) that, slanting the cradle with
respect to the roll, modifies the drive ratio appropriately between package and roll. Movement extent and cradle
position are controlled by sensors (2).
In the standard version the modulation system is obtained with sudden accelerations of the roll (ON−OFF
modulation).

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5.3.1.1.3 AXIAL DISPLACEMENT [OPT]

Its purpose is to move the package axially on the drum so as to produce a specific package for dyeing. The unit
comprises a motor (1), controlled by an electronic card placed in the check electronic equipment compartment and
an eccentric axle (3).

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5.3.1.1.4 COUNTER-WEIGHING AND INSTANT LIFTING

The counter-weighing function is to reduce the package’s force of contact on the drum by acting on the counter-
weighing piston supply pressure.
Instant lifting lifts the package off the drum before braking starts at the beginning of the splicing cycle.
Both functions are controlled by the same pneumatically powered piston.

The piston of the counterweight has the ball joint of the base which can be positioned in three different points:

- Position nearest operator >> counterweight lower (arm heavier, high density)
- Intermediate position >> normal (standard arm, warping, knitting)
- Position the far greater counterweight operator >> (arm lighter, dry cleaners)

The counterweight C.A.D. electronics (OPT) is provided with a proportional valve which regulates the piston in
accordance with the set sull'Ispector Control, and is particularly suitable for elastic yarns or high elongation at break
(to eliminate the hips rock skirted).

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5.3.1.1.5 NOZZLE-PACKAGE DISTANCE COMPENSATOR

The function of this device is to maintain constant the distance between nozzle and package, irrespective of the
latter’s diameter, to guarantee maximum package yarn tail suction efficiency by the nozzle.
It consists of the following elements: a cam 1 adjusting the distance on support 2 of arm 3, a slide 4 driven on one
end by cam 1 which brings the limit position probe 5 to the other end on which package yarn nozzle 6 is placed.

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5.3.1.1.6 PACKAGE UNLOAD CHUTE

Its job is to transfer the package during the doffing phase from the supporting cradle to the package unloading belt.
It consists of the following elements: a fixed plane used as package guide chute.

5.3.1.1.7 GROOVED ROLL AND SIDE YARN GUIDE

The drum turns the package between the cradle’s centres and guides the yarn during package formation.
It is driven by an electric motor (1) positioned axially with the drum (2).
The drum is also fitted with the following devices that intervene if the yarn is interrupted:
 side yarn guide, to stop the tail coming off the side (3);
 yarn brake, to brake the tail (4).

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5.3.1.1.8 COLLECTION UNIT FRONT

The collection unit front protects the package brake and the speed and centre opening sensor and is equipped with
the following controls and functions:
- Packaging unit start push-button 1, symbol "I"
- Packaging unit stop push-button 2, symbol "O"
- Disconnection switch 3 of the packaging unit control parts
- Red LED 4 signalling alarms of the packaging unit with the following meanings:
- Red fixed light means LOCAL STOP / RED LIGHT (the unit is not able to successfully complete
splicing)
- Red fast blinking light means SYSTEM ALARM (unit component fault)
- Red slow blinking light means TEXTILE ALARM (Textile alarms of clearer, rolls and excessive
number of interventions for bobbing cut and package splicing)
Other related signals
When either a RED LIGHT, SYSTEM ALARM or a TEXTILE ALARM turn on the front, it is necessary to search on
the packaging unit a red LED that will turn on at the same time and indicate the unit causing the inefficiency. The
signalling LEDs are located on
- Package cradle: on live centre guard front side
- Package tail suction unit, waxing unit and clearer: underneath the clearer on the RH side and on the clearer
itself
- Splicing unit: on the RH front of the splicer
- Bobbin tail suction unit, yarn tensioner, knife, yarn feeler and unwinder: on the RH front side, between the
yarn tensioner and the bobbin tail nozzle
Other related controls
Pressing the stop push-button 2 for 3 consecutive times allows you to:
- Free the work position unlocking the bobbin in use (to discharge manually)

Pressing start 1 and stop 2 push-buttons once at the same time and then start push-button 1 again for 1 time,
allows you to:
- Reset the length of the package in use

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5.3.1.2 PACKAGE TAIL SUCTION UNIT, WAXING UNIT AND CLEARER

The unit supports and contains the parts designed for package tail suction, yarn waxing and yarn defect check and
contains the electronic cards to manage and control the components.
The unit comprises the following subunits or functions:
- Box 1 containing the suction nozzle actuator (through stepping motor and toothed belt) with covers 1a and 1b;
- Package tail suction nozzle 2;
- Suction air outlet fitting from the suction unit of the packaging unit
- Waxing unit 3 ;
- Top introducer 4 ;
- Tensor and antiwrap sensor 5 ;
- Clearer 6 ;
- Air distribution duct 7 to clean the unit (distributed on clearer, tension sensor and waxing unit);
- Sky-blue LED 8 signalling unit faults
- Unit control electronic card compartment 9

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5.3.1.2.1 TENSOR AND ANTI-WRAP DEVICE

This device, located above the clearer, detects the unwinding tension of the bobbin yarn with the aim of maintaining
it as constant as possible.
A variation in tension is obtained with the winding head’s control card that acts either on the yarn tensioner or on
winding speed.
The sensor also has the function of preventing winding laps on the drum or package.
In the version without tensor, the formation of the wrap is detected with a check run by the winding head
programme that causes take-up to stop instantly.

5.3.1.2.2 CLEARER

The clearer’s job is to detect dimensional defects and impurities on the yarn.
Note: to use and service the clearers follow the instructions provided by the Manufacturers,
indicated in the manuals which are part of the documentation provided with the
machine.

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5.3.1.2.3 PACKAGE YARN SUCTION

The purpose of the package yarn suction unit is to take the tail from the package during knotting and insert it in the
splicer (see also the splicing cycle).
It consists of the following parts:
- nozzle 1 for yarn suction;
- combs 1a [OPT]
- yarn positioning cam for doffing trolley 1b
- reference 2 to reset nozzle position during tail suction cycle; position sensor is placed on the slide driven by
the above-mentioned arm cam.
- stepping motor 3 for nozzle driving;
- toothed drive belt 4
- connection fitting 5 to suction unit of the packaging unit

Note: the correct vacuum of the suction air during the cycle is modulated by the single suction unit of the packaging
unit, according to the cycle phase and the activation software.

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5.3.1.2.4 WAXING UNIT [OPT]

The waxing device has the function to apply uniformly to the yarn a predetermined quantity of paraffin.
It is controlled by a motor of the take-up lever (1) on-axis, and is composed of:
- Paraffin container (2) with visual indicator (3) of the exhaustion of the same;
- Support pegs (7) of the disk of paraffin;
- Pneumatic device (4) removal of the paraffin during the introduction of the wire;
- Probe indication (5) for the depletion paraffin [OPT];
- Button (6) for locking / unlocking of the axis, for the extraction of the cartridge (2).

The waxing device can be mounted either above or below the yarn clearer, acting for the waxing side screws at the
left, for the yarn clearer on the front screws and for the sensor (5) on the clamping ring nuts:

A - Side screws waxing

B - Tightening locknuts sensor 5
C - Front screws clearer

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5.3.1.3 SPLICING UNIT

The unit joins yarn coming from the bobbin and package after the two ends have been inserted in the splicer from
the relevant bobbin suction nozzles.
This unit comprises:
- box 1 to hold solenoid valves, stepping motor and splicer electronic card;
- splicer body 2
- tail introduction levers 3
- yarn control components 4
- splicing chamber 5
- preparing devices 6 of the ends to splice
- Sky-blue LED 7 signalling faults

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5.3.1.4 FEELER KNIFE YARN TENSIONER BOBBIN TAIL SUCTION UNIT

The unit has different functions; the first is to pick up the tail coming from the bobbin in order to perform splicing;
the second is to properly tension the yarn; the third is to stop yarn continuity (for example after a defect detected by
the clearer); the fourth is to check yarn presence coming from the bobbin before carrying out splicing.
This unit comprises:
- box 1 containing electronic and solenoid valve support cards
- bobbin tail suction nozzle 2
- yarn tensioner 3
- knife 4
- pre-clearer 5
- bobbin yarn feeler 6
- yarn unwinder 7
- 8 blue sky LED signaling abnormalities

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5.3.1.4.1 KNIFE

The function of the knife, which is placed just above the take-up lever, is to intervene to stop the wire to the
passage of a defect detected by the yarn clearer, or for making cuts votes for service functions of the spooling units
(eg interruption of thread following a reel).
The thread trimming the end coming from the spool is captured by the suction nozzle clue cop.
The knife is formed by:

- Box (1) for containing the electromagnet and the movable knife
- Knife Mobile (2)
- Anvil (3)
- Ceramic thread guide (4)

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5.3.1.4.2 PRE-CLEARER

The pre-clearer unit is the first yarn “linearisation” point in the unit and its job is to guide the yarn and to intercept
yarn coil getup according to the adjustment set.
The mobile introducer is turned on during the knotting or bobbin change cycle to thread the yarn.
The pre-clearer unit comprises:
- support 1;
- pneumatic cylinder 2 to control opening of the mobile introducer;
- mobile introducer 3;
- Fixed introducer 4, 4 positions for yarns from large to fine.

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5.3.1.4.3 BOBBIN TAIL SUCTION NOZZLE

The nozzle wire spool has the purpose to pick up the yarn end coming from the pirn (above the probe of the thread)
after a yarn clearer intervention or a bobbin change, and returned into the splicer for the subsequent splicing cycle.
The bocchettina is located, in the rest position, in the intake position with the hatch open. As soon as the yarn
clearer cuts the thread or detects the lack, is operated 8 jet venturi and the wire is immediately captured by the
nozzle
The group consists of:
- Bocchettina 1 with the device in the door 2 for stapling of the wire spool in the lower position of the jack, and
the transfer in the upper position of the junction;
- 3 pegs door opening stapling wire. (the door engages on two fixed cams, one positioned inferiorly on the
group for unwinding the suction phase wire spool, and the other on the upper support yarn clearer for the
suction phase of the waste junction;
- Tube 4 connecting the group to the main intake pipe;
- 5 stepper motor for moving;
- Belt 6 for transmitting motion;
- 7 probe for the detection of the position of rest of the group.
- to jet venturi effect to facilitate the suction of yarn difficult
- Screw the pin 9 for the belt tension.

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5.3.1.4.4 YARN TENSIONER

The group yarn tensioner has the aim to provide the yarn collection in a voltage value suitable for the
characteristics of the yarn itself and to pack a reel with predetermined density. The voltage is supplied via the
deviation of the path of the wire comb implemented by two bodies, one fixed and the other movable.
The group yarn tensioner is composed of:
- 1 stepper motor for the translation of the mobile;
- Movable unit 2, equipped with lateral movement, which houses two locators ceramic sprung 3 independent of
each other;
- Evidence ceramic fixed 4;
- 5 introducers shaped containment wire;
- Introducers 5 shaped containment wire (the introducer top also acts as an introducer for the knife);

The movable assembly opens to allow the introduction of the wire, and closes in a position where the stops are
ceramic divert the path of the wire (in red dashed in the figure) in passing from one abutment to another. The
tension imparted to the wire is detected downstream from the voltage sensor that pilot consequently the
advancement of the movable or less. The two feedback ceramic 3 are made independent of each other to respond
more quickly to changes in the thread tension, and to more effectively amortize the changes.

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5.3.1.4.5 YARN FEELER AND UNWINDER

The feeler wire is optical and detects the presence of the wire spool during the cycle; failing this, generates a signal
requesting activation of the exchange spool. E 'consists of a feeler 1 fixed, placed above the group unwinder wire.
The group unwinder wire has several functions:
- Reduction of the unwinding tension of the spool and attenuation of voltage peaks; the function is obtained by
the device rompiballon 2;
- Transfer of the end from the spool to the wire spool suction nozzle during the change cycle cop; the nozzle
thread spool is already in position of suction, and a jet of compressed air coming from the feeding bobbin
change and raises the yarn end of the spool through the rompiballoon 2 until out is captured by the suction
nozzle; the feeler wire 1 controls the outlet of the end occurred.
- Evacuation of the end to bobbin change; the function is obtained by means of an air jet 3, in place rompiballon
2;
- Tension of the thread during the cycle and the phases of acceleration and deceleration, to avoid the formation
of curls; the function is obtained by means of a shaped rod 4, which rests at the tip of the cops. The rod is
connected to a lever 5 subject to a torsional spring 6; the lever 5 is released by a pneumatic piston 7, which
determines the fall on the tip of the spool.

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5.3.1.5 BOBBIN FEEDING AND CHANGE UNIT

The whole unit has the function to pick-up the peg with the bobbin from the feeding belt on the machine rear side
and to bring it to buffer, to transfer the peg with the bobbin from buffer position to unwinding position; to lock the
peg during unwinding. The peg transfer from the reserve position to the unwinding position also causes the peg
unloading with the unwound bobbin on the unloading belt on the machine front side.
The peg pick-up devices of the feeding belt are composed of:
- the peg detection lever 1 from feeding belt, with pneumatic opening 1a and closing by means of the detected
peg;
- motor-driven belt 2 for peg transfer with motor 2a
- control pneumatic cylinder 3 with activation tie rod 4 of peg lock lever 5 in buffer and its following release
The peg transfer devices from buffer to unwinding position are composed of:
- motor-driven belt 2 for peg transfer;
control pneumatic cylinder 3 with peg lock lever 6 in unwinding position;
position sensor 7 of the coming peg;
peg position and lock striker 8 in unwinding.
The striker 8 is composed of:
two spring rods 9 to fix the tube on peg pin.
A striker spring lever 10 of the peg collar on the locking lever 6. Lever 10 is also necessary to eject the peg.
The unit is driven by the electronic card and the solenoid valves in box 11; electric and pneumatic supply is
ensured by a channel all along the machine.

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5.3.1.6 PACKAGING UNIT SUCTION UNIT

The suction unit of the packaging unit is placed inside a "C"-shaped bar of the structure supporting multifunctional
units and interfaces exactly with the units fitted outside the bar itself. It comprises a lint and dust collection case
connected on one side to the package tail suction nozzle and the bobbin tail suction nozzle and on the other side it
is connected to a high capacity centrifugal suction unit through a filter. On the bottom it is connected to the
communication gate of the lint and dust evacuation central system.
This unit consists of:
- Lint and dust suction case 1
- Package nozzle air outlet 2
- Bobbin nozzle air outlet 3
- Dust suction air outlet 4 [OPT]
- Filter 5
- Centrifugal suction device 6
- Motor 7
- Discharge chamber 8 and silencing of the air coming out of the suction device
- Lint discharge gate 9 into the evacuation central system

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Every time that the packaging unit needs suction, the centrifugal suction unit 6 is enabled for a short period
suctioning the air, through package nozzle and bobbin nozzle already positioned, to the most suitable vacuum for
the tail pick-up. The tails that were suctioned end up in collection case 1 where they remain until periodic
evacuation; under the collection case 1 there is gate 9 which comprises a piston 10 that opens/closes gate 11
connecting case 1 with lint evacuation duct 12. In duct 12 vacuum is created by a small suction device located in
the machine headstock and the lints are collected in the headstock by the lint and dust collection system.
Packaging unit gate 9 opening is programmed by control software and is carried out when the packaging units do
not require suction to tail suction nozzles.
The suction device (6) is hinged and can be completely opened to allow cleaning and check operations.

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In case of dust suction [OPT], the suction device is activated at low speed and duct (4) is connected through pipe
(13) to a normally open gate (14) which communicates with the suction nozzle (15) of the dust generated during
bobbin unwinding. The gate (14), pneumatically activated, is closed every time that the packaging unit starts its
cycle.

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5.3.1.7 UNREELING ASSISTED GROUP (OTP)

The unit [OPT] is located over the bobbin feeding and change unit and allows to unwind the bobbin using a
drawtube moves down in a continuous way during unwinding. When it is assembled, it replaces the yarn feeler and
unwinding unit described above in point 5.3.1.4.5
The unit comprises:
- Yarn sensor 1
- Fixed drawtube (2)
- Mobile carriage (3)
- Stretch feeler lever (4)
- Stretch feeler lever sensor (5)
- Mobile carriage motor (6)
- Toothed belt for mobile carriage (7)
- Aided unwinding unit support (8)
- Electronic card box (9)
- Cable-support chain (10)
- Trumpet (11)
- Blower (12)

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At every bobbin infeed in the packaging unit, the stretch feeler lever (4) lowers to feel tube end, then the mobile
carriage lowers in order to have the lever (4) rotate until sensor (5) commutes indicating the position in which
bobbin full diameter starts. The lever (4) is then lifted, the mobile trolley (3) lifts and starts unwinding.
During bobbin unwinding, the mobile carriage (3) slowly lowers along the bobbin axis as controlled by suitable
software and dragging the fixed drawtube (2).
Yarn ballon is checked by the steel trumpet (11), concentric with the fixed pipe (2).
If the bobbin is ejected from the packaging unit, blower (12) ejects the bobbin tail blowing it downwards.

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5.3.2 TECHNICAL DATA
5.3.2.1 WINDING UNIT COMPRESSED AIR CONSUMPTION

 Winding unit (excluding splicer) ---------------------------------------------------------------------------- 2.8 NI/cycle

 Waxing unit ------------------------------------------------------------------------------------------------------ 0.5 NI/cycle
 Splicer 895 ------------------------------------------------------------------------------------------------------ 1.8 NI/cycle
 Splicer 8951 ----------------------------------------------------------------------------------------------------- 1.8 NI/cycle
 Splicer 4982 ----------------------------------------------------------------------------------------------------- 2.0 NI/cycle
 (splicer consumption can vary by ± 30% depending on the minimum/maximum settings)
 Splicer 4928 ----------------------------------------------------------------------------------------------------- 7.0 NI/cycle
 (the splicer air consumption is given by: 2.5 blow + 4.5 preparer)
 clearer cleaning blow -------------------------------------------------------------------------------------------- 18 Nl/min

Increase for losses (K) 1.3

Note
Other specifications of the winder are integral part of the machine general specifications.

Please consult chapter 2 of this manual.

5.3.2.2 PACKAGING UNIT EXTRACTION TROLLEY DIMENSIONS AND WEIGHTS [OPT]

The trolley’s size and weight are as follows:

Width ----------------- 660 mm

Height --------------- 1225 mm
Length----------------- 715 mm
Weight ------------------ 50 kg

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5.3.3 ADJUSTMENTS

PREMISE

This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety, by reading and appropriately
consulting this paragraph.

ATTENTION!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

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5.3.3.1 MODULATION SYSTEMS

The On-Off modulation system is obtained by means of a cylinder and relative control motor; no adjustments are
required.
The electronic modulation (C.A.P.) system uses a stepping motor, a worm screw and limit switch sensors.
If the system needs adjusting, the procedure is:
1)remove the front protection cover from the modulation box; keep the package cradle – on the dead centre
side – lifted to recover play at the base of the cradle.
2)Insert a socket head screw wrench in the external end (1) of the worm screw (2) so the control screw can
turn.

N.B.: IF MODULATION IS INACTIVE (Position zero), LEDs 3, 4 AND 5 ARE OFF.

(The clockwise/counter-clockwise indications used below to identify direction in which the worm screw is turning
refer to the side on which the socket head screw wrench is inserted.)
3) With the wrench turn the worm screw (counter-clockwise) until the left LED (4) turns on.
4) Now turn the screw in the opposite direction (clockwise) until the left LED turns off.
5) The instant the left LED turns off, continue turning the screw by 180°. With the system under these
conditions, position the motor encoder disk (6) so it is equally distant from the sides of the optical reading
fork (7) and with the reference slot in the middle of the fork (LED 3, on the card, should be off). Determining
the system’s zero position.
6) From position zero, established in point 5, continue turning the screw another 180°.

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7) In the position reached, slightly loosen the screws (8) and (8a) fixing the front cam (9). UNDER NO
CIRCUMSTANCES MUST THE POSITION OF THE REAR CAM BE CHANGED.
8) Turn the front cam counter-clockwise. After the right LED (5) turns off, lock the cam in the new position. The
cam is turned using the tool (pin) (11) supplied with the machine. Insert the terminal (A) in the service hole
(10) on the modulation unit and turn the pin. Due to the eccentricity of the top part (B) of the pin, there will be
an angular movement of the front cam.

FINAL CHECKS
Check that the front cam (9) turns the right LED (5) on by rotating the relative screw at a maximum angle of 270°,
from position zero of the motor encoder.

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5.3.3.2 CONES TO COLLECT, CYLINDER AND YARN DEPOSIT

This adjustment determines the position of the take-up cone between the centres of the package cradle.
Loosen fixed centre dowel (1) in order to axially free it; take a Φ 4 mm and at least 80 mm long pin and insert it
inside the hole (2). Take a cone and insert it between centres (3) and (4), then push the fixed centre (3) against the
live centre (4) until it touches the Φ 4mm pin. Tighten the dowel (1).

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5.3.3.3 YARN DEPOSITING AREA ON THE TAKE-UP CONE AND PARALLELISM BETWEEN THE TAKE-
UP CONE AND GROOVED ROLLER

Adjustment must be made using the taper increase value,if the mechanical lever and finger system is present, set
to zero with the cone mounted between the centres.
To change the position of the cradle with respect to the cylinder, it is necessary to loosen the screws (1) used to
fasten the group to the package cradle.

To ensure parallelism, perform the operation with the cone against the grooved roll along its entire length.
Once the cradle position is adjusted, while observing the values of distance A shown hereunder, tighten the
screws (1) and check that, when the cone makes a complete rotation, the distance between the cone and the
grooved roll is equal to distance B = 0 ÷ 0.3 mm.

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Note:
In the event of axial movement, adjustments must be made with the motor in the zero position.

a. For conical tubes (without belt), with the following lengths (L), respect relative distance A:
L = 170 mm ⇒ A = 11 ± 1 mm
L = 172 mm ⇒ A = 12 ± 1 mm
L = 175 mm ⇒ A = 13 ± 1 mm

b. In the case of driving with belt and conical tubes A = 11 ± 1 mm.

c. In the case of driving with belt and cylindrical or semi-cylindrical tubes, centre the tube with respect to the
displacement of the cylinder.
With tube length L= 165 mm ⇒ A = 10 ± 1 mm.

d. In the case of a drive belt and cylindrical or semi-cylindrical tube with holes, the holes must be covered.

Note:
Ensure that the live centre, with no tube mounted, never interferes with the cylinder.
Upon completion of cradle adjustment, with the cone still inserted between the centres, loosen the nut (1) and
adjust the screw (2), placing it at a distance from the upper edge of the box A = 0.2 ÷0.5 mm, as shown in the
figure.

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Adjustment must be made using the taper increase value,if the mechanical lever and finger system is present, set
to zero with the cone mounted between the centres.
To change the position of the cradle with respect to the cylinder, it is necessary to loosen the screws (1) used to
fasten the group to the package cradle.

To ensure parallelism, perform the operation with the cone against the grooved roll along its entire length.
Once the cradle position is adjusted, while observing the values of distance A shown hereunder, tighten the
screws (1) and check that, when the cone makes a complete rotation, the distance between the cone and the
grooved roll is equal to distance B = 0 ÷ 0.3 mm.

Note:
In the event of axial movement, adjustments must be made with the motor in the zero position.

a. For conical tubes (without belt), with the following lengths (L), respect relative distance A:
L = 170 mm ⇒ A = 11 ± 1 mm

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L = 172 mm ⇒ A = 12 ± 1 mm
L = 175 mm ⇒ A = 13 ± 1 mm

b. In the case of driving with belt and conical tubes A = 11 ± 1 mm.

c. In the case of driving with belt and cylindrical or semi-cylindrical tubes, centre the tube with respect to the
displacement of the cylinder.
With tube length L= 165 mm ⇒ A = 10 ± 1 mm.

d. In the case of a drive belt and cylindrical or semi-cylindrical tube with holes, the holes must be covered.

Note:
Ensure that the live centre, with no tube mounted, never interferes with the cylinder.
Upon completion of cradle adjustment, with the cone still inserted between the centres, loosen the nut (1) and
adjust the screw (2), placing it at a distance from the upper edge of the box A = 0.2 ÷0.5 mm, as shown in the
figure.

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5.3.3.4 TAPER INCREASE

Taper increase may be either electronic [OPT] and therefore the requested value comes directly from the Ispector
Control, or, as an alternative, the increase is obtained with a mechanical lever and finger system with fixed
positions.
The taper increase may vary from 0 to 5 with one-degree increases.
An increase of 0° is obtained by matching the hole of the finger (5) with the first threaded hole of the index finger
(6).
With a tube with a taper of up to 4° 20’ inclusive, lock the increase at 0 (zero) (first threaded hole from the left).
With tube in excess of 4° 20’ lock at value 3 (third threaded hole from left).

N.B.
Assemble the group by tightening screws (5) and (6) counter-clockwise.

The steps for adjusting the mechanical system are the following:
1. Loosen the nut (1) at the upper end of the tie rod (2).
Loosen and remove the screw (3) and the washer (4).
Move the finger (5) and select the desired increase, by matching the hole of the finger with the relative
finger support threaded hole (6); put the screw (3) and washer back in place.
When tightening the nut (1) the cone must be kept firmly in contact with the cylinder (and hence parallel);
2. Again check parallelism between cone and cylinder as explained in the relevant paragraph.

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5.3.3.5 INSTANT CRADLE LIFTING

Detachment of the package from the cylinder during braking must be at distance B = ÷ 10 mm, shown in the figure.
The extent of package detachment from the cylinder can be adjusted by turning the ring nut (1) on the
counterweight piston (2).
By turning the ring nut counter-clockwise the distance between the package and cylinder will grow.

N.B.
when turning the ring nut be careful not to unscrew it completely from the counterweight piston.

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5.3.3.6 NOZZLE-PACKAGE DISTANCE COMPENSATOR

Adjustment of the compensator (1) takes place, using as a practical reference a package with a diameter of 180 ±
10 mm (as an alternative use a tool that simulates the position of the cradle with that diameter).
With a package inserted between the centres of the cradle check:
 alignment between the mark (2) on the movable cam (5) and positioning rod (3).

If the cam (5) needs repositioning, loosen the screw in position (4).

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5.3.3.7 PACKAGE SUCTION NOZZLE CONTROL UNIT

The control belt is tightened by one complete turn of the whole motor unit (2); this is done using the screw (1) as
the pin and, after having loosened the remaining three screws, turning the motor counter-clockwise.

For this operation the unit has to be removed from the winding head.
The belt is considered tight when, applying a load F of 4,4 ± 0.4 N, there is a deflection f of 1,5 mm, as shown in
the figure.

The four screws that hold the motor must be tightened with a maximum torque of 3.2 ÷ 3.5 Nm

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5.3.3.8 CLEARER

During assembly, ensure alignment of the axis of the clearer (yarn axis) with the axis of the tensor (2) maintaining a
maximum error of ± 0.3 mm.

A: Clearer Axis
B: Sensor Axis

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5.3.3.9 PACKAGE YARN SUCTION NOZZLE

PARALLELISM WITH THE CYLINDER

With the aid of the same instrument (the one used to adjust the cone in relation to the grooved roll), move the
nozzle (3) to the suction position and check parallelism in relation to the cylinder (1), as shown in the figure.

If changes to nozzle position are required, they can be done by loosening the band (2) fixing the nozzle to the
sleeve (4).
When closing the screw on the side of the clamp, use a maximum torque of 10 Nm.
When adjusting take care with the following points:
 check that the screws on the clamp edge are tightened with maximum torque of 10 Nm;
 check that the sleeve (4) is inserted completely in the control elbow fitting and that the magnetic
reference (5) is aligned with the top limit switch sensor (6);
 check there is no interference between the package nozzle and the bobbin-yarn nozzle fulcrum or
the fixed nozzle above the yarn tensioner.

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DISTANCE FROM PACKAGE

Position the nozzle at a minimum distance from the package (distance A in figure), according to the following table

PACKAGE ASPIRATION NOZZLE DISTANCE A (mm)

without combs 2÷3
with combs 5÷6
flax 6÷7

The distance varies depending on where the sensor (6) is mounted which is also used as the top limit switch.

USE OF COMBS
If yarns are used with fine counts or with high hairiness or slippage values, the package suction nozzle can be fitted
with
combs, as generally shown in the following table:

YARN COUNT
Cotton > 50 Ne
Cot/pes > 24 Ne
Polyester > 20 Ne
Wool, Acrylic, Blends > 32 Ne
Viscose > 10 Ne
Fancy Yarns Always

The use of combs, however, depends strictly on the intrinsic features of the yarn being processed so each case
must be evaluated separately.

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5.3.3.10 PACKAGE ASPIRATION NOZZLE

On the ECO PULSARS I-DLS winding unit, there must be mounted a special package suction nozzle equipped
with two introducers (1-2).

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5.3.3.11 WAXING UNIT

WAX SENSOR
If the wax finished device is installed, [OPT], the sensor (1) must be positioned at 1 ÷ 1.5 mm from the magnet on
the wax holder container.

YARN PATH INTERFERENCE

The take-up yarn path interference (misalignment) value in relation to the wax disc, determines the amount of wax
removed from the yarn.
This value can be varied by inserting spacers (0.15 mm thick) at the base of the central grooved roll (2).
To insert/remove these spacers simply loosen the grub screw (3) and pull the grooved roll out (2).
Interference can have a maximum value of 0.6 mm.

INTRODUCERS
If the top (5) and bottom (4) introducers are removed, make sure that when putting them back they are
properly in place on plane A.

WAX DISCS
The discs of wax to use in the ECO PULSARS I-DLS waxing unit must be the following size:

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5.3.3.12 KNIFE

During adjustment, have the yarn slightly touch the RH side of the knife's ceramic.
Therefore slightly loosen the screws (1) and move the knife to the left until it touches the yarn on its ceramic's RH
side.

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5.3.3.13 BOTTOM UNWINDER UNIT

Through the customer’s reference bobbin (1), positioned in the bobbin unwinding station, adjust the rompiballon
bell (2) to the value A shown in the figure.
Possible variations in the A value can be carried out by the screw in position (3).

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5.3.3.14 PRE-CLEARER OPENING

In the pre-clearer unit the distance between the mobile introducer (1) and the fixed introducer (2) can be set to 4
different opening settings, suitable to work with fine to thicker yarns.
The recommended setting is 0.8 to 1.5 for fine-medium counts and 1.8 to 2.5 for medium-thick counts.
The adjustment of the prestribbia takes place in the following way:
- Raise the introducer fixed (2) against the spring of the lid (3) so as to disconnect it from the notches of
mechanical retention
- Rotate the introducer fixed (2) until the desired position with the opening
- Release the introducer fixed (2) to them again with the notches of mechanical retention.

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5.3.3.15 BOBBIN YARN NOZZLE CONTROL UNIT

The control belt is tightened by one complete turn of the whole motor unit; this is done using the screw (1) as a
pivot and, after having loosened the remaining three screws, turning the motor clockwise.
To access the nozzle control unit, remove the winding head’s right side guard.
The belt is considered tight when, applying a load F of 3 ± 0.5 N, there is a deflection f of 3 mm.

1) Tightening torque MOTOR SCREWS 3.2-3.5 Nm

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5.3.3.16 BOBBIN CHANGE UNIT

BOBBIN CENTRING

The check for the bobbin run-out in the unwinding station involves the use of the sample peg (1) as shown in the
figure.
Diagram A shows how to use the sample peg in the standard version (use with all yarns).
The peg in the unwinding position must be coaxial to the square ballon breaker.
The check for the bobbin run-out in the unwinding position involves the use of the sample peg (1) secured on the
bobbin change unit.
With the peg in position there must be a fitting without any hindrance of the sliding bush (2) within the balloon
breaker cone (3).

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To carry out such checks it is necessary to slightly loosen the screws (4), have the lever (5) touch the peg collar
and centre sample peg (1).
Tighten the screws (4)

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5.3.5 MAINTENANCE

PREMISE

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Only a qualified electrician is allowed to work on the electrical equipment.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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5.3.5.1 PACKAGING UNIT GENERAL CLEANING

ATTENTION!
The collection unit must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Brush,
Carefully clean any wax residues on
ceramics and pins in the waxing unit area Personal protection
24 equipment as required by the
and on the square axis of the wax
container. laws of the country where the
machine is installed.

#H_OPERATO
#H_TIME# RE# #H_TIPO_MTN# #H_MATERIALE#

Aspirator,
Cleaning of live (1) and fixed (2) centre Compressed air system
from dust and any wound yarn. (gentle blow),
#MTN1#150 Use Super O-Lube grease,
@TO_002@
Make sure axial movement is smooth and Personal protection
grease pin seals (3) if necessary. equipment as required by the
laws of the country where the
machine is installed.

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Manually remove any flocks on the taper Personal protection
150 equipment as required by the
engaging lever (1).
laws of the country where the
machine is installed.

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

- Make sure live centre (1) and fixed

centre (2) axial movement is smooth Aspirator,
and free from dust and possible wound Compressed air system
yarns; (gentle blow),
- Make sure yarn tensioner unit (3) axial Personal protection
500 movement is smooth; if not, clean the equipment as required by the
internal side of the sliding bush (4). laws of the country where the
machine is installed,
- Make sure the wax cartridge movement Brush.
is smooth; remove dust, wax residues
and lints from the ceramics and the
contact points (5).

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Photocell cleaning "Electronic yarn

detection and movement feeler".
WARNING: This intervention requires
the separation of the plastic guard from
the photocell casing.
The cleaning of the emitter-receiver Soft cloth,
(photocells) surface and of the plastic
Personal protection
1000 guard must be carried out only using a soft
equipment as required by the
cloth, without compressed air and/or
laws of the country where the
aggressive products such as solvents and
machine is installed.
similar products.
PHOTOCELL ASSEMBLY POSITION: the
take-up yarn must move through the yarn
presence detection race without
interfering with the detection surface
(vertical walls).

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

Clean the inside of the cylinder support box (gentle blow),
(toothed belt and disk for speed detecting
Silicone-based lubricant
probe). (Parker Super O-Lube type).
8000
Personal protection
Check smoothness of the counter weight equipment as required by the
piston (1) and lubricate it if necessary. laws of the country where the
machine is installed.

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5.3.6 TWINSPLICER® - A MECHANICAL SPLICING SYSTEM

INTRODUCTION
The Twinsplicer is a yarn splicer which operates on a purely mechanical system; one of its advantages is to control
and guide the yarn during the entire splicing operation.
The untwisting/re-twisting action on the yarn is carried out between two self-compensating interfaced disks which
can adapt to all yarn diameters.
The presence of wax on the yarn does not affect the characteristics of the splicing.
The device is fitted with a dust-protection cover; the cover is opened only during splicing.
A set of special tools is supplied to check, test and clean the Twinsplicer.
Special bench testing equipment is available on request.

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5.3.6.1 MAIN TWINSPLICER UNITS

FRONT COVER
The package yarn suction nozzle and the bobbin yarn suction nozzle insert their yarn ends into the splicer.
Before the yarn is introduced, the package yarn nozzle opens the cover (2) by hitting the lever (1); the cover closes
after splicing.

EXTERNAL CLAMPS
Two external clamps, one on the lower side (3) and one on the upper side (4), are used to draft the CLAMPS two
ends for splicing.
The lever (5), which is actuated by the movement of the clamp (3), holds the yarn as it is untwisted on the lower
part of the unit.

RIPPING GRIPPERS
The clamps (1) withdraw the yarn to be unwound at the end of the pegs (4) and rip the yarn; At the end of their
travel, the clamps open and free the yarn ends so they can be removed.
Note: If one of the two clamps (1) needs changing, you will be supplied with the whole unit because each single
part is assembled with specific equipment to guarantee correct function.

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TWIST LOCK
TWIST The twist inhibitors (2) mounted on the peg separate (before the ripping phase) the section of yarn
INHIBITORS to be unstrung from the yarn to be left whole; they also prevent the twisting of the yarn to be left whole
(this twisting action is exerted by the internal part of the pegs).

PEGS
The pegs consist of rubberised coated disks with concentric cuts by means of which, by proceeding as described
below, splicing is done.
The pegs are moved through the lever (3).
The following is the sequence of operation of the pegs:
1) the yarn ends are introduced parallel to each other between the pegs;
2) the pegs are brought together;
3) the pegs rotate to untwist the yarn ends and, at the same time, the two threads are brought together by four
pegs, while they are being drafted by the external clamps;
4) the twist inhibitors work as described above;
5) the combs on the inside of the pegs are actuated;
6) the pegs open slightly and turn in the direction opposite their direction during untwisting; this re-twists the yarn
and completes the splice.

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5.3.6.1.1 WATER SUPPLY FOR WATER-SPLICER®

There are two types of water splicer :

692 type, with water injection, which needs water supply and discharge pipes.
6901 type, with moisture injection, which needs only water supply pipes.
The minimum water supply pressure for both types is 0,5 Bar.

The water consumption is diferent according to the splicer type :

692 : 1 liter per 2.000 joints
8951 : 1 liter per 50.000 joints

The water supply to the machine must have the following characteristics :
WATER CHEMICAL-PHYSICAL PARAMETERS VALUES RANGE
Total dissolved Solids Absent
pH 7 < pH < 8
Conductivity < 100 μS / cm
Chlorides and Sulphates Free (*)
Hardness <= 1° F

The value in the above table are usually reached through water softeners using reverse osmosis or using ion and
cations exchange resins , normally on sale in each country.
The use of demineralized or distilled water (per se corrosive ) is allowed only after adding 55 grams of sodium
polyphosphates for every 1000 liters of water , subject to the limits given in above table.

(*) pay attention to the regeneration of ion exchange resins , to avoid any pollutions of acid / alkali in to the water
towards the splicers.
The presence of sulfur and chlorine , due to the acids used for resin regeneration, can be revealed with chemical
analysis on the corroded parts.

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5.3.6.2 TWINSPLICER® ADJUSTMENTS - A MECHANICAL SPLICING SYSTEM

The adjustments to be carried out on the Twinsplicer are as follows:

1) UNTWISTING: notches from 1 to 7 (A); loosen the screw (1a) and move the pointer to the desired value.
2) RE-TWISTING: notches from 1 to 7 (B); loosen the screw (1b) and move the pointer to the desired value.
3) DRAFTING: notches from 0 to 4 (C); loosen the screw (1c) and rotate the peg (2c).
The adjustments described at points 1 and 2 directly influence the tensile strength of the splice; the adjustment
described at point 3 adjusts the final diameter of the splice.

Adjustments are carried out as follows:

- move the pointer of the untwisting scale (A) to 5, the re-twisting pointer (B) to 3, and the pointer on the
drafting scale (C) to 1.
Carry out a few splices.
- If the splices are weak (low tensile strength), move the untwisting and re-twisting scales to a higher value.
We recommend increases of 1/2 notch at a time.
- Splices which break at the centre, even if partially, may be caused by excessive tension. If this occurs,
move the re-twisting scale to a lower value.
- If the yarn ends are not securely tied to the yarn, increase the difference between the untwisting and the re-
twisting values by moving the re-twisting scale to a higher value.
- If the diameter of the splice is excessive, gradually move the index of the scale to a higher value.

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5.3.6.3 TWINSPLICER® OPERATING CYCLE - A MECHANICAL SPLICING SYSTEM

The splicing cycle takes place as shown in the figure.

In brief, the splicing is carried out with the following procedure:
after the two yarn ends have been introduced between the disks (1), they are untwisted and drafted (2); the yarn
ends are brought together to create the central part of the splice and the excess yarn at the ends is unstrung to be
detached (3); the yarn ends and the spliced yarn are then joined together (4) and the yarn is re-twisted (5); the
disks are then opened (6) and the splice is extracted.

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5.3.6.4 TWINSPLICER® MAINTENANCE - A MECHANICAL SPLICING SYSTEM
5.3.6.4.1 MAINTENANCE PROGRAMME

ATTENTION!
Have all maintenance operations on the TWINSPLICER® carried out by qualified
staff, complying with the provisions under paragraph "GENERAL SAFETY
PROVISIONS".
The special kit for checking and servicing the Twinsplicer should be used. You will
find the tools to make an excellent job of it in the kit.

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Servicing programme for the mechanical

Refer to the tables in the
splicing system TWINSPLICER®, refer to
chapter
the tables in the chapter

The Twinsplicer needs regular maintenance to guarantee good splicing results.

As a rule, besides daily maintenance (every 24 hours) that entails checking for fragments and lint under the
mobile guard (open the access door and use the special tweezers to remove any yarn fragments), you have to
establish a general maintenance programme that could be:
Legend: A= partial cleaning of the Twinsplicer, about 15 minutes
B= thorough cleaning, removing and checking the parts, about 45 minutes
C= like B, changing worn parts (see the table giving the parts subject to wear), about 60
minutes.

- 100% cotton, Ne 5.75 ÷ 12 counts

C twinsplicers
average that can be
average number of serviced by
cycles/1’ A B A life of the hours a mechanic
time rubber worked in in a year (8
elements a year hours a
in cycles
day)
0.5 9 months 18 months 27 months 3 years 2346
1 6 months 1 year 18 months 1320
650000 7500
1.5 3 months 6 months 1 year 880
2 3 months 6 months 9 months 660
If there are more than 2 cycles/min the maintenance programme has to be customised

- 100% cotton, Ne 12 ÷ 40 counts

- Compact cotton, Ne 12 ÷ 40 counts
- Cotton/Lycra (Lycra drafting no less than 2.8), Ne 12 ÷ 40 counts
- Cotton/Nylon (at least 50% cotton), Ne 12 ÷ 40 counts

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C twinsplicers
average that can be
average number of serviced by
cycles/1’ A B A life of the hours a mechanic
time rubber worked in in a year (8
elements a year hours a
in cycles
day)
0.5 1 year 2 years 3 years 4 years 3128
1 6 months 12 months 18 months 2 years 1727
1000000 7500
1.5 4 months 8 months 12 months 18 months 1295
2 3 months 6 months 9 months 1 year 863
If there are more than 2 cycles/min the maintenance programme has to be customised

- 100% cotton, Ne > 40 counts

- Compact cotton, Ne > 40 counts
- Cotton/Lycra (Lycra draft no less than 2.8), Ne > 40 counts
- Cotton/Nylon (at least 50% cotton), Ne > 40 counts

C twinsplicers
average that can be
average number of serviced by
cycles/1’ A B A life of the hours a mechanic
time rubber worked in in a year (8
elements a year hours a
in cycles
day)
0.5 9 months 18 months 27 months 3 years 2346
1 6 months 1 year 18 months 1320
650000 7500
1.5 3 months 6 months 1 year 880
2 3 months 6 months 9 months 660
If there are more than 2 cycles/min the maintenance programme has to be customised

ATTENTION!
When the Twinsplicer has reached 650,000 cycles it can be used, without changing the rubber
elements, for Ne < 60 counts, retouching the adjustments, up to a limit of 1,000,000 cycles.

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- Cotton/Polyester (65% maximum polyester percentage), Ne 12 ÷ 60 counts

C twinsplicers
average that can be
average number of serviced by
cycles/1’ A B A life of the hours a mechanic
time rubber worked in in a year (8
elements a year hours a
in cycles
day)
0.5 6 months 1 year 18 months 2 years 1546
1 3 months 6 months 9 months 1 year 782
450000 7500
1.5 3 months 6 months 8 months 596
2 2 months 4 months 6 months 440
If there are more than 2 cycles/min the maintenance programme has to be customised

ATTENTION!
The rubber elements cannot be stocked for more than two years. They are to be kept in their
original packaging in a dark and conditioned room (20°÷30 °C, C.U. 50÷70%).

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5.3.6.4.2 INTERVENTION AND MAINTENANCE PHASES

Maintenance interventions can be divided into three phases:

PHASE A
Entails cleaning the equipment that can be done by an inside mechanic.
The equipment has to be removed from the machine and then the plates as described under "DISASSEMBLY
INSTRUCTIONS" from phase 1 to phase 4.
Remove the dirt that has settled inside the equipment with tweezers and a brush.
Compressed air can be used moderately but in this case you first have to turn the rotation axis 90° so the rubber
elements come into contact with it and stop dirt from getting inside. Remount all the parts proceeding in the reverse
order.
Check exact synchronism of the draft levers (arriving together) and correct coupling of the closing guard.
This takes a total of about 15 minutes for each device.

PHASE B
Proceed as described in the previous point for removing the bottom and top plates after which you have to pull the
base plate out that comprises the ripping gripper unit.
Proceed as described under "DISASSEMBLY INSTRUCTIONS" from phase 1 to phase 8 until the equipment is
completely open.
Now clean using tweezers and brushes also inside where it was not cleaned during the previous maintenance.
Take the rubber elements off the pegs and clean, removing the dirt from under the sets.
Do not dirty the rubber elements; clean them if necessary with a dry cloth and then execute 20 cleaning splices.
It is absolutely forbidden to clean them with water, alcohol or other detergents.
Check integrity of the tearing of the components subject to wear indicated in the table.
Now put all parts back in their original places following the assembly instructions, greasing where necessary.
This takes about 45 minutes.

PHASE C
This is the same operation as phase B. Here you have to check and, if necessary, change the ripping gripper
rubber elements and rubber sets to ensure the equipment works properly.
Also check the main components subject to wear given in table "COMPONENTS SUBJECT TO WEAR" below.
This takes at most about 1 hour.

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COMPONENTS SUBJECT TO WEAR

Ref. Spare Part Description Life in years

Rubber sets:
See tables at
6. 1) intermediate disc point 15.6.
2) external disc
3) spiral

Comb springs 2.5

7.

8. Spiral springs 2.5

9. External disc spring 2.5

Intermediate disc 2.5

10.
spring

11. Peg opening guide 4

12. Peg opening guide 4

13. Peg opening spring 4

14. Grooved roll comb 2

15. Grooved roll comb 2

Ripping gripper rubber 1

16.
elements

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Ref. Spare Part Description Life in years

17. 3rd yarn lever 3

18. 3rd yarn plate 3

Bottom ripping gripper 4

19.
lever

Bottom ripping gripper 4

20.
lever

Top ripping gripper 4

21.
lever

Top ripping gripper 4

22.
lever

23. Ripping gripper lever 4

24. Ripping gripper lever 4

25. Ripping return spring 4

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5.3.6.4.3 PREVENTIVE CHECKS

It’s not strictly true that once the duration indicated in the table is reached, the rubber elements have to be changed
at all costs.
It is however advisable to carry out preventive checks on the quality of the splicing (usually by personnel from the
technological and textile lab).
This makes it easier to understand when a component needs changing.
It is normally good practice to check the number of extra cycles on the machine’s PC.
If this is too high on some winding heads it could be the fault either of the Twinsplicer or the head so it is important
to find the reason for the extra cycles.
It is also important to test the splice tension grip, usually done using either the USTER TENSORAPID or the
MESDANLAB.
This is done examining about 20 consecutive splices on each winding head.
Average splice strength values, referring to a 100% carded cotton yarn, should not drop below 90% of the average
yarn while, for minimum strength, they should not drop below 75% of the minimum yarn.

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5.3.6.4.4 DISASSEMBLY

ATTENTION!
Have all maintenance operations on the TWINSPLICER® carried out by qualified
staff, complying with the provisions under paragraph "GENERAL SAFETY
PROVISIONS".
The special kit for checking and servicing the Twinsplicer should be used. You will
find the tools to make an excellent job of it in the kit (the table below details the
content of the service Kit supplied with the machine).

Kit of spanners and brushes

Punch (for Ne 6 ÷ 40)

Punch (for Ne 60 ÷ 90)

Spring release rod

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Top plate for positioning the sides

Bottom plate for positioning the sides

Plate positioning screw (4 pieces)

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Base for control and general assembly

Twin testing equipment

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STEP 1
The splicer is removed from the winding unit by loosening the retaining screw (1).

STEP 2
Unscrew the socket head screw (2), remove the snap ring (3) and cover (4).
Now remove the lever (5).

STEP 3
Remove the screws (6-7) and pull the levers (8-9) out.

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STEP 4
Remove the guards by loosening their screws.

STEP 5
Unscrew the socket head screws (10) on the base plate and pull the ripping gripper unit out (A).

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STEP 6
Unhook the spring (11) from the side, loosen the screws (12) and remove the levers (13).

STEP 7
Unscrew the hex.head screw (14) while holding the flange (15) and then remove the flange (16).
Slightly turn the two sides to release the cam from the peg control roller.
Detach the two sides.

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STEP 8
To remove the rubber elements from the discs, unscrew the screws (17) and be careful with the springs inside

ATTENTION!
Do not dirty the rubber elements; clean them if necessary with a dry cloth and then
execute 20 cleaning splices.
It is absolutely forbidden to clean them with water, alcohol or other detergents.

The rubber elements on a splicer must always be in pairs and, if worn, must both be changed at the same time.
When changing these elements, remove any glue residues from the threaded holes of the screws (17); they must
then be put back with a drop of medium strength thread locking agent.

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5.3.6.4.5 ASSEMBLY INSTRUCTIONS

ATTENTION!
Have all maintenance operations on the TWINSPLICER® carried out by qualified staff,
complying with the provisions under paragraph "GENERAL SAFETY PROVISIONS".
The special kit for checking and servicing the Twinsplicer should be used. You will find the
tools to make an excellent job of it in the kit (the table below details the content of the
service kit supplied with the machine).

ATTENTION!
Lubricant from the container of Molikote G-N Plus grease must be diluted with 5 ÷ 7% of ISO
G220 OIL

To remount the unit proceed in the following way:

- Ripping unit assembly as shown.
- Grease the moving parts subject to contact (B) with MOLIKOTE GN PLUS.

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A: 15mm Tearing opening lever.

- Evenly grease the cam tracks (1) with MOLIKOTE GN PLUS and all zones subject to contact with parts (B).
- Verify that the roller (2) of the peg feed lever (3) is turning freely.

- Misalignment of the pegs with respect to the notch engraved on the cover could oscillate on both sides by
value X max. 0.5 mm; if necessary check the pins of the toothed sectors (A) that control the pegs and change
any worn parts.
- When reassembling the peg unit make sure the levers (1) are in position (2) and the reference notch on the
pegs points upwards (3).
- Check there are no signs of deformation or wearing on the twist-lock; if necessary straighten or replace it.
- Grease the parts that touch and subject to movement with MOLIKOTE GN PLUS.
- Make sure the tearing levers resting on the surface (B) of the corresponding levers on both sides are
simultaneously and correctly aligned, adjusting or changing any ruined parts.

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C: notch alignment
D: peg guard notch

IMPORTANT!
ADJUSTMENT OF DISTANCE BETWEEN RUBBER ELEMENTS (during ripping).

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Ne counts Twin ECO PULSARS I- Distance between

Twists
DLS wheels min + max.
5.75 ÷ 56 0017 0.7 ÷ 0.95
Z
> 56 0018 0.55 ÷ 0.8
5.75 ÷ 56 0019 0.7 ÷ 0.95
S
> 56 0020 0.55 ÷ 0.8

Mount the Twin sides positioning supports and then turn the cam until it is in the tearing phase position (tearing
tweezers closed).
Now check the distance between the rubber elements on both sides with the punches indicated in the table,
adjusting if necessary as follows:
- open the plastic guard containing the screw with the eccentric and, with a box spanner and screwdriver, turn
the eccentric clockwise until you have the right distance between the rubber elements;
- after having closed the eccentric nut, execute a few settling cycles and check the distance between the rubber
elements on both sides with the punch indicated.

Note: if you are unable to achieve correct parallelism of the rubber elements, turn the rubber 180°.

- Mount the top and bottom plates as illustrated in the figure:

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- Mount the levers on the top and bottom plates checking, and adjusting if necessary, the levers of the
balancing unit (1), so they are accurately centred on the slot of the mobile plastic block (2).
- Check on both sides that the drafting levers (1) close simultaneously against the blocks (2); if necessary turn
the set screws (4), tightening them simultaneously.
- Adapt the mobile guard (3) so the resting and closing points match along its contact surface.
- Carry out several cycles to manually test the right movement of the Twinsplicer mechanisms.

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5.3.6.4.6 FAULTS, CAUSES AND REMEDIES

The following information is designed to assist in locating and correcting malfunctions which may occur during
normal operation.

FAULT POSSIBLE CAUSE(S) REMEDY

THE YARN END IS WOUND ON  The combs do not open Eliminate all dust that is preventing
THE INSIDE OF THE DISCS sufficiently; therefore, the comb movement and ensure that
yarn cannot be positioned the comb opening tab is not bent.
inside the combs at the end
of untwisting. During re-
twisting, the yarn ends are
not in contact with the yarn,
and the result will be an
excessively twisted yarn
end which is not correctly
wound. This condition may
be caused by dust
accumulation, or by bent
opening tabs on the combs. Make sure that the prescribed play
 The combs close the yarn of 0.5 mm is set between the comb
end too tightly; then, when teeth.
the combs move back into
the peg unit they pull the
yarn end inside and too far
away from the adjacent
thread. This condition may
be caused by insufficient
play between the teeth.
THE SPLICING IS BROKEN AT  If the splicing is broken at The distance between the twist
THE ENDS the upper or lower end, the inhibitor and the ring must be 0.3 to
cause may be an accidental 0.5 mm (see figure).
bending of the twist inhibitor
(1), which can then move
too close to the ring (2);
thus, when the pegs move
closer to each other, the
bent twist inhibitor can rip
the yarn.

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FAULT POSSIBLE CAUSE(S) REMEDY

YARN FRAGMENTS  Sometimes, fragments may Check that the levers (1) on the
be found inside the splicer. clamps (2) are perfectly aligned
The cause may be a poor with the V-shaped groove.
gripping efficiency of the
external clamps.

LOOPS  A loop in the splice, which is Check the rubber element on the
usually caused by grippers for excessive wear.
excessively ”nervous” yarn
movement, may occur
because the threads have
not been properly inserted
between the pegs.

Y-SHAPED YARN  A yarn end has not been Check the rubber element on the
removed; this occurs when grippers for excessive wear.
one of the grippers is not
functioning properly.

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5.3.6.4.7 CLEANING WATER FILTER FOR WATER-SPLICER®

For machines with water/moisture splicers®: depending on the impurities in the water it is necessary to program a
periodic cleaning of the filter (from 1 cleaning each month to one cleaning each 6 months); remove the filter an
clean it using compressed air. Also check the internal cleanliness of the inlet/outlet water pipes removing any
obstructions. Eventually substitute the inner filtering element every 12 months.

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5.4 CONNECTION BELTS TO THE SPINNING FRAME
5.4.1 TECHNICAL DESCRIPTION
5.4.1.1 CONNECTION BELT UNIT TO THE SPINNING FRAME

The connection between peg spinning frame and winder is made by two belt conveyors, a peg exit transferor from
the spinning frame (2) and a peg entry transferor into the spinning frame (3)
The pegs with bobbins are conveyed to the front belt of the winder through the peg exit transferor from the spinning
frame to be processed.
The pegs with clean tubes are conveyed from the rear belt of winder through the peg entry transferor to the
spinning frame to be processed.
Probes, photocells and stepping motors used to manage connection belts are connected to the electronic cards in
the preparing device box (4).

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5.4.1.2 BOBBIN TRANSFER BELT UNIT

The bobbin transfer unit is aimed at taking the peg with the bobbin, through a belt, from the spinning frame to the
winder.
This unit comprises:
1. peg conveyor belt;
2. fixed return pulley;
3. adjustable return pulley;
4. tensioner for the belt;
5. stepping motor for belt driving;
6. peg presence photocell;
7. peg guides;
8. adjustable and swinging supporting brackets.
The edges of the upper guides (8) can be suitably shaped so that they can interface with the different models of
spinning frame.
The stop (6) is usually in peg lock position and adjusted according to the peg type.
The photocell (7) detects peg presence and, according to the program logic, determines the enabling of the
different stops and of some stations.

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5.4.1.3 TUBE TRANSFER BELT UNIT

The tube transfer unit is aimed at taking the peg with the tube, through a belt, from the winder to the spinning
frame.
This unit comprises:
1. peg conveyor belt;
2. fixed return pulley;
3. adjustable return pulley;
4. tensioner for the belt;
5. stepping motor for belt driving;
6. peg stop with antenna for spindle acknowledgement;
7. peg presence photocell;
8. peg guides;
9. adjustable and swinging supporting brackets.
The edges of the upper guides (7) can be suitably shaped so that they can interface with the different models of
spinning frame.
The photocell (6) detects peg presence and, according to the program logic, determines the enabling of the
different stops and of some stations.

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5.4.2 TECHNICAL DATA

INTRODUCTION

Since no special specifications are available for the connection belts to the spinning frame, all its technical data are
included in the machine overall specifications.

Please consult chapter 2 of this manual.

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5.4.3 ADJUSTMENTS

PREMISE

This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety, by reading and appropriately
consulting this paragraph.

ATTENTION!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

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5.4.4 USE INSTRUCTIONS

ATTENTION!
The connection belts to the spinning frame can be started only by authorised staff.

DON'TS

Correct use of the system includes complying with all the operating and routine maintenance conditions.

ATTENTION!
Do not alter system operation unless proceeding as described in this paragraph and in the
paragraphs concerning maintenance.

ATTENTION!
Do not build up and push dust, lint, paper or any other material under the suction pipes to have
them sucked.

ATTENTION!
Do not push or drag the blowing and suction pipes.

ATTENTION!
Do not put your hands or any other part of your body in front of the blowing nozzles, since
material particles might be sucked from the floor and ejected from the blowing nozzles at a high
pressure and speed.

INSPECTION BEFORE STARTING

Before starting the system, the authorised operator must:

 ensure that the cable drag chain is correctly seated in the runway;
 ensure that the photocells (if installed) are in the correct detection position, check their efficiency by testing
one photocell at a time: when the photocell beam is interrupted, the travelling blower must reverse its
running direction after the preset time;
 check the efficiency of the lever switches at limit stop;
 ensure that the dust collector door (if installed) is closed;
 visually make sure that no operator is close to one of the two winder fronts and that nobody is within the
working area of the travelling blower;
 if the system is equipped with air-operated devices, make sure that the valve secured to the regulator filter
is open, so as to restore air flow.

ATTENTION!
Nobody is allowed to work or pass through the area where the travelling blower is working, or in
such a position as to likely interfere with it.

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There are two different operating modes for the mobile suction and ventilation unit:
 automatic
 manual

these operating modes are explained under paragraph “ISPECTOR CONTROL”

STARTING

The travelling blower is controlled by the switch on the machine control panel at the headstock.

ATTENTION!
After starting, make sure that the cable drag chain smoothly slides in the runway.

STOPPING

Like for starting, the travelling blower stop is controlled by the switch on the machine control panel at the
headstock.

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5.4.5 MAINTENANCE

PREMISE

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Only a qualified electrician is allowed to work on the electrical equipment.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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5.5 CLEANER BACK-UP PREPARING DEVICE
5.5.1 TECHNICAL DESCRIPTION
5.5.1.1 CLEANER BACK-UP PREPARING DEVICE

The bobbin preparing function is to supply bobbins to distribution all along the machine (1);

- receive the pegs arriving from the machine (2), distinguishing between:
- bobbins to be recycled (3), because the bobbins held are not fully unwound
- bobbins to recover because the bobbins on board do not have the tail threaded in the tube (8);
- tubes to be cleaned, because the tubes they hold feature some yarn residues (4);
- clean tubes, ready to be sent out (5) to the spinning frame;
- pegs without tube, that must be restored manually or through the tube loader (6) [OPT];
- clean the tubes with yarn residues using the automatic cleaner (7) [OPT].
- recover the bobbin tails (8) through the back-up station (9)
Note: In case of lot end, pegs with empty tubes are prevented from entering the tail pick-up units all along the
machine through the feeler unit (10).

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5.5.1.2 PEG TRANSPORT

Peg movement to the different stations of the preparing device is done through the same machine conveyor belts 1,
2, 3; the exchange between belt (3) and (2) is performed using recirculation belt (4) and belt (5) used for cleaner (7)
infeed.
The “transport unit” is composed of:
1 peg conveyor belt from the spinning frame to the machine;
2. belt for accumulating pegs with bobbins that need a manual action by the operator;
this to aid the following tail threading trial in the tube in search;
3. peg conveyor belt from the machine to the spinning frame;
4. transfer belt from 3 to 2;
5. cleaner infeed belt
6. peg conveyor belt returns (motors are in the headstock)
7. transversal belt driving motors;
8. peg stops (only some are indicated)
9. peg shunters (only some are indicated);
10. peg presence sensors (in the drawing only one is indicated since they are all the same)
11. belt for accumulating pegs with bobbins showing spinning faults;

The stops (8) are usually in peg locking position and are equipped with Hall effect sensor for reading the peg
presence; the shunters (9) are positioned to aid the most frequent operations.
The sensors (10) (all with Hall effect) detect the peg presence and determine the operation of the different shunters
according to the operating logic.

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5.5.1.3 TUBE BOBBIN FEELER STATION

The bobbin/tube feeler unit (A1) is positioned in the inlet channel of the pegs to the machine.
Its function is to define if the tubes, supported by the pegs moving towards the machine, have a sufficient quantity
of yarn to continue towards the tail pick-up units all along the machine and to the following operations or if they
have to be immediately recycled (in case of tubes they are sent to the spinning machine after one turn around the
machine headstock; if they are bobbins they are recycled to make tail pick-up unit compartments all along the
machine available).
The unit shown in the figure comprises:
- photocell (1) feeling tube diameter;
- fixed support (2);
- mobile support (3) adjustable according to tube height;
- tube housing and supporting guides (4a) and (4b);
- guide (5) for photocell (1);
The peg passage management, through the bobbin/tube feeler unit and the following addressing, is performed by:
- a relevant peg stop with Hall effect sensor, installed at the feeler station;
- the suitable shunter of the peg's path, just downstream of the bobbin/tube feeler unit, for the deviation towards
the first tail pick-up unit along the machine (if this is not empty, the peg will be moved to the second or third tail
pick-up unit along the machine, if any).
Photocell (1), stop and shunter are connected to the electrical box.

A similar unit (A2) is located on the transversal branch connecting winder return belt and intermediate belt and has
the function to discriminate the bobbins to send to the back-up station or directly to the winder feeding belt.

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5.5.1.4 DIRTY-CLEAN TUBE FEELER STATION

The dirty/clean tube feeler unit (B) is positioned in the return channel of the pegs coming from the machine. Its
function is to define if the bobbin tubes coming from the packaging units are cleaned and can then be sent to the
spinning frame, if they feature yarn residues and need to be sent to the cleaner, or if they have a sufficient quantity
of workable yarn so they can continue to the following operations.
The unit shown in the figure comprises:
- comb (1) for detecting yarn residues;
- stepping motor (2) for comb movement;
- probe for the comb resting position (3);
- probe for the comb limit position (4);
- mobile support (5) adjustable according to tube height
- tube housing and supporting guides (6a) and (6b);
- support with tube/bobbin reading photocell (7)
- tube/bobbin presence reading photocell (8)

The peg passage management, through the dirty/clean feeler unit and the following addressing, is performed by:
- a relevant peg stop with Hall effect sensor, installed at the feeler station;
- suitable shunter of the peg's path, just downstream, for the deviation towards the following bobbin recycling
operations or towards the tube cleaner OPT that cleans the tubes and make them recirculate and send them
to the spinning frame or parks the pegs waiting for manual cleaning.
Probes (3) and (4), motor (2), stop and shunter are connected to the electrical
box.

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5.5.1.5 TECHNOLOGICAL WASTE BELTS

The belt for the ”technological waste” (C) is aimed at conveying the bobbins with packaging heads, after set
repeated clearer cuts, cannot package because of yarn faults. These bobbins shall be later taken from the
accumulation section by the operator manually.

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5.5.1.6 TUBE LOADERS [OTP]

The tube loader has the function to insert the tube on the empty peg and then send it to the spinning frame. It
comprises a tube tank (1) and a tube chute/centring unit (2) mainly made of two guides driven by a pneumatic
cylinder which is adjusted according to the tube used by the customer. The photocell (3) allows inserting the tube
on the peg.
Locking for insertion is performed by means of a pneumatic stop and peg presence reading is done by a Hall-effect
sensor.

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5.5.1.7 STATION UNDER INCANNO

The back-up station is a bobbin tail pick-up unit (with underwinding), used to recover the bobbins rejected by the
tail pick-up units all along the machine.
It is aimed at preparing the bobbins with the tail threaded in the peg hollow section, so that the tail can be later
grasped by the packaging units.
The unit shown in the figure comprises:
- peg feeding intermediate belt (1)
- peg transfer disc (2);
- peg rotating unit (3);
- live centre (4);
- tail pick-up unit (5);
- bobbin tail suction nozzle (6);
- unit to verify bobbin tail presence and cut (7);
- unit for threading the tail in the peg hollow section (8);
- underwinding unit (9);
- antenna unit (10);
- box containing electronic card for search management (11)
- solenoid valves (12)
- box containing motor control cards (13)

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5.5.1.7.2 GROUP MOBILE TAILSTOCK

The live centre has the function to centre and push the peg against the peg driver and to keep it vertical during
rotation. The unit shown in the figure comprises:
- centre support (1);
- centre (2);
- two pneumatic cylinders driving centre (3);
- centre position probe (4);
- pneumatic supply (5) to pistons;
- air supply for threading (6) and threading blow hole (7).
The peg located in the rotation unit is fastened at the top by the live centre. At the end of tail gripping cycle, the
yarn exits the bobbin tail suction nozzle, it is cut and then inserted in the bobbin tube through the threading blow (7)
coming from the live centre (2).

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5.5.1.7.3 TAIL PICK-UP GROUP

The bobbin tail pick-up lever unit lifts the bobbin’s binding coil with a vertical movement along the body of the
bobbin to allow tail suction by the nozzle.
The downward movement of the lever is activated by the bobbin which rotates in the yarn winding direction.
The unit shown in the figure comprises:
- motor-driven unit (1) for lowering and lifting;
- comb unit (2) composed of a rubber tail pick-up block;
- comb pneumatic cylinder (3);
- sensor (4);
- comb stroke striker (5);
- blower tube (6);
The station detects the bobbin cone position through sensor (4) and then activates the suitable cycles of
tail pick-up.

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5.5.1.7.4 BOBBIN TAIL SUCTION NOZZLE

The suction nozzle is aimed at sucking the bobbin tail and unwinding a preset quantity. The nozzle is set in suction
by opening the economiser, while the bobbin unwinding is carried out by the bobbin peg rotation in the yarn
unwinding direction.
The tail extraction is obtained by closing the economizer. The unit shown in the figure comprises:
- tail suction nozzle (1);
- mobile economiser (2);
- economiser movement pneumatic cylinder (3).

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5.5.1.7.5 YARN CHECKING AND CUTTING UNIT

This unit checks yarn presence and it cuts the bobbin tail. The unit, which is on the yarn tail suction nozzle consists
of:
- yarn guide introducer (1);
- yarn detection sensor (2);
- fixed scissors blade (3);
- mobile scissors blade (4);
- mobile blade drive pneumatic cylinder (5).
The yarn, captured by the nozzle, upon closing of the economiser is inserted in the unit by the yarn guide (1) in
order to verify its presence through sensor (2).
The tail pick-up operation is repeated as many times as is set on the Ispector Control.

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5.5.1.7.6 GROUP UNDER DECEPTION

For bobbins coming from spinning frames without doffing, the unit is necessary to break/detach the binding at the
bobbin base in order to facilitate tail gripping. This unit comprises:
- Adjustable support (1);
- Body with integrated pneumatic cylinder (2);
- Chisel approach lever (3);
- tail separating chisel (4);
- Pneumatic system (5).

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5.5.1.8 TUBE CLEANER [OPT]

The SAVIO TUBE CLEANER is a machine aimed at removing yarn residues from the tubes coming back from the
winder, already selected by the clean/dirty check station, according to the expected method.
The thread separated from the tube is sucked and conveyed in the collection compartment at the machine
headstock.
The Tube Cleaner comprises the following units:
- feeding unit (1), that transfers the peg from the buffer position to the
stripping position and return;
- a positioning and stripping unit (2) that cleans the tubes from yarn waste;
- a pusher unit (3) that provides the pressure needed for yarn stripping;
- a discharge unit (4) that eliminates yarn waste;
- a box for the electrical equipment plus a control panel (5);
- pneumatic system.
The tube cleaner is provided with transparent guards. The front guard can be removed for maintenance purposes
or for adjustments.

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5.5.1.8.1 FEEDING UNIT

This unit comprises:

- a conveyor belt receiving the peg coming from the check station;
- a photocell (1) detecting peg presence in reserve;
- a stop (2) allowing peg in reserve moving forward towards the cleaner while stopping other pegs
infeed;
- a shunter (3) that positions the peg coming from reserve between the upper (4) and lower (5) grippers
of the cleaner;
- a photocell (6) that detects the arrival and correct positioning of the peg between the grippers;
- a sensor (7) detecting the lower gripper position at the beginning of the cycle and, with the cycle under-way,
stops
other pegs from entering the cleaner;
- an elevator trolley (8), normally positioned in the lower part of the cleaner, which upon peg arrival
locks it and transfers it to stripping position. The presence
of the elevator trolley (8) in the peg waiting position is verified by sensor (7).

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5.5.1.8.2 POSITIONING AND STRIPPING UNIT

This unit has the following functions:

- it positions the tube by the stripping devices;
- it blocks the tube with jaws so the yarn can be stripped (cleaning) from
the tube body.

The tube is positioned in the following way:

- the peg is locked by the elevator trolley;
- the jaws close (1) to guide the tube vertically as it moves up;
- the elevator trolley moves up with the tube, guided in its movement;
- the tube reaches the position on the pusher strut (2);
- the jaws open to let the tube finish its ascent;
- the photocell (5) detects the presence of tubes with yarn.

The yarn waste is stripped off in the following way:

- the jaws close (1) round the base of the tube;
- trolley lowering with pushing strut (2) for residual yarn stripping;
- the economiser opens (3) to suck up yarn waste;
- air blasts (4) send yarn waste towards the economiser;
- the economiser closes;
- the jaws open and the trolley positions itself with the strut in the zero position;
- the elevator trolley moves down with the clean tube on board.

Closing of the stripper jaws and movement of the elevator trolley are controlled by
the pneumatic cylinders located above these units.
Movement of the trolley with pusher strut is actuated by the pusher unit.
The jaws supports also house a pair of knives (1) for cutting the yarn while
stripping.

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5.5.1.8.3 PUSHER UNIT

The pusher unit comprises:

- ratiomotor located above the tube cleaner;
- mobile trolley equipped with pusher strut. The ratiomotor and trolley are connected by
a rack system.
The trolley lowering and lifting phases are controlled by the ratiomotor.
If the trolley moves too far the safety switches (1) (top and bottom limit switches) stop it from moving any further.

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5.5.1.8.4 DISCHARGE UNIT

This unit comprises:

- an economiser (1) to suck up the stripped yarn waste from the tube. The waste is taken to the
collection compartment in the machine’s headstock;
- conveyor belt for transferring the peg at the bobbin preparing device exit. The peg transfer
from the cleaner to the belt is checked by the sensor (3), refer to paragraph "FEEDING UNIT",
positioned at the base of the cleaner.

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5.5.1.8.5 PNEUMATIC PLANT

The pneumatic supply for the tube cleaner entails the use of a line with air treated with
the addition of atomised oil (except for the blast which has its own separate line with dry air).
Both supply lines lead directly from the winder’s pneumatic unit.
The various pneumatic devices are operated with the aid of a set of solenoid valves located
at the back of the control panel.
This unit’s functions are given in the following table:

FUNCTION ACTIVATED CONTROL No. of Part in

SOLENOID VALVE Figure
Pegs exit stop from the elevator trolley area YV1 1
Pegs inlet stop in the elevator trolley area YV2 2
Elevator trolley upstroke YV3 3
Elevator trolley downstroke YV4 3
Cams for closing the extractor plates YV5 4
Economiser opening YV6 5 5
Stripped waste yarn evacuation blow YV7 (dry air) 6

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5.5.2 TECHNICAL DATA

5.5.2.1 BOBBIN PREPARER COMPRESSED AIR CONSUMPTION

Cycle with underwinding blows 11 NI/cycle

Cycle without underwinding blows 7 NI/cycle

. Increase for losses (K) 1.3

Note
Other specifications of the bobbin preparing device are integral part of the machine general specifications.
Please consult chapter 2 of this manual.

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5.5.2.2 TUBE CLEANER TECHNICAL DATA

TUBE CLEANER CONFIGURATION

Mod. Cleaner Machine headstock type Applicable on winder Workable yarns

RIGHT Right ECO PULSARS I-DLS Wool, cotton, synthetic
fibres
LEFT Left

The cleaner has operation and management completely independent from the bobbin preparing device and has
production power of 120 tube/hour.

EXTRACTOR PLATE AND PUSHER STRUT CONFIGURATION

SAVIO provides the following accessories specifically for each type of tube that will be used
in the cleaner:
- pair of metal extractor plates;
- pair of rubber extractor plates;
- pusher strut;
- spacer between trolley and pusher strut for tubes L=180÷230.

In the following table the working ranges of the extractor plates and of the pusher struts are given according to the
dimensions of the tube used:

FUNCTIONAL DIMENSIONS OF THE EXTRACTOR PLATES AND PUSHER STRUT

METAL EXTRACTOR PLATES

C= Øa – (0, 0.5 mm)

RUBBER EXTRACTOR PLATES

D= Øa – (1mm)

PUSHER STRUT
ØE = Øb + (4, 5mm)
ØF = Øb – (0.5, 1mm)

N.B.: A change in the outside diameter of the tube base (Øa) greater than 0.5mm means that the extractor plates
must be changed.

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5.5.2.3 TUBE CLEANER MATERIAL TECHNICAL DATA

The dimensions and shapes of the tubes used in the cleaner are given in the following
table:

TUBE FEATURES
Length (mm) Base outside diameter (mm) Tip inside diameter (mm)
min. maximum min. maximum min. maximum
180 280 22 38 8 23

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A, B, C, D: possible tube configurations

The material used to make the tubes should be good quality, preferably in 6-6 polyamide loaded with fibreglass so
that it cannot deform when loaded.
Cardboard and disposable cardboard tubes are advised against.
The tubes should not be deformed, crushed, nicked and, above all, there should be no
scaling or deformations on the base or nose.

SPECIAL TUBES:
dimensions necessary for defining the extractor plates and pusher strut
TUBES WITH PROJECTING RING NUTS
Øa = diameter to find in order to define the metal extractor plates.
h1 = “bobbin discharge” starting height. A value of 9 mm is required.

TUBES WITH A HIGHLY TAPERED BASE

Øa = diameter to find in order to define the metal extractor plates.
h1 = “bobbin discharge” starting height. A value of 9 mm is required.
N.B.: Diameter of the rubber extractor plate D = Øa.

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5.5.3 ADJUSTMENTS

INTRODUCTION
This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety,
by reading and appropriately consulting this paragraph.

ATTENTION!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

5.5.3.1 CONVEYOR BELT TENSIONING

5.5.3.1.1 PORTABLE PUSH BUTTON PANEL TO CONTROL BELTS

ATTENTION!
The push-button panel can only be used by the “MAINTENANCE ENGINEER”, that is, the
technician who is enabled and authorised by the Customer to carry out routine maintenance
work.

ATTENTION!
Before starting any maintenance work on the belts, it is necessary to forbid access to the area
around the machine headstock in order to keep the area segregated and inaccessible to other
workers.

ATTENTION!
The safety key used for the microswitches and connected by a metal wire to the push-button
panel cable, must not be detached from the push-button panel for any reason whatsoever.

The portable push-button panel is used to manually control the forward movement of the peg conveyor belts
whenever it is necessary to adjust or centre them.

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To use the portable push-button panel to control the belts, proceed as follows:
- Emergency stop push-button (1) to immediately stop the motor-driven rollers driving
the belts.
- Set of microswitches (2) controlling motor-driven rollers: two of them (m3−m4) also
reverse belt direction and in this case stop position is the central one.
- LEDs (3) for signalling motor-driven rollers state.
- Safety key (4) to be used for the microswitch checking motor-driven rollers closing
panel presence.
- Cable (5) with connector (x2) for the connection of the push-button panel to the card (ap8) in the
electric equipment a2.

Then proceed;
- Stop the machine and set the main switch to OFF.
- Switch the motoroller control electric board on the machine rear side on and disconnect the connector x2
from the card
ap8 without removing the Plexiglas guard.
- Connect the push-button board through the connector x2 in its place.
- Open the motor-driven roller compartment closing panel and insert the safety key in the microswitch
detecting the panel presence.
Set the main switch on again and operate the belt adjustments using the
push-button board.
- Alternatively operate on the two machine sides always leaving the panel on the opposed side closed.

N.B.: During the described operations do not intervene on any other point of the electric equipment.
When restoring the standard operating conditions of the winder, remember to position again the previously
removed connector.

ATTENTION!

When the winder returns to normal working conditions, the safety devices must be reset
and checked to ensure they are working properly.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and crushing remains.

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5.5.3.3 DIRTY-CLEAN TUBE FEELER STATION

The tube control station requires the following adjustments:

- the screws (1) are necessary to bring the entire unit close to the tube to feel.
- adjustment B = 4.5 mm is the same as the one of the bobbin/tube feeler stations; adjustment A = 0
indicates that tube end must freely enter between the introducers and in place
with the "V"-shaped guide during comb movement
- the guide (2) must be positioned so that, with the comb (3) positioned on the sensor (4), it should
have an extra travel between 1.5 and 2 mm from the moment when it touches the tube (check
signal presence continuity on sensor (4));
- the sensors (4) and (5) must be positioned at a distance between 1.5 and 2 mm from the magnetic strikers.
- adjust the photocell (6) so that it is in the centre of the tube midway point.

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5.5.3.4 GROUP MOBILE TAILSTOCK

This unit needs the following adjustments:

- adjust the centre (1) positioning it in the middle of the slots of the centre support working on the screws (2)
- adjust the unit height using the telescopic post equipped with screws (3) and inserting a sample bobbin
between
centre and peg rotation unit; supply with 5 Bar compressed air and lift/lower the whole
centre unit until value A = 6mm is reached between stem exit and centre body.
Tighten the screws (3) of the telescopic post.

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5.5.3.5 BOBBIN TAIL SUCTION NOZZLE

This unit needs the following adjustments:

 adjust nozzle depth to 1mm from the sample bobbin surface; work on the screws (1) of the fastening plane
(2);
 check that the nozzle is aligned with bobbin axis; shim the fastening surface (2) if necessary;
 check that the economiser (3) has a gap of 4 mm when closed.

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5.5.3.6 SEARCH GROUP STARTED ON ROLL

This unit needs the following adjustments:

 check the distance between comb base and trolley support, it must be A = 15mm;
 check the rod length (2), it must be B = 78 mm between trolley support and rod head;
 check that the supply pressure of the swinging comb (3) at outlet is 0.2 bars; adjust it on the adjuster -
gauge assembled on the unit;
 check that the swinging comb (3) completely out of the insert (4) activates the probe (5) in these two
conditions: with and without tube; to correctly position it, work on its lock nut;
 with a sample bobbin in position, have the comb (3) adhere to the bobbin side and check that the probe (5)
is off; then lift the comb (3) towards the stretch cone and, when the swinging comb (3) starts approaching
the tube axis, check that the probe (5) turns on; repeat the procedure until the system reads the stretch
starting position as accurately as possible.

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5.5.3.7 GROUP UNDER DECEPTION

This unit needs the following adjustments:

 adjust height of tail separating tab (1), through screws (2); tab middle must work at approx. 25-30 mm from
tube bottom;
 adjust unit tilt through screws (3) so that chisel axis A, indicated in the figure, is centred to the middle of the
bobbin when chisel is approached (working);
 check that set position ensures free bobbin access to Smart search.

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5.5.4 USE INSTRUCTIONS
5.5.4.1 PREPARER BOBBIN RECOVERY

The bobbins rejected by the tail pick-up units all along the machine are sent to the preparing device back-up
station, or recirculated if it is too full.
The bobbins that failed back-up station preparation many times, are parked in the accumulation branch (1) where
the operator searches the tail and threads it on the bobbin body. Then, insert the bobbin back freeing the park
branch using the key on the PC touch screen located over the first tail pick-up unit along the machine.

The bobbins with technological alarms are accumulated in the accumulation branch (2). The recovery operation
from the accumulation branch (1) is responsibility of the operator that extracts the bobbin from the peg and rejects it
or tries to unwind another quantity of yarn (in addition to the quantity already eliminated by the machine devices).
The pegs are manually inserted back through the doors (3) all along peg's path.

If the operator's intervention does not occur within the set time, the bobbins with technological alarms recirculate in
a continuous way. This is the reason why it is important that the operator picks up the faulty bobbins from the
accumulation branch and removes them from the cycle.

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5.5.4.2 DISPOSAL OF TUBES WITH YARN RESIDUES

In case of machine without cleaner, the tubes featuring yarn residues are transferred to the branch (4).
The tube cleaning and recirculation operation is responsibility of the operator.
In case of machine with tube cleaner (5) [OPT], cleaning is carried out by the tube cleaner; the clean tubes are sent
to the machine and then to the spinning frame.

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5.5.4.3 BOBBIN PREPARER CONTROL STATION

The control station is located on the first tail pick-up unit of the last section near the bobbin preparing device and
comprises the following elements:
- Alarm reset blue backlighted push-button (1)
- Ispector Control with push-buttons on touch screen
- Clearer control unit (integrated on the Ispector control)
The blue light turned on the push-button (1) indicates the operator recall for alarm removal.

The control station is equipped with suction fan to recover the yorn ends coming from the toil pick-up unit, similar to
those of the winding spindles.
The portholes are used to control yorn waste entity, and for its removal.

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5.5.4.4 BOBBIN PREPARING DEVICE ALARMS

The presence of alarms is indicated by the switching on of the blue warning light on the control
panel.
The alarm reason is displayed on the Ispector Control, with a graphic indication of where the alarm has occurred
and with an explanation text line, and can involve: the preparing device electric section, the operating mode of the
preparing device components or the link.
As a general rule, intervene to restore the operating conditions only after having checked the components involved
in the alarm and having stopped the machine.
If you need to stop and restart the machine, please refer to the relevant procedures (chapter 6); whereas if the
requested operation is only a reset the command can be activated by the control panel pressing the blue push-
button (1) or by the key on Ispector Control touch screen.

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5.5.4.5 CLEANER CONTROL STATION [OPT]

The containing case of the electric equipment of the clearer and the control panel are located in the back side of
the cleaner.

The control panel consists of:

 selector (5) to select the functioning mode: Automatic (A), Manual (B);
 blue push-button (1), if the light is on it requires the intervention of an operator (press it to reset the
alarms);
 white push-button (2), to select manual cycle; press (1) and (2) at the same time for 3 seconds, the white
light turns on to indicate manual mode:
- press the white push-button several times to obtain cleaner forward step by step movement
- press and hold the white push-button continuously to obtain a continuous forward
movement of the cleaner;
 mushroom-head push-button (3) to stop the cleaner.

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5.5.4.5.1 TUBE CLEANER ALARMS RESET

A resetting cycle must be carried out every time where there is a misalignment between the software cycle and the
drives of the single units or simply in the cases of resetting subsequent to an alarm.

The alarm status is signalled by the blue light on. The alarm reset is performed by pressing push-button (1).

Any time the cleaner is in alarm, the red lamp on the cleaner control panel turns on, and the alarm code and
description are displayed on the PC in the headstock.
The most frequent alarms are usually caused by obstacles to peg movements, or by a wrong position of the peg to
be processed, or by photocells darkened by dust or foreign objects.
The cleaner features specific cycles that, in case of overload, reposition the machine at the starting point. It may
therefore happen that a visual check will not highlight any more the root cause of the alarm (such as lint that has
broken).
If the cleaner has stopped due to a jam for a tube placed across the path, report to the maintenance engineer.
In all other cases, operator is recommended to follow the procedure below, respecting the step sequence:
7) visually check that the peg movement area is free from jams and obstacles (lints, tubes, dust, etc.);
8) ensure that the peg being processed is duly centred on pick-up gripper;
9) ensure that photocell (B1) above the jaws is free from flocks or lints;

After performing these checks, to ensure safety conditions, proceed as follows:

10) press the black mushroom-head push-button, cutting off power and disabling all pneumatic drives thereby
setting the solenoid valves in a rest condition
11) remove by hand any jams and reposition the peg, if required
12) reset the black mushroom-head push-button; an automatic reset cycle of the cleaner is then started (with
check routine of all sensors and photocells)

If everything is fine, the cleaner will work normally.

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If it is not so, the cleaner will stop again in alarm condition and the maintenance engineer intervention will be
necessary since he can view alarm type from the machine PC and react accordingly. It is usually not necessary to
use cleaner manual operating mode, except when motor up and downstroke end stops trip.
TABLE ABOUT TUBE CLEANER SEQUENCE OF OPERATION

No. Function Affected sensors and

solenoid valves
1 Peg control and stop at cleaner's infeed Reserve photocell B3
2 Reserve inlet stopper raises to release the peg Reserve inlet stopper YV2
3 The peg reaches work position and sets against the stopper Photocell B2
Work position stopper YV1
4 Punch moves down to cycle start position:
The punch can carry out two different cycles, according to tube length.
With tube length below 230 mm, the safety light curtain photocell B1 is
darkened at beginning of cycle.
With tube length equal to 230 mm or higher, the safety light curtain
Safety light curtain photocell
photocell B1 is not darkened at beginning of cycle.
B1
If tube length is below 230 mm, the punch frees up the safety light curtain
photocell and sets 5 mm above.
If tube length is equal to 230 mm or higher, the punch moves down to
darken the safety light curtain photocell and then moves up by 5 mm to
free it.
5 Closing the extractor plates Solenoid valve YV5

6 Piston-controlled peg lift (with resulting closing of the peg clamp)

and:
- check that work position Photocell B2 is free Solenoid valve YV3
- check that clamp position sensor SQ1 is free
- if PC settings require tube base check, the bobbin photocell B4 Photocell checking peg presence in
checks that tube has not too much yarn at the end during upstroke (if place B2
it is too much, the cleaner reverses drive direction and releases the
peg) Clamp position sensor SQ1
- check that safety light curtain Photocell B1 is darkened, i.e. that
tube tip is centred on the punch (otherwise the tube is probably Bobbin control photocell B4
engaged under the extractor plates: the cleaner tries twice to centre
the tube into extractor plates, and in case of failure it reverses drive Safety light curtain photocell B1
direction and releases the peg)
- check piston stem, through the extension limit switch (in this case Piston out limit switch SQ6
there is a jam and cleaner alarm is triggered)

7 Opening the extractor plates Bobbin control photocell B4

8 Peg upstroke until stripping start position, and:

- check (with bobbin photocell B4) that tube does not have too much
Bobbin control photocell B4
yarn on it (if it is too much, the cleaner reverses drive direction and
releases the peg)

9 Closing the extractor plates Solenoid valve YV5

10 Stripping with motor and rack, and: Cycle zero sensor SQ2
- check that the punch passes through the cycle zero probe (if it is
not so, it means there is a jam and cleaner alarm is triggered) Safety light curtain photocell B1

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- check, by counting motor steps, that tube has fully passed through
strippers Limit switch
- check that piston sensor SQ7 does not trip (in this case there is a
jam and cleaner alarm is triggered) Piston in sensor SQ7

11 - punch upstroke in cycle start position, when tube tip is above

strippers piston descent is controlled and peg is taken down.
Cycle zero sensor SQ2
Meanwhile, blow starts and economiser is opened to take in stripped
waste yarn.
Clamp position sensor SQ1
- check that punch reaches target onto cycle zero sensor SQ2
Photocell checking peg presence in
- check that the Safety light curtain photocell B1 is free
place B2
- check that peg clamp reaches target position on SQ1

12 Peg release with clean tube, and: Photocell checking peg presence in
- check that work position photocell is free place B2
- check that work mushroom-head switches
Work position stopper YV1
13 Peg presence photocell on cleaner
Check that released peg has arrived onto preparer photocell B3
section exit stopper B3 (belongs to
preparer)

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5.5.5 MAINTENANCE

INTRODUCTION

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push-button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Work on electrical equipment must only be carried out by a qualified electrician.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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5.5.5.1 BOBBIN PREPARER GENERAL CLEANING

ATTENTION!
The bobbin preparer must be cleaned with the machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

(gentle blow),
8 Bobbin preparer path cleaning Personal protection
equipment as required by the
laws of the country where the
machine is installed

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

Bobbin preparer path complete cleaning. (gentle blow).
Operation to be carried out removing the Manual tools,
24 lateral guards.
Personal protection
Check the general operation of the search equipment as required by the
cycle. laws of the country where the
machine is installed

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator.
Cleaning suction nozzles on pegs Personal protection
150 equipment as required by the
conveyor
laws of the country where the
machine is installed

Aspirator.
Manual tools,
Bobbin preparer conveyor belt pulley
150 cleaning (the top guard must be removed Personal protection
to perform this operation). equipment as required by the
laws of the country where the
machine is installed

Aspirator.
Peg rotation unit cleaning in the tail search
and insertion station (this operation Manual tools,
requires the removal of the upper guards; Personal protection
150
when working with paraffin wax we equipment as required by the
recommend to clean the unit at closer
laws of the country where the
intervals).
machine is installed

Cotton cloth,
Peg detecting photocell and tube laying Personal protection
150 equipment as required by the
down unit cleaning
laws of the country where the
machine is installed

Manual tools,
Compressed air system
Inserting station complete cleaning (this (gentle blow).
150 operation requires the removal of the
Personal protection
guards).
equipment as required by the
laws of the country where the
machine is installed

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

(gentle blow).
Yarn cutting and threading presence units
Spray oil Contrakor Fluid H1,
cleaning and lubrication.
Klüber,
300 WARNING: Be very careful when
Manual tools,
lubricating the yarn presence scissors and
do not let any oil get on the electronic Personal protection
feeler. equipment as required by the
laws of the country where the
machine is installed

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Oil HM 46,
Manual tools,
Check the lubrication unit oil level (top up if
750 Personal protection
necessary)
equipment as required by the
laws of the country where the
machine is installed

Manual tools,
Personal protection
750 Tube extraction ramp pinion cleaning equipment as required by the
laws of the country where the
machine is installed

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Manual tools,
Check inserting station chain lubrication, it Personal protection
1500 equipment as required by the
should feel partially greasy.
laws of the country where the
machine is installed

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator.
Cleaning movable conveyors, yarn suction Personal protection
4000 equipment as required by the
at peg base
laws of the country where the
machine is installed

lukewarm water and sodium

hydrate solution (40°C),
NOTE: Avoid using tools that
could scratch the inside
Bobbin tail suction nozzle cleaning.
4000 surface of the nozzle.
Remove the bobbin.
Personal protection
equipment as required by the
laws of the country where the
machine is installed

Manual tools,
Check conditions of the tail pick-up lever
profile (foot) where it usually touches the Personal protection
4000 equipment as required by the
bobbin body; make sure the lever axial
movement is smooth. laws of the country where the
machine is installed

Manual tools,
Checking tension of peg conveyor belts to Personal protection
4000 equipment as required by the
preparer
laws of the country where the
machine is installed

Compressed air system

(gentle blow).
Lubricant Asportec 70-07 –
Cleaning and checking tension of control Metaflux,
chain of the peg conveyors to preparer.
4000 Manual tools,
This intervention needs the upper and
lower guards to be removed. Personal protection
equipment as required by the
laws of the country where the
machine is installed

Compressed air system

(gentle blow).
Manual tools,
Check of the tube extraction station belt
4000
tension. Personal protection
equipment as required by the
laws of the country where the
machine is installed

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WARNING!
Failure to apply the above procedures, a residual risk of snatching, intoxication and dust
inhalation remains.

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Manual tools,
Checking operation of the tube selecting Personal protection
8000 equipment as required by the
combs
laws of the country where the
machine is installed

Manual tools,
Personal protection
8000 Replacement of the pegs spacer lever equipment as required by the
laws of the country where the
machine is installed

Manual tools,
Check the stretch value of the clamp
Personal protection
8000 supporting chain, and replace it if it is no
equipment as required by the
longer possible to keep the required
laws of the country where the
deflection value. machine is installed

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5.5.5.2 TUBE CLEANER MAINTENANCE

ATTENTION!
Bobbin preparer must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

(gentle blow).
Cotton cloth,
Extrusion area reflector and photocell
150
cleaning Personal protection
equipment as required by the
laws of the country where the
machine is installed

Personal protection
equipment as required by the
150 Check a complete tube cleaning cycle
laws of the country where the
machine is installed

Check integrity and functionality of the Manual tools,

emergency push button located on the Personal protection
150 control panel. When the push button is equipment as required by the
pressed it must stop all activities in laws of the country where the
progress in the tube cleaner. machine is installed

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Lubricant Molykote Dx,

Manual tools,
Clean and lubricate the spring (1) that
4000 Personal protection
locks the peg on the elevator trolley edge equipment as required by the
laws of the country where the
machine is installed

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5.5.5.2.1 STRUT REPLACEMENT THRUST

Make sure the pusher strut is the right one for the type of tube that is going to be used. The definition of the
geometrical features of the strut can be found in the table in paragraph "TUBE CLEANER MATERIAL TECHNICAL
DATA"
Change the pusher strut proceeding as follows:
- Loosen the nut (1);
- Unscrew the pusher strut (2) and screw down the new one until it comes up against the supporting trolley;
- In case of tubes with L between 180 and 230 position a spacer (3) between trolley (4) and punch.

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5.5.5.2.2 CHANGING THE EXTRACTOR PLATES

Make sure that the extractor plates are the right ones for the type of tube that is going to be used. The definition of
the geometrical features can be found in the table.
Change the extractor plates proceeding as follows:
- remove the two pairs of screws (1) and remove the extractor plate securing block (2);
- pull out the top metal extractor plates (3) and the bottom rubber ones (4);
- check that the cutting edge of the new metal extractor plates is perfect and then put them in place in the
tube cleaner with the cutting edge facing upwards. The rubber plates must be positioned with the flared part facing
down;
- put the block back (2) and screw the screws (1) down without tightening them;
- with the push-button panel commands and in the manual feed mode, move forward with the cycle up to
when the extractor plates close round the base of the tube (start of the yarn stripping phase). In this position, centre
the extractor plates by hand with the tube and then tighten the pairs of screws (1);
- make sure the knife is locked with the locking dowel (5);
- the control cam movement extent can be adjusted by the screw (6), working as a limit switch, locking it with
the nut.

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5.5.5.2.2.1 ADJUSTING EXTRACTOR PLATE STROKE

The tube cleaner must be in the Manual operating mode when adjusting and checking the extractor plates.
The horizontal stroke of the extractor plates (1) derives directly from the vertical stroke of the control cams (2).
Where the extractor plates close completely (1), distance A – relative to the vertical stroke of the control cams (2) –
must be equivalent to that given in the figure below.
Once adjusted, check that:
 the extractor plates are the same distance from the tube surface;
 during the cycle, the surface of the tube stays in contact with the extractor plates up to about 80 mm from
the nose of the tube.

The control cam (2) movement can be adjusted by the screw (1), working as a limit switch.

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5.5.5.2.3 ADJUSTING THE PEG LOCK LEVER

With the elevator trolley in peg (1) pick-up position, ensure that the peg (2) centring semicircular area is below the
conveyor belt (not visible in the figure), at distance A.
Distance A can be reached by changing the position of nut (3), used as a stop for the elevator trolley in pick-up
position.

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5.5.5.2.4 POSITION OF THE STRIPPING AREA CONTROL PHOTOCELL

Set photocell B1 (1) so that it is aligned with reflector (2), located on the opposite side.
Also ensure that photocell reading line intersects tube (3) vertical axis, when in stripping position (see figure).
If required, adjust photocell support mounting position.

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5.5.5.2.5 POSITION OF THE CYCLE SENSOR

The cycle sensor SQ3 (1) is used to detect the mechanical zero point of the tube cleaner cycle.
The zero point is defined when there is an exact match between the value set on the Ispector Control in the Initial
Millimetres field and the first point of contact of the jaws with respect to tube base (start of the yarn waste stripping
cycle).
Any variations can be achieved by altering the position of the sensor support.
To define the position of the support it is necessary to:
 use a sample tube with the relative settings on the Ispector Control (Tube Length and Initial Millimetres
in the TUBE CLEANER folder);
 use the tube cleaner in the Manual mode.
The distance between the sensor and relative reference (on the strut trolley) must be between 1 and
1.5 mm.

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5.5.5.2.6 POSITION OF THE CLEANING BLOW

The nozzle (1) must be positioned, with respect to the pusher strut (2), so that the surface of the strut touched by
the blow is about 10 ÷ 15 mm from the end that is touching the tube.

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5.5.5.2.7 POSITION OF THE ECONOMISER GATE VALVE

The gate valve, in closed position (3), must be at distance A from economiser edge.
Any changes to distance A can be obtained by changing the position of the gate valve with respect to the control
cylinder stem (4).

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5.5.5.2.8 POSITION OF THE SAFETY SWITCHES

The position in which the safety switches (1) are mounted must allow for an additional extra stroke of the mobile
feelers (2) if the former are activated due to an extra stroke of the trolley with the strut.

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5.5.5.2.9 ADJUSTING THE YARN CUTTING BLADE

It is necessary to align the knife slot present onto guide column (1), with the notch present on the strippers support
jaw (2).
The column is aligned operating on the upper end (3).

The cutting device is adjusted as follows:

 remove the block (1) and insert the knife (2);

 loosen the securing screw (3);
 position the tube and close the jaws, starting the tube cleaner cycle in the Manual mode;
 bring the knife close by turning the screw (4) until it is 0.2 mm away from the tube’s surface;
 tighten the knife securing screw (3);
 run a few trial cycles to make sure the blade cuts the tube;
 carry out the same steps for the opposite blade.

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5.6 BOBBIN TAIL SEARCH UNIT ON SECTIONS
5.6.1 TECHNICAL DESCRIPTION
5.6.1.1 BOBBIN TAIL PICK-UP STATION

The tail pick-up unit is aimed at preparing the bobbins with the tail threaded in the tube hollow section, so that the
tail can be later grasped by the packaging unit.
This unit comprises:
 Peg rotation group (1);
 Live centre (2);
 Threading centre (3);
 Tail pick-up lever unit (4);
 Bobbin tail suction nozzle (5);
 Group checking the presence of sucked tail (6);
 Group cutting the sucked tail (7);
 Box containing the electronic cards (8);
 Solenoid valves (9);
 Peg stop at outfeed (10);
 Peg transfer disc (11);
 Disc rotation motor (12);
 Peg conveyor belt at infeed (13);
 Peg conveyor belt at outfeed (14);
 Rejected peg conveyor belt (15);
 Peg rejection shunting lever (16);
 Peg presence feelers (17);
 Disc positioning photocell (18);
 Peg positioning and yarn breaker lever (19);
 Self-levelling feet (20);
 Supporting plate (21).

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5.6.1.2 PEG ROTATING UNIT

This unit rotates the peg for the operations relative to the bobbin tail pick-up and suction. Peg rotation direction
depends on the operation to carry out.
This unit comprises:
 Motor (1);
 Peg driver (2);
 Toothed belt (3);
 Pulleys (4);
 Spring (5).
The peg is transferred by the peg transport disk and positioned by the peg positioning lever. When this is pressed
downwards against live centre spring (5), it is centred by the centring internal side (2a) of driver (2) and it touches
the rubber external side (2b). Then the motor (1) rotates the peg by driving.

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5.6.1.3 LIVE CENTRE UNIT

The live centre is aimed at keeping the bobbin tube vertical during the rotation driven by the peg rotation unit.
This unit comprises:
Rotating centre (1) on bearings;
Centre swinging arm (2);
Piston (3);
Position probe (4);
Magnet (5);
Support rotation fulcrum (6);
Adjustment block of the arm stop (7);
Unit height adjustment support (6).

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5.6.1.4 BOBBIN TAIL PICK-UP LEVER UNIT

The bobbin tail pick-up lever unit lifts the bobbin’s binding coil by means of the vertical movement of a chisel-
shaped lever along the body of the bobbin to detach the tail and allow tail suction by the nozzle.
The downward movement of the lever is activated by the bobbin which rotates in the yarn winding direction.
This unit comprises:
 Tail pick-up lever (1);
 Thrust spring to tail pick-up lever (2);
 Blower tube (3);
 Support (4) for units (1) and (2);
 Grooved plates (5) for guiding the tail pick-up unit;
 Pneumatic cylinder (6) driving the tail pick-up unit;
 Tail pick-up lever position sensor (7);
 Shaped guard (8) to protect the tail pick-up lever;
 Group mounting bracket (9).

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5.6.1.5 GROUP INTAKE SUCTION ROLL TOP COP AND CONTROL WIRE EXTRACT

The suction nozzle is aimed at sucking the bobbin tail and unwinding a preset quantity.
The nozzle is set in suction by opening the economiser, while the bobbin unwinding is carried out by the bobbin
holder peg rotation in the yarn unwinding direction.
The tail extraction from the nozzle is obtained upon economiser closing and the control unit of the extracted yarn
has the function to ensure that the yarn unwound from the bobbin actually exits the nozzle.
This unit comprises:
 Tail suction nozzle (1);
 Mobile economiser (2);
 Pneumatic cylinder for economiser (3) driving;
 Economiser and piston support (4);
 Yarn clamping sensor (5);
 Extracted yarn reading sensor (6);
 Nozzle supporting bracket (7).

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5.6.1.6 GROUP THREAD TRIMMING EXTRACT

The yarn cutting unit is aimed at cutting the bobbin tail after that the control unit checks that the yarn unwounded
from the bobbin actually exited the nozzle.
This unit comprises:
 Scissors unit supporting bracket (1);
 Yarn guide introducer (2);
 Fixed scissors blade (3);
 Mobile scissors blade (4);
 Scissors drive pneumatic cylinder (5).

The yarn sucked by the bobbin tail nozzle, when economiser turns off, passes through the slot in nozzle front side
and then, once extracted, gets to the extracted yarn sensor reading, which checks its actual presence. With peg in
threading position, after entering the yarn guide introducer (1), extracted yarn sensor controls scissors for yarn
cutting.

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5.6.1.7 BOBBIN TAIL THREADING UNIT

The unit is aimed at threading the bobbin tail - already extracted and cut - inside the bobbin tube.
This unit comprises:
 Yarn accompanying guides (1) from tail pick-up position to threading position;
 Centre (2) with slot;
 Hub (3) with slot and threading cone;
 Couplings (4) for threading blow air;
 Centre swinging support (5);
 Centre arm (6);
 Position probe (7);
 Magnet (8);
 Arm starting cylinder (9);
 Venturi system (10) for tail suction.
The peg with the bobbin on board, as soon as the sensor detects that yarn (A) has been extracted, is transferred by
transfer disk to threading position (B); the tail is driven by the guides (1) and enters the hub (3) and the centre (2).
Then it is cut and blown/sucked inside the bobbin tube.

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5.6.1.8 LEVER POSITIONING PLATE AND BREAK TAIL

This unit has the function to position the peg on the peg rotation unit and to break the yarn wound around the
bobbin base.
This unit comprises:
 Peg positioning lever (1);
 Peg positioning lever drive cylinder (2);
 Yarn breaker lever (3) with blade (4);
 Yarn breaker lever drive cylinder (5).

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5.6.1.9 GROUP DISK TRANSPORTER

The group receives pegs from infeed belt, transfers them to tail pick-up and threading positions and then takes
them inside the machine. Peg rejection and shunting lever is used to recirculate bobbins whose tail was not picked
up.
This unit comprises:
 Transfer disc (1);
 Peg conveyor belt at infeed (2);
 Peg conveyor belt at outfeed to machine (3);
 Rejected peg conveyor belt (4);
 Peg rejection and shunting lever (5);
 Peg inlet track (6);
 Peg outlet track (7).

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5.6.2 TECHNICAL DATA

INTRODUCTION

Since no special specifications are available for the bobbin tail section search group, all its technical data are
included in the machine overall specifications.

Please consult chapter 2 of this manual.

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5.6.3 ADJUSTMENTS

INTRODUCTION

This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety, by reading and appropriately
consulting this paragraph.

ATTENTION!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

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5.6.3.1 SETTING TAILSTOCK MOBILE

ATTENTION!
Before starting any adjustment work on the belts, it is necessary to forbid access to the area
around the machine headstock area in order to keep the area segregated and inaccessible to
other workers

Adjust the height of the live centre unit as follows:

 Loosen the screws (3) and when peg with bobbin is present, fasten the unit so that the centre (1) allows the
tube end to easily enter;
 once the piston is activated, work on the screws (3) so that the centre arm (2) is parallel to the base and
presses against the tube end in order to push the peg against the rubber side of the peg rotation unit driver;
 the push against the rubber side of the driver must ensure bobbin rotation during search phases; work on
the screws (3) if necessary;
 check that probe (4) is activated by arm (2) pushing on the bobbin tube end;
 once adjustment is completed, check that no collisions occur during tail pick-up cycle.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and crushing remains.

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5.6.3.2 SETTING GROUP INTAKE COP

ATTENTION!
Before starting any adjustment work on the belts, it is necessary to forbid access to the area
around the machine headstock area in order to keep the area segregated and inaccessible to
other workers.

This unit needs the following adjustments:

 adjust nozzle depth to 2-3mm from the sample bobbin surface; work on the screws (1) of the fastening
plane (2);
 check that the nozzle is aligned with bobbin axis; shim the fastening surface (2) if necessary;
 check that the economiser (3) has a gap of 4 mm when closed. The opening extent of the economizer
mobile blade (4) can be adjusted through the fastening nut (5) on the stem of the control cylinder and the
cam (6);
 Adjust the position of the yarn guide introducer (7) working on the screws (8) and make sure that the yarn
enters the scissors (9) and sensor (10) in the correct position.

It is possible to have a min. height adjustment of the nozzle for special bobbin sizes. Its position must follow the
bobbin profile. If the original position of the nozzle changes, make sure that when the tailstock closes, on a peg
without bobbin, it does not impact the nozzle upper part, damaging the thread sliding profile. Adjustment is obtained
by changing bracket fastening point.
The opening extent of the economiser (3), check to be made in at-rest position, depends on the type of used yarn.
Anyway, it shall ensure a secure yarn tensioning while transferring the peg to the threading position.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching, crushing and cutting
remains.

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5.6.3.3 ADJUSTMENT LEVER START SEARCH HANK COP

ATTENTION!
Before starting any adjustment work on the belts, it is necessary to forbid access to the area
around the machine headstock area,
in order to keep the area segregated and inaccessible to other workers.

TROLLEY STROKE
When the pneumatic cylinder stem is completely out, the trolley unit (1) must comply with the dimension
A = 109.5 ÷ 110 mm.
Distance A can vary according to the position in which the pneumatic cylinder stem is installed in relation to the
trolley.

BOBBIN TAIL PICK-UP LEVER DISTANCE

This adjustment depends on the diameter of the bobbin in use.
With the bobbin tail pick-up lever (6) positioned on the straight part of the guide cam, it should have an extra travel
compared to the bobbin body equal to distance B = 7 ÷ 8 mm.
Distance B is determined by the position in which the lever unit is installed in relation to the support.

POSITION OF THE TROLLEY’S GROOVED CAM GUIDE

Small variations (approx. 10 mm) are possible in the length of the contact area of the tail pick-up lever on the
bobbin body, by changing the position in which the guide cam is mounted in relation to the slots on the main
structure.
The movable cam is the one opposite the unit fixing flange and is the one that controls the lever return phase.
Adjust with screws (2).

HEIGHT OF THE TAIL PICK-UP UNIT

The whole tail pick-up unit must be in a position so that the area in which the lever operates is always in the
cylindrical part of the bobbin, preferably at the bottom.
The position of the station can vary, by means of the slot along the supporting bracket.

LEVER TRANSLATION SPEED

Translation speed can be varied by means of the adjusting device (3) on the pneumatic cylinder.
The duration of the lever’s active travel on the bobbin can be consulted in the “PREPARER REPORTS".
Speed, according to the type of binding on the bobbin body, is normally between 400 and 600 ms.

S/Z YARNS – LEVER POSITION

The tail pick-up lever has to be oriented according to the type of twist in the yarn (S or Z).
Positioning is determined on the basis of guide (4) assembly configuration, according to what is printed on the edge
of the guide itself.

BOBBIN TAIL PICK-UP LEVER POSITION SENSOR

Position sensor (5) so that the distance from the stop is 1.5 ± 0.2 mm.

ALIGNING THE BOBBIN TAIL PICK-UP LEVER

After specific work has been done it might be necessary to reposition the whole tail pick-up station and supporting
structure.
In such an event, alignment between the path of the tail pick-up lever and bobbin axis must be guaranteed.
Positioning is obtained by varying the position in which the square support is installed in relation to the holes on the
base plate.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching, crushing and cutting
remains.

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Ref. Description
7 Bobbin dir. of rotation for yarn tail suction
8 Bobbin unwinding direction and foot operation
9 Tail pick-up position indicator
10 Bobbin dir. of rotation for yarn tail suction
11 Bobbin unwinding direction and foot operation
12 Tail pick-up position indicator

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5.6.3.4 SETTING GROUP INSERTION THE BEGINNING HANK COP

ATTENTION!
Before starting any adjustment work on the belts, it is necessary to forbid access to the area
around the machine headstock area,
in order to keep the area segregated and inaccessible to other workers.

This unit needs the following adjustments:

 In case of peg with sample bobbin and with piston not active, the tube end must enter without interfering
with the centre with slot (1). If necessary, work on the height positioning screws of the whole unit;
 Then check that the live centre with piston active, slightly presses against the tube end; adjust the screw
(3) if necessary;
 Check that peg with bobbin transfer from search position to threading position is carried out freely and
smoothly and that the yarn is correctly guided by the yarn guide (2) inside the centre with slot (1);
 Adjust so that the sensor (4) is activated by the centre touching the bobbin tube end.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching, crushing and cutting
remains.

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5.6.3.5 ADJUSTMENT LEVER POSITIONING PLATE AND BREAK TAIL

ATTENTION!
Before starting any adjustment work on the belts, it is necessary to forbid access to the area
around the machine headstock area,
in order to keep the area segregated and inaccessible to other workers.

The peg positioning lever requires the following adjustments:

 Manually centre a peg with bobbin, above the rubber-coated driver of peg rotation group. Close live centre
so as to obtain a downward push on the peg;
 Use nut and lock nut (1) to adjust piston rod length until peg positioning lever (2) grazes peg collar;
 Adjust the piston stem using nut and lock nut (3) until the yarn breaker (4) touches the bobbin tube at
around 3mm from the tube base;
 Check parts centring by feeding 4-5 pegs in a row.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching and crushing remains.

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5.6.4 USE INSTRUCTIONS

INTRODUCTION

Since no special use instructions are available for bobbin tail section search unit, this document includes use
instructions for the machine body, as for all machine components.

Please consult chapter 6 of this manual.

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5.6.5 MAINTENANCE

INTRODUCTION

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push-button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Work on electrical equipment must only be carried out by a qualified electrician.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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5.6.5.1 GENERAL CLEANING GROUP RESEARCH BRANCH ROLL TOP COP

ATTENTION!
The unit must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

(gentle blow),
Manual tools,
8 Unit general cleaning
Personal protection
equipment as required by the
laws of the country where the
machine is installed

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

Complete cleaning of tail pick-up unit path (gentle blow),
 Operation to be carried out Personal protection
24 removing the lateral guards equipment as required by the
 Check the general operation of laws of the country where the
the search cycle machine is installed

Cotton cloth,
Manual tools,
Cleaning, by a cloth, of the reading area (2)
24 of the sensor (1) for thread presence on the Personal protection
economizer. equipment as required by the
laws of the country where the
machine is installed

Manual tools,
Visual check, from the transparent Personal protection
24 inspection windows, of the cleaning of the equipment as required by the
peg conveyor belt pulleys. laws of the country where the
machine is installed

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Cleaning of the belt pulleys transporting Manual tools,
bobbin tail section search unit.
150 Personal protection
This intervention needs the upper guards equipment as required by the
to be removed. laws of the country where the
machine is installed

Aspirator,
Peg rotation group cleaning.
Manual tools,
This intervention needs the upper guards
150 to be removed; when working with paraffin Personal protection
wax we recommend to clean the unit at equipment as required by the
closer intervals. laws of the country where the
machine is installed

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Yarn cutting and threading presence units Compressed air system

cleaning and lubrication (gentle blow),

 Clean the unit scissors: Yarn Lubricate with spray oil

Contrakor Fluid H1, Kluber,
presence and cut and threading.
300 Manual tools,
WARNING: Be very careful when Personal protection
lubricating the yarn presence scissors and equipment as required by the
do not let any oil get on the electronic laws of the country where the
feeler. machine is installed

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Cleaning movable conveyors, yarn suction Personal protection
4000 equipment as required by the
at peg base
laws of the country where the
machine is installed

Bobbin tail suction nozzle cleaning lukewarm water and sodium

hydrate solution (40°C),
 Bobbin tail suction nozzle
4000 disassembly and cleaning. When Personal protection
cleaning, do not use tools that equipment as required by the
could scratch the inside surface of laws of the country where the
the nozzle machine is installed

Manual tools,
Check tail pick-up lever profile (foot) where Personal protection
4000 it usually touches the bobbin body; make equipment as required by the
sure the lever axial movement is smooth. laws of the country where the
machine is installed

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching, intoxication and dust
inhalation remains.

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5.7 PACKAGE CONE MAGAZINE [OPT]

5.7.1 TECHNICAL DESCRIPTION

The package cone magazine automatically supplies cones to the doffing trolley. The unit includes:
1) a chain with cone holding pegs;
2) a cone conveyor;
3) a control panel;
4) box to house the electric equipment.

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Either a single or double package cone magazine can be installed. The double magazine is made up of two
identical, independently operating sections which can be loaded with two different types of cones (either different
colours or different sizes).
The capacity of each section is 138 cones. Both sections deliver their tubes to a single cone conveyor belt which
services the entire machine.
The twin-section magazine is installed for the simultaneous production of packages with different taper or yarn
count.
The twin-section magazine can service 1 or 2 trolleys, either ”with or without on-board cone reserve”. The following
conditions can be true:

Twin-section magazine with two different types of cones of different sizes. 2 trolleys “with on-board reserve”
Twin-section magazine with two types of cones of different colours but of 1 trolley “without on-board reserve”
the same size 2 trolleys “with on-board reserve”

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5.7.2 TECHNICAL DATA

PREMISE

Since no special specifications are available for package cone magazine, all its data are included in the machine
overall specifications.

Please consult chapter 2 of this manual.

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5.7.3 ADJUSTMENTS

PREMISE

This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety, by reading and appropriately
consulting this paragraph.

ATTENTION!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

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5.7.3.1 CONE EJECTOR LEVER

LEVER POSITION
The tube ejector lever (1), in rest position, shall be under the level of the tube-holding chain, as shown by the value
(A); further, in its movement, it shall comply with the values (B) and (C) to reach then the front dead center, where
the clearance indicated by the value (D) must be ensured; for the adjustment, operate the pair of screws (2) and
(3).

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5.7.3.2 APPROACHING DEVICE(ONLY FOR CONES WITH A L < 155 MM)

If cones shorter than 155 mm are used, adjust the approaching device (2) so that, with the cone (1) resting against
the chain, the clearance between the cone and approaching device is equal to distance A.
Adjust with the screw (3), used to bring the approaching device closer to the chain line, up to a minimum of 100 mm
(distance B).

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5.7.3.3 CONE HOLDER SUPPORTS

There are two different supports depending on the size of the cone used.
The support with a 25 mm outside diameter is suitable for using with cones with up to a minimum inside tip
diameter (plain or inverted) of 26 mm;
the support with a 14 mm outside diameter is suitable for using with cones with an inside tip diameter ranging from
16 to 26 mm as shown in the figure.

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5.7.3.4 CONE HOLDER CHAIN

BELT ASSEMBLY AND TENSIONING

The belt must be assembled so that, with respect to the direction marked by the arrow, it is positioned as shown in
the figure.
It is tightened by loosening the screws (2) and acting on the plate (3) until there is a torque of 4 Nm (Max) (torque
wrench) on the pinion gear axis (1).

TENSIONING OF CONVEYOR CONTROL MOTOR BELT

To correctly tension the control belt (6) apply a force F = 4 N as shown in the figure, so as to obtain a deflection f =
3 ÷ 4 mm; if necessary act on the screw (5) after having loosened the motor support screws (4).

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5.7.3.5 CONE CONVEYOR BELT

BELT ASSEMBLY AND TIGHTENING

To carry out this adjustment proceed as follows:
1) Mark two points on the belt at a distance “A” = 2000 mm as shown in the figure;
2) place the belt on the driving pulley (1);
3) remove the return pulley (3) after having unscrewed the relative pin; fit the belt in the pulley’s race;
4) fix the fork (4) on the hole (2) using the pin;
5) reposition the pulley (3) with the belt on board, using the relative pin;
6) check that the distance between the two previously marked points (distance A) is now equal to distance (A1)
of the following table.
If necessary reposition the pulley (3), moving the pin from hole (2) over to the adjacent one;
7) check that the belt is in the middle of the pulley’s race.

SINGLE / DOUBLE MAGAZINE

Distance
No. units
A1
Up to 20 2008
from 24 to 44 2010
from 48 to 64 2012

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CONE SENDING BELT ALIGNMENT

The belt can be aligned by acting on the control plate retaining screws operating as shown in the figure:
 a. loosen the nuts (1) and (2);
 b. start the belt driving motor;
 c. adjust the alignment acting on screw (3);
 d. screw the nuts under the plate fully into positions (1) and (2) so as to prevent the plate from moving;
 e. tighten the nuts that are in positions (1), (2) and (3).


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CONE SENDING BELT MOTOR CHAIN TENSIONING
Applying a load F = 4 N to the centre and vertically to the tract A of belt (1) there must be a deflection f = 3 mm.

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5.7.3.6 PROBE POSITION

The distance from the sensors (2 - 3) strike must be equal to value A = 2 mm.
The sensor screws must be tightened to a torque of 1.5 Nm (torque wrench).
The tube presence probe supporting bracket (1) has a double drilling.
Use the couple of drills ”F1” for tubes with outside diameter up to 60 mm, while for tubes with larger diameter fasten
the bracket using the couple of drills ”F2”.

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5.7.4 USE INSTRUCTIONS
5.7.4.1 CONTROL PANEL

The control panel placed on the magazine front side includes:

 Start control (1);
 the switch (2) for the "automatic" (A) or "manual" (B) operation;
 Stop push button (3).

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5.7.4.2 SPLICING CYCLE

5.7.4.2.1 LOADING OF CONES ONTO A TROLLEY “WITH ON-BOARD TUBE RESERVE”

The doffing trolley usually is equipped with a cone.

When the trolley starts the doffing cycle, the magazine receives a cone request signal.
The ejector (1) removes the tube (4) waiting at the entry of the chute (5) from the stake, making the tube fall on the
belt (6) transporting it to the trolley.
The cone-holding chain (3) activates till taking a new cone in the ejection area and it is stopped when the probe
operated by the lever (2) detects its presence; if the chain moves for 3 minutes without the probe detecting an
available tube, an alarm will be activated to signal the need for loading new tubes.

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5.7.4.2.2 LOADING OF CONES ONTO A TROLLEY “WITHOUT ON-BOARD RESERVE”

When the trolley stops at a unit that has reached the required length, it sends a signal to the head which requests
the appropriate cone in the respective section 1 or 2 of the magazine.
The trolley and the cone magazine will begin their cycles at the same time. At a certain point in its cycle, the trolley
will wait for a cone to be delivered; when the cone arrives, it will continue its cycle.

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5.7.4.3 HOW TO LOAD CONES

When there are no more cones in the centralised magazine, the lamp in the Start push button (1) on the control
panel flashes.
The operating sequence for loading cones in the magazine is the following:
 prepare the cones to use on the cone holder support accessible to the operator (at the bottom of the
magazine);
 set the switch (2) to the manual position (B) and activate the start (1), so as to start the chain and enabling
the load to the other stakes, as well.
Note: it is recommended to load a single cone for each stake, paying attention to the fitting
direction.
 put the selector switch back to the automatic position (A) and give the start command.

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5.7.4.4 ALARMS

ACTIVATION
The presence of alarms concerning the cone magazine is signalled by the blinking of the lamp of the Start push
button (1) in the control panel.
The occurrence of alarms due to failed communication with the Ispector Control is indicated by the blinking of the
main signalling lamp placed on the tube extraction ramp and with the alarm reason displayed on the Ispector
Control.

RESET
As a general rule, intervene to restore the operating conditions only after having checked the components involved
in the alarm and having stopped the peripheral.
The peripheral stop and re-start procedures are described in the paragraph 6.2. (single peripheral stop/re-start).
In case of communication alarms (main lamp switching-on) the reset control can be sent by the main panel (1) or
by the key on the Ispector Control.

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5.7.5 MAINTENANCE

PREMISE

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio S.p.A. Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Only a qualified electrician is allowed to work on the electrical equipment.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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5.7.5.1 PACKAGE CONE MAGAZINE GENERAL CLEANING

ATTENTION!
Package cone magazine must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS"

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Compressed air system
(gentle blow),
8 Package cone magazine general cleaning
Personal protection
equipment as required by the
laws of the country where the
machine is installed

Aspirator,
Manual tools,
Clean the ratiomotor, reserve
8 Personal protection
compartment and cone conveyor tail
equipment as required by the
laws of the country where the
machine is installed

CLEANING
SERVICE INTERVAL every 8 hours
General cleaning by gently blowing compressed air.
Clean the ratiomotor, reserve compartment and cone conveyor tail. The guards on the front of the magazine have
to be removed for this job.

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Brush with hard bristles,

Personal protection
150 Cone conveyor cleaning equipment as required by the
laws of the country where the
machine is installed

SERVICE INTERVAL every 150 hours

Clean the cone conveyor belt with a hard bristle brush.

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Personal protection
750 Belt guide cleaning equipment as required by the
laws of the country where the
machine is installed

SERVICE INTERVAL every 750 hours

Clean the belt guide all along the machine and check that the cone conveyor belt is centred.

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Manual tools,
Clean tension of the belt of the pin chain’s Personal protection
8000 equipment as required by the
command motor
laws of the country where the
machine is installed

SERVICE INTERVAL every 8000 hours

Clean tension of the belt of the pin chain’s command motor.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching, intoxication and dust
inhalation remains.

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5.8 AUTOMATION TROLLEY
5.8.1 TECHNICAL DESCRIPTION

The trolley is a mobile automatic unit along the front of the machine that handles doffing of the
finished packages, insertion of a new tube, formation of the buffer on the bottom of the tube and subsequent
restarting of the collection units.
The trolley is equipped with two sets of wheels on guides. One set is motorized for movement. The sets rest on the
support guides of the trolley.
It is attached to a flexible cable-support chain located at the rear in the centre of the machine, which supplies it with
electrical and pneumatic energy, and stops in front of each unit, attaching to the guides with brakes.
Referring to the figure below:
trolley structure
brake for attaching to the guides
group with motor-driven guide wheels
free wheels

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The figure shows other details. On the inside of the right and left side of the trolley, there are
ratiomotors and electric/pneumatic components for activating and controlling the automated parts. The
automated parts are located in the compartment between the two sides of the trolley.
The trolley is equipped with a control panel with a 3-digit display, multi-function keys (automatic, manual),
emergency push-button.
Two LEDs on the upper sides indicate the movement direction of the trolley. Two lower photocells act as a
safety device against contact with the operator by causing the trolley to slow down. Also, on the two external
sides,
near the photocells, additional safety devices stop the trolley in case of contact
with an object.
At the end of the trolley there are two elastic bumpers.
1) control panel with 3-digit display
2) brake release push-button
3) emergency push-button
4) alarm and direction indicator LEDs
5) photocells for trolley inversion
6) elastic bumpers
7) push-buttons for selection of cycles, start, stop
8) side safeties.

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In the figure, viewed from above, you can see:
. the safety micro-switch which acts on the two cams located at the right and left ends of the
winder,
- the movement motor connected to the set of drive wheels,
- the set of free wheels,
- the connection point to the electric and pneumatic supply line,
- the elastic bumpers to absorb shock of impact with the ends of the guides or with the
second trolley.
1) overrun safety micro-switch
2) driving motor
3) set of drive wheels
4) set of free wheels
5) connection point for power supply line
6) elastic bumpers
7) brake for attaching to the guides
8) chain cables shunt terminal board
9) containment and guide rollers

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The figure shows the inside of the left side of the trolley, and the location of components can be noted.
The location of controls is shown:
1) cone pick-up and delivery group
2) cone pick-up grippers
3) cone aligner
4) cone separator group
5) motor drive group for the yarn gripping, cutting and delivery group
6) control panel group
7) bar code reading unit

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The figure shows the inside of the right side of the trolley, and the location of components can be noted.
The location of controls is shown:
1) yarn gripping, cutting and delivery group
2) grippers and yarn-cutting scissors
3) yarn gripping control unit
4) buffer yarn insertion group
5) buffer yarn insertion lever
6) package pushing lever

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The figure shows the outside of the right side, with the cards, solenoid valves, pneumatic equipment and motor
drive of the group for arm raising and opening:
1) yarn buffer motor group card
2) package pushing unit card
3) solenoid valves
4) pneumatic equipment
5) package control unit motor
6) terminal board
7) contactor
8) power supply control card 60 V DC
9) 60V/24V supply unit

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The figure shows the outside of the left side, with the cards, solenoid valves, and motor drive of the
cone gripper and delivery group:
1) scissor piston motor group card
2) trolley management CPU card
3) solenoid valves
4) tube pick-up and delivery group motor drive
5) cone pick-up motor card
6) driving motor card

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5.8.1.1 TUBE PICK-UP AND DELIVERY GROUP

The group picks up the tube in the cone basket of the winding head. The group turns, the separator lowers and
stops, moving the other cones away from the one to be picked up. The self-centring grippers grasp the cone.
The group turns again until lined up with the loading position. A deflector moves the tubes so that it passes through
the grippers, so as to centre the tube in the space between the centres. The same device includes the tube aligner
which rests on the fixed centre, to align the tube between the centres.
Once the centres close, the grippers open and the group returns to its at-rest position, retracting the tube separator
as it returns.

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5.8.1.2 CLAMPING GROUP, CUTTING, DELIVERY OF YARN

With the group stopped, the large piston makes a first movement. The piston on the side extends and moves the
scissors/gripper at a right angle to the yarn to be picked up under the package yarn nozzle. The group rotates until
it intercepts the yarn. The grippers close on the bobbin tail to be held and cut the winder bobbin tail to be released.
The group rotates, moving clear of the nozzle. The large piston retracts. The group rotates further until the yarn is
past the live centre. The large piston extends partially (the positioning of the yarn is aided by the buffer yarn
insertion group), while the piston on the side turns so that the yarn passes through the middle of the centre.
When the centre is closed, the bobbin tail is blocked between the centre and the cone.
The large piston retracts, the group rotates in the opposite direction until it is at the at-rest position.

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5.8.1.3 BUFFER YARN INSERTION GROUP

The group aids the grippers, cutting and delivery group in the insertion of the bobbin tail between the cone and the
fixed centre, with the hook lever.
Once the yarn has been blocked between the centre and the tube, the hook lever moves so as to
position the bobbin tail on the bottom of the tube. The cylinder rotates creating the buffer. Finally, the hook lever
releases and returns to its at-rest position.

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5.8.2 TECHNICAL DATA

PREMISE

Since no special specifications are available for the automation trolley, all its technical data are included in the
machine overall specifications.

Please consult chapter 2 of this manual.

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5.8.3 ADJUSTMENTS

INTRODUCTION

This chapter, dedicated to the PERSONNEL in charge of running the machine, includes the adjustments to be
made to the various devices that make up the machine.
The qualitative and quantitative results required can be achieved, in complete safety, by reading and appropriately
consulting this paragraph.

WARNING!
To ensure machine is used under safe conditions, before reading through this chapter please
make sure you are familiar with the content of paragraph 1.2 “General Safety Provisions”.
As far as this chapter is concerned, any specific provisions to safely interface with the machine
are detailed in the paragraphs below.

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5.8.3.1 PRELIMINARY INSPECTION AND ADJUSTMENTS

Before proceeding with specific adjustments group by group, here are some general adjustments that need to be
checked:
following any maintenance work,
to avoid clearance problems,
based on the type of tube to be used.

STEP 1
adjust the group as shown in the figure, guaranteeing the value of 12 mm.

STEP 2
after adjusting the stop as shown in the figure (Draw. 1) check the values indicated in the figures (Draw. 2-3).

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STEP 3
cutting the trolley off and releasing the pressure to the scissors rotation piston, check that the group rotated in the
direction of the arrow does not stop at an angle wider than 20° to support (A).
This way, while rotating, the group must not interfere with the reserve rod (B) (Dwg. 1), thereby guaranteeing the
scissors group closing angle of 83° as shown in the figure.

STEP 4
Check, in operating conditions, that the yarn deflects from 2 to 4 mm when tangent to
the centres, as shown in figure A, and possibly intervene on the value 10 as described in the step 1.

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5.8.3.2 TROLLEY PRECISE POSITIONING

Near the baskets, on the basket support bed, there is a bar code for every collection unit. The bar code is created
to identify the unit order number and to allow precise trolley positioning on the collection unit.
Before adjusting the trolley according to the unit, proceed as follows:
1) position the basket on the first unit with respect to the centres (see 5.5.3.8)
2) adjust the trolley with respect to the packaging unit as follows:
A) Position the trolley over the first or last collection unit and lock it with the parking brake at a value of 76.5
mm between the internal wall of the collection unit and the internal wall of the trolley right shoulder.

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B) to facilitate positioning on the following units, fit the suitable master (1) on trolley buffer unit; in order to do so
remove the two screws (2) of the buffer unit and insert the template (1), position it so that its end (3) touches the
live centre internal wall. Tighten the two screws (2).

3) adjust the bar code of the first unit until the display of the trolley shows "0";
4) To adjust the following heads, move the trolley using the brake release push-button,
position over the head and make the template touch the tailstock
as described above
5) adjust the bar code of the following units until the display of the trolley shows "0"
To do so, loosen the bar code fastening screw, position and tighten.

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5.8.3.3 TUBE PICK-UP AND DELIVERY GROUP

1) Position the group so that the fulcrum of the tube pick-up rod is at a distance from the inside of the left shoulder
of the value of A ± 2 mm, as shown in the figure. To make this adjustment, loosen the screw (1), position the
group, then tighten the screw (1).

Value A for collection 152 = 197

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2) With arm (1) open, position support lever (2) in the centre of the metal plate. In doing this, consider the deflection
of the trolley, keeping the support indicated above from interfering with the lint guard of the dead centre.
With the adjustment screws (3-4) align the piston with the axis of the insert support (support lever).

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3) Acting on the points (1-2-3), position the tube, in the loading phase, aligned with the centres, with a
tolerance of 1 mm on the diameter.

Tilt adjustment

Horizontal adjustment

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Vertical adjustment with grub screw

4) After the adjustments described in point (3), adjust the tube deflector to a distance from the dead centre of 0 to 2
mm, as shown in the figure.

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5.8.3.4 TUBE GRIPPING AND DELIVERY CONTROL GROUP ADJUSTMENT

To prevent the yarn clamping unit from falling on the package being wound due to a machine power cut-off during
the doffing cycle, a device mechanically locking the group has been installed.

The group is pneumatically controlled and required the fitting of a solenoid valve (NC) positioned on the solenoid
valve group of the left shoulder numbered with no. 16 (this seat was previously empty).

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Adjust the control group lever by the piston fork so that there is a clearance of A = 0.5 mm to the tooth base, as
shown in the figure.

To avoid lever and/or tooth wear, it is very important to adjust the sensor so that there is a distance between the
sensor axis and the positioning tooth axis B = 5 mm ± 1 mm, checking that, while the lever detaches from the tooth
and it re-positions to zero, they do not touch.

Check that on the machine PC, in the section trolley / tube clamp unit / machine version, the item with brake is set.

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5.8.3.5 YARN CLAMPING GROUP ADJUSTMENT

1) Adjust the sensor (1) at the centre of the countersunk washer (2), located on the rotation piston support, at a
distance between 1.5 to 2.5 mm.
2) In the cutting/clamping phase of the yarn, adjust, using the nut (3) and the scissors group fulcrum insert (4)
so that the V of the scissors inserter group (5) is centred with respect to the yarn (6) (tolerance ± 2 mm).

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3) Once gripping is completed, the scissors/gripper makes the yarn touch the surface of the live centre. This
position, which can be adjusted through the PC of the machine, must be reduced to a minimum the
segment of yarn that will come out of the cone, but it must prevent interference with the arm opening lever.
To meet these needs, keep the scissors group (1) at a distance of 5 mm (from 0 to 1 mm) from the
connection point of the arm opening lever (2) when it is closed (cone held by centres).

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4) Also, the group must ensure that the yarn, once placed on the centre, has a minimum deflection of 2
mm from the surface of the centre, ensuring the provisions described in point (3) are complied with. The
buffer lever final position can be adjusted by the Ispector Control.

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5.8.3.6 BUFFER GROUP ADJUSTMENT

1) The measurements are provided for adjustment of the group in relation to the front and left side of the trolley.
These measurements ensure that yarn is positioned in the centre part of the hole for fastening of the live centre.

Turn the yarn buffer lever until it is at the point nearest the centre and ensure that there is a gap of at least 2 mm,
as shown in the figure.

Along with the descriptions provided above, the buffer arm must be inclined by 10 degrees.

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Therefore, turn the adjustment screw (1) in contact with the buffer arm support rod.

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2) Adjust the sensor so that its centre is aligned with the buffer arm, with a tolerance of ± 1
mm. The distance relative to the arm must be between 1 and 2.5 mm.

3) The position of the buffer on the cone, which can be set from a PC, is 8 ± 2 mm with respect to the end part of
the cone (or under the yarn deposit in specific cases).

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5.8.3.7 TUBE, BASKET VERSION TROLLEY SEPARATOR ADJUSTMENT

For correct separation of the tube, the group must be adjusted as follows:
turn the fastening screws (see photo) to adjust the two separators so that when they are inserted between the first
and second tube there are no impediments. Due to the inclination of certain types of tubes (3° 30’, 4° 20’, etc.) the
right-hand separator will unavoidably touch the first tube, and the left-hand separator will touch the second. This
test is to be carried out manually by slowly lowering the group by hand and checking that there are no
impediments.
Adjust the separators - right-hand separator (1), left-hand separator (2) - in height so that, when the tube is
released, they detach from the tube at the same time.

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To separate the second tube from the first, rotation of the group must start at about 5 mm from the axis
of the tube.
Place the separators (1) at the distance indicated above and adjust the strap (2), for rotation of the group, in
contact with the stop (3).

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5.8.3.8 TUBE HOLDING BASKET ADJUSTMENT

The adjustment of the basket (1) is based on the position of the dead centre (2) of the package cradle.
The basket is moved further to the left of the dead centre with a distance of 2 mm from 0 to + 3.
Adjust the lateral straps (3) so that during the tube pick-up phase the distance from it is 2 mm (from 0 to +1).

NOTE: Width setting for the two baskets

is equal to the tube length (X) plus or
minus 0 to + 1 mm

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5.8.3.9 TUBE PRESENCE PHOTOCELL CALIBRATION ADJUSTMENT

To calibrate the distance of the photocell (1), place a piece of black cardboard (2) on the support surface of the
cone on the basket (3).
Rotate the switch to the position L (ON).
Rotate the adjustment trimmer till the red LED turns on (adjustment value 230 mm).
You must now position the photocell so that when you move the tube 5 to 10 mm (red LED on) away from the
support straps (4), the photocell loses the signal.
To do this, use the fastening screws (5) and turn the photocell.

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5.8.3.10 ADJUSTMENT OF TUBE UNIT ON BELT AND BASKET TROLLEY - VERSION WITH CONE
MAGAZINE

5.7.3.7 ADJUSTING THE TUBE UNIT ON BELT AND BASKET TROLLEY - VERSION WITH CONE
MAGAZINE

Install the group and adjust the screw so that the tube mover is 4 mm (from 0 to + 1 mm) from the belt guide during
the tube pick-up phase.

Place the group so that the fixed strap is at a distance, from the start of the diagonal part of the cone basket, of 95
± 5 mm.
In order to do this, turn the three screws of the lever that supports the group when it is at rest.
This adjustment is possible by means of the play between the hole and the screw.

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Position the left semi-basket of the trolley (1) at a distance of 3 mm (from 0 to + 2 mm) to the left, with respect to
the dead centre (2) of the package cradle.

Check that the tube moving sensor strap (3) is positioned tangent to the sensor circumference, with a one-
millimetre tolerance to the sensor outside. This adjustment can be obtained operating on the dowel shown in the
figure below (4).

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5.8.3.11 TUBE GRIPPING ADJUSTMENT FOR RH MACHINE

With the cycle in manual (P04) take the tube pick-up unit close to the basket, before the piston positions it in the
loading area on the belt. Acting on the screws (1), take the end side of the tube moving sensor strap to a value of 2
mm (± 1 mm) from the wall of the left semi-basket, as shown.

Always using the manual program (P04) load one tube manually, so that the unit takes it from the belt, and check,
positioning the tube in contact with the tube moving sensor strap, that the latter is at 2 mm (from 0 to + 1 mm) from
the right semi-basket.

Ref. Description
2 Adjuster grub screw fully home against the top part
3 Tube fully home against strap
4 Centring device right part
5 Tube at 2 mm from semi-basket

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5.8.3.12 TUBE GRIPPING ADJUSTMENT FOR LH MACHINE

5.7.3.9 ADJUSTING THE TUBE PICK-UP ADJUSTMENT FOR LH MACHINE

Lightly move away the right semi-basket so that it does not interfere with the sensor strap. Load a cone on the
baskets with the program P04. After having loosened the fastening screws, move the feeler unit to the left so as to
position the tube at a distance of 2 mm (from 0 to + 1 mm) from the vertical wall of the right semi-basket.

Ref. Description
1 Feeler unit retaining screw
2 Feeler unit retaining screw
3 Adjuster grub screw fully home against the top surface
4 Tube bottom fully home against tube moving sensor strap

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Position the right semi-basket at a distance of 2 mm (± 1 mm) from the tube moving sensor strap.
If cylindrical tubes are used for winding the yarn, install on the unit (both RH and LH) the block (5) shown in the
figure on the suitable holes, to avoid crossing while loading the tube on the basket.

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5.8.3.13 BRAKE GROUP ADJUSTMENT

The group, in at-rest mode, is to be adjusted through the two retaining screws on trolley, so that the two brake pads
are at the same distance from the upper and lower parts of the guide.

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5.8.3.14 PNEUMATIC PLANT ADJUSTMENT

Hereunder are the functions of the solenoid groups installed on the right side and left side of the trolley:

Right side

SOLENOID VALVE Pertinent group Corresponding function(s)

No.
1 Yarn clamping group Scissors closing (N.C.)
2 Scissors opening (N.O.)
3 Scissors rotation (N.O.)
4 Piston stroke 50 mm (N.C.)
5 Piston stroke 200 mm (N.C.)
6 Piston at-rest position (N.O.)
8 Laser cleaning air jet (N.C.)

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Left side

SOLENOID VALVE Pertinent group Corresponding function(s)

No.
9 Brake Brake control (N.C.)
10 Tube pos.lever control Lever opening (N.O.)
11 Lever closing (N.O.)
12 Tube clamping Clamp closing (N.C.)
13 Clamp opening (N.C.)
14 Tube clamping position (N.O.)
15 Tube clamping from belt Tube loading to basket
and at-rest position (N.O.)

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5.8.3.15 PROCEDURE FOR ADJUSTING THE SIDE PHOTOCELLS

1) Set the potentiometer in the min. distance position NEAR,

2) position a possibly black obstacle:
version E/I: at a height of about 600 mm from the floor,
version M/L: at a height of about 1000 mm from the floor,
single-stake version: at a height of about 400 mm from the floor,
3) rotate the probe adjusting potentiometer clockwise till activating the sensor → position A (obstacle),
4) remove the obstacle,
5) continue rotating the potentiometer clockwise till activating → position B (background):
version E/I: bobbin point,
version M/L: bobbin-holding drum and tube unload belt in head/tailstock (vertical),
single-stake version: machine base,
6) set the potentiometer in central position between the positions A and B.

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5.8.4 USE INSTRUCTIONS

5.8.4.1 OPERATING LOGIC
5.8.4.1.1 FORWARDING OF TROLLEY TOWARDS WINDING UNIT

- During the stand-by phase, the trolley is stopped and hooked onto the last collection unit on which it performed
doffing, or on the unit where it assumed position;
- when a package is about to reach its established length, the collection unit recalls the trolley;
as soon as it is available, the carriage will move towards the calling packaging unit, detecting its position
by reading the position indicator of the unit, and stopping at the waiting unit,
and it checks that the unit where it is positioned is in the condition to carry out doffing (that is,
length reached and with complete yarn);
- the head PC checks that the package unloading belt is not moving
- once these conditions are met, the trolley carries out a doffing cycle.

5.8.4.1.2 CYCLE WITH INDIVIDUAL CONE MAGAZINE

- The trolley photocell checks whether the cone is present in the magazine of the unit that requires doffing;
- if the cone is present, the doffing cycle is enabled. If there is no cone, the
trolley does not start the doffing cycle and the signal lights of the carriage and of the packaging unit
come on.
In the event of request for doffing on another unit, the trolley is moved to the unit that requires it, and
the alarm light on the trolley goes off.
To start the collection unit that is in alarm status, the operator must insert the cones in the magazine and
press the
Start push-button on the trolley;
- at this point the cycle comes to a stop, and if the various parts and levers controlled by probes are not re-
positioned, the trolley
goes into alarm status.
In this case, the red indicator light of the trolley comes on as well as the blinker on the
preparing device
At the end of the cycle, collection unit is re-started.

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5.8.4.1.3 DOFFING CYCLE

- The tail accompanying unit of the collection unit lifts, extracts the yarn through a shaped lever and unwinds
it
from below;
- the "yarn gripping, cutting and delivery unit" of the trolley grasps and cuts the yarn below the shaped
lever
of the tail accompanying unit;
- the drum rotates to extract the yarn from the yarn guide and thread it onto the package
- the arm raises and opens the centres of the arm, frees the package, and moves the arm to the
cone loading position;
- the package is unloaded by the package pushing lever and carries with it the cut tail;
- the "yarn gripping, cutting and delivery" unit, aided by the buffer yarn insertion unit and by the yarn
guide,
positions and deposits the tail between the live centre and the cone;
- the "tube pick-up and delivery" group picks up a cone and positions it between the tip and the centre;
- the arm closes the centres and descends until it is in contact with drum that turns forming the buffer;
- at the end of the cycle, collection unit is re-started.

5.8.4.1.4 PACKAGE UNLOADING CYCLE

- Once the package is freed, it descends by gravity and stops on the bar.
- when the lever is lowered, the package then comes down on the package discharge belt;

5.8.4.1.5 LOT STARTING CYCLE

- The starting is manual, latching the yarn between centre and tube and starting the unit: buffer
is automatically carried out by the yarn guide

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5.8.4.2 MAIN INDICATORS

The trolley operating indications can be found:

- in the 3-digit display on the control panel (1);
- in the direction and alarm indicator LEDs (5)
There are different operating conditions for the trolley, needing specific interventions by
the operator.
The tables here below show the display indications, the status of the signalling light and the possible required
corrective action, depending on the trolley status.

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5.8.4.2.1 SELECTION OF THE WORKING PROGRAM (MANUAL CONTROLS OR AUTOMATIC CYCLE)

The working program is manually set by the operator through a selection on-board the trolley.
The selection is changed by holding the STOP push-button (2) pressed and pressing the START push-button (3)
shortly.
The selection is confirmed pressing the START push-button.
To exit the selected program, press STOP at any time.

DISPLAY CORRESPONDING STEP IN THE TROLLEY

RED LIGHT
INDICATION
Manual cycle for the return in idle position of the units (default at the start if there
P00 Steady on
are non-positioned units)
Start of the trolley automatic working mode (default at the start if there is no non-
P01 Steady on
positioned unit)
P02 Manual doffing cycle Steady on
P03 Manual batch start cycle (if supported by the head configuration) Steady on
P04 Doffing cycle with trolley movements only (without head movements) Steady on

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5.8.4.2.2 AUTOMATIC CYCLE

This condition (automatic cycle) identifies the standard trolley activity, thus no intervention by the operator is
expected.

DISPLAY CORRESPONDING STEP IN THE TROLLEY

RED LIGHT
INDICATION
A-- Automatic waiting for doffing requests Off
Automatic with the doffing request by the head no. xx in progress If moving, the one in the
Axx movement direction
blinks

5.8.4.2.3 MANUAL CYCLE

This condition identifies the execution of one of the possible manual commands. The manual command is always
started in stepping mode with stop points preset in the program.
Press the START push-button shortly to run the cycle.
Hold the START push-button pressed for 5 [sec] to make the cycle continue in continuous mode.

DISPLAY CORRESPONDING STEP IN THE TROLLEY

RED LIGHT
INDICATION
Exx Program xx in progress. Steady on
Syy Manual cycle stopped at the step no. yy. Press START shortly to continue. Steady on
tzz Manual cycle waiting for the condition zz Steady on

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5.8.4.2.4 TROLLEY IN ALARM

The alarm condition is indicated in the trolley by quickly blinking red lights and a series of numeric codes on the
board display in the following format:

−−−> Fxx ... (1 sec) ... yyy ... (1sec) ... zzz … (1 sec) … kkk −−−>
| |
−−−−−−−−−−−−−−−−−−−−<−−−−−−−−−−−−−−−−−−−−−−−

where:
xx: alarm code;
yy: identification code of the alarmed function;
zzz: first alarm sub-code;
kkk: second alarm sub-code;

The identification codes of the functions are:

n00: System
n01: Arm raising unit
n02: Tube loading unit
n03: Transfer unit
n04: Yarn buffer unit
n05: Yarn pick-up unit
n06: Communication with head

Alarm Function Description Trouble shooting

No.
The trolley has started the positioning Check motor and operation of motor
F01 n03
while another unit was still moving. control card.
Brake has closed during transfer Check the operation of parking brake and
F02 n03
control card
n01 The unit has lost the rest position Check motor and operation of motor
n02 during trolley positioning. control card.
F03
n04
n05
n00 Unit reset failed Repeat procedure. Check zero sensors
n01
n02
F04 n03
n04
n05
n06
n01 Doffing completed or interrupted. The Unit possible jam. Check possible jamming
n02 unit was unable to return to parking conditions and remove them.
F05 n04 position. Report also the value of first
n05 alarm sub-code.
n06
F06 n00 Generic error during doffing

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F07 n00 Reserved

n01 Motor card cannot be configured (no Change motor card, check CANBUS wiring
n02 communication on CANBUS or faulty and termination resistances.
F08 n03 motor card).
n04
n05
Alarmed motor card Check power supply of motor card.
n01 Replace motor card. Possible alarm codes
n02 of the card (first alarm sub-code) are:
F09 n03 - 91: Low input voltage;
n04 - 92: overload of
n05 motor control circuit;
99: generic alarm.
Configuration reading alarm from Re-send configuration from PC. If problem
F10 n00
EEPROM. persists, replace control card.
n01 Reserved for motor control card
n02
F11 n03
n04
n05
F12 n00 Reserved
Error of machine structure identification Repeat procedure. Check laser sensor and
F13 n03
procedure TAG reading card.
n01 Input signal is not as expected Check sensor operation.

Input signal is not as expected Check sensor operation. Possible

n02 identification codes (zzz) of input signal
are:
6: Zero sensor
Input signal is not as expected Check sensor operation. Possible
n04 identification codes (zzz) of input signal
F14 are:
5: Zero sensor
Input signal is not as expected Check sensor operation. Possible
identification codes (zzz) of input signal
are:
n05 1: Piston in upper position
2: Piston short stroke
3: Piston long stroke
25: Zero sensor
Alarm for communication with TAG Check wiring. Replace TAG reading card.
F15 n00
reading card.
Alarm for communication with laser Check wiring. Replace laser sensor.
F16 n00
sensor
Package unloading request time-out on
F17 n00
package unloading belt.

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Missing cone from cone magazine. Check the operation and the loading of the
F18 n00
cone magazine.
n01 Missing communication on CANBUS Check wiring and motor card
n02
F19 n03
n04
n05
F20 n00 Reserved
n01 Reset time-out at the end of doffing Possible jam. Check unit configuration.
n02 cycle.
n03
F21
n04
n05
n06

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5.8.4.2.5 ALARMS RESETTING PROCEDURES

The following procedure describes the operations to be made in the trolley to restore its operation after an alarm.
- Look at the alarm code and sub-codes in the display.
- Eliminate the alarm causes, solving any locking.
- Hold the black STOP push-button (3) pressed for 4 [sec] as long as the alarm is cleared from the display.
- If the display shows "P01" (units in rest position), press the white START push-button (2); on the other hand, if
the display shows "P00" press one time the START push-button (2) to move the units back to rest position,
then, when the display shows "P01" press the START push-button (2) again.

5.8.4.2.6 EMERGENCY TROLLEY

The trolley is in emergency condition following to one of these events:

1) Emergency mushroom push-button pressed on the trolley
2) Anti-impact side bands pressed
3) Trolley in the position of the limit switch cam

DISPLAY CORRESPONDING STEP IN THE TROLLEY

RED LIGHT
INDICATION
--- Trolley in emergency condition Slowly blinking

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5.8.4.2.7 TROLLEY IN BASKET VERSION

In the machines with tube loading from baskets, the trolley checks for the presence of the empty tube before every
doffing.
If the tube is missing, the trolley does not continue the doffing on the head and serves the other heads. The head
where the tube is missing starts blinking slowly (ATTENTION RATHER THAN ALARM MODE) to call the attention
of the operator.
To continue, load the tube on the basket and press the START push-button of the head till it stops blinking.

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5.8.5 MAINTENANCE

INTRODUCTION

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio S.p.A. Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push-button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Work on electrical equipment must only be carried out by a qualified electrician.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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5.8.5.1 AUTOMATION TROLLEY GENERAL CLEANING

ATTENTION!
Package cone magazine must be cleaned with machine STOPPED.

ATTENTION!
Cleaning operations should be done wearing adequate, individual protective gear as required by
the local health and safety laws in force where the machine is installed and complying with
provisions under 1.2 "GENERAL SAFETY PROVISIONS".

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Cleaning of external groups, transfer Personal protection
24 guides and blade-lifter control piston of equipment as required by the
automation carriage laws of the country where the
machine is installed

CLEANING
SERVICE INTERVAL every 24 hours
Cleaning of external groups, transfer guides and blade-lifter control piston.

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Automation carriage dust brushes and Personal protection
150 equipment as required by the
wheels cleaning
laws of the country where the
machine is installed

SERVICE INTERVAL every 150 hours

Clean the stand/translation wheels and the anti-dust brushes on the sides of the wheels.

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Compressed air system

(gentle blow), spray oil
Contrakor Fluid H1 Kluber,
Package tail cutting and pick-up scissors
350 Personal protection
cleaning and lubrication
equipment as required by the
laws of the country where the
machine is installed

SERVICE INTERVAL every 350 hours

Clean the scissors of the package tail cut and pick-up unit with compressed air (gentle blow) and lubricate with a
spray oil (Contrakor Fluid H1, Klüber).
Check that the blades overlap properly.

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Personal protection
equipment as required by the
750 Doffing cycle complete check
laws of the country where the
machine is installed

SERVICE INTERVAL every 750 hours

Carry out a complete check of the doffing cycle.

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INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Manual tools,
Compressed air system
Automation carriage general internal (gentle blow),
4000
cleaning
Personal protection
equipment as required by the
laws of the country where the
machine is installed

Lubricant paste Molykote Dx,

Manual tools,
4000 Greasing cams, gears and automation Personal protection
carriage shafts equipment as required by the
laws of the country where the
machine is installed

Personal protection
Checking trolley alignment with the units equipment as required by the
4000
below laws of the country where the
machine is installed

Personal protection
Checking the torque value at which the
equipment as required by the
4000 doffing cycle control ratiomotor clutch kicks
laws of the country where the
in
machine is installed

Aspirator,
Dust suction from automation carriage Personal protection
4000 equipment as required by the
electric parts
laws of the country where the
machine is installed

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CLEANING
SERVICE INTERVAL every 4000 hours
 Use compressed to clean the inside, first removing the outside guard(s) (1).
 Grease the cams, gears and pins using the lubricating paste Molykote Dx.
 Check the trolley alignment with the units below, if necessary adjust the position of the block (2) on the
packaging unit front, by removing the cover (4).
 Check the torque value at which the doffing cycle control ratiomotor clutch kicks in.
 Remove the top guard (3) and suck up all dust from the electrical components.

ATTENTION!
Failure to apply the above procedures, a residual risk of snatching, intoxication and dust
inhalation remains.

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5.9 MOBILE SUCTION AND CLEAN UNIT
5.9.1 TECHNICAL DESCRIPTION

It mainly consists of the following groups:

 Mobile unit with blower;
 Air suction/delivery pipes
 Air suction/delivery nozzles

5.9.1.1 MOBILE BLOWING AND SUCTION SAVIO BELT BLOWER

The travelling blower is a unit located on machine top part, that keeps the machine parts clean.
It is composed of:
1) mobile unit with blower
2) suction sleeves
3) blowing sleeves
4) mobile unit cable holder chain
5) waste outfeed unit
6) suction fan to clean the mobile unit
7) belt
8) differential pulleys
9) return pulleys
10) bayonet exchanger
11) reverse cam
12) blower
13) economiser control
14) economiser guide
15) filter.

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5.9.1.2 MOBILE BLOWING AND SUCTION ELECTROJET [OPT]

The travelling blower is a unit located on machine top part, that keeps the machine parts clean.
It is composed of:
1) mobile unit with blower
2) suction sleeves
3) blowing sleeves
4) mobile unit cable holder chain
5) waste outfeed unit
6) suction fan to clean the mobile unit.

Note: Please refer to the Manufacturer (OEM) instructions manual supplied with the machine for any further
detail about maintenance, adjustment and spare parts for the Electrojet mobile blower/aspirator.

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5.9.1.3 REVERSE DEVICE [OPT]

On request, it is possible to install, as option, a device automatically detecting any obstacles along the blower path
that can, in case of obstacle, stop the blower and reverse its direction.
This device is installed to detect obstacles only on the front of the machine (where the operator works) and not at
the back. The user must make sure there are no obstacles at the back of the machine.
Should it be necessary to work at the back of the machine the blower must be switched off and switched back on
only when work at the back is finished.

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5.9.1.4 OBSTACLE DETECTION SYSTEMS [OPT]
5.9.1.4.1 OBSTACLE DETECTION SYSTEM SAVIO BELT BLOWER [OPT]

The obstacle detection system of the travelling blower Savio Belt Blower, consists of:
1) Front sleeve support swinging arm (installed in place of the fixed standard one)
2) Impact protection device
they are only applied to machine working front.
The front sleeves, in case of obstacle, tilt the swinging arm, that drives the exchanger to reverse direction, through
the impact protection device linkage.
In this way the travelling blower stops and reverses its running direction, as it normally happens at travel ends.

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5.9.1.5 OUTFEED SYSTEMS

5.9.1.5.1 OUTFEED SYSTEM FOR SAVIO BELT BLOWER

Collected dust is automatically dumped when the travelling blower reaches the Headstock, in this position it gets
against the rigid pipe (1) fixed to the rails by means of a support (2) and connected to the Headstock suction by
means of a flexible spiral tube (3).
The rigid pipe (1), when at rest, is blanked by a rubber plug (4), positioned onto a mobile cradle (5), to which, in
turn, a cam (6) is fastened.
When the travelling blower starts the outfeed stage, economisers (7) - fastened to the front and rear rails - stop the
suction/blowing air flow.
At this position, the travelling blower works cam (6) at the top, which raises mobile arm (5) to open the rigid pipe
(1). Thus enabled, it sucks and removes any build-up from the filter inside the travelling blower. Moreover, thanks
to the exchanger found in the bottom part, running direction can be reversed and the same operations will be
carried out in the opposite direction.

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5.9.2 TECHNICAL DATA

IDENTIFICATION DATA
Identification data for the mobile suction and cleaning unit as well as its weight are specified in the nameplates onto
electric board door.

PREMISE
Since no special specifications are available for mobile suction and cleaning unit, all its data are included in the
machine overall specifications.

Please consult chapter 2 of this manual.

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5.9.3 ADJUSTMENTS

PREMISE
Since no special adjustments are available for the mobile suction and cleaning unit, all required adjustments are
explained in the manufacturer's user's manual and incorporated in the machine general literature.

Please consult the relevant chapter of the attached documents.

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5.9.4 USE INSTRUCTIONS

ATTENTION!
The travelling blower can be started only by authorised staff.

WHAT NOT TO DO

Correct use of the system includes complying with all the operating and routine maintenance conditions.

ATTENTION!
Do not alter system operation unless proceeding as described in this paragraph and in the
paragraphs concerning maintenance.

ATTENTION!
Do not build up and push dust, lint, paper or any other material under the suction pipes to have
them sucked.

ATTENTION!
Do not push or drag the blowing and suction pipes.

ATTENTION!
Do not put your hands or any other part of your body in front of the blowing nozzles, since
material particles might be sucked from the floor and ejected from the blowing nozzles at a high
pressure and speed.

INSPECTION BEFORE STARTING

Before starting the system, the authorised operator must:

 ensure that the cable drag chain is correctly seated in the runway;
 ensure that the photocells (if installed) are in the correct detection position, check their efficiency by testing
one photocell at a time: when the photocell beam is interrupted, the travelling blower must reverse its
running direction after the preset time;
 check the efficiency of the lever switches at limit stop;
 ensure that the dust collector door (if installed) is closed;
 visually make sure that no operator is close to one of the two winder fronts and that nobody is within the
working area of the travelling blower;
 if the system is equipped with air-operated devices, make sure that the valve secured to the regulator filter
is open, so as to restore air flow.

ATTENTION!
Nobody is allowed to work or pass through the area where the travelling blower is working, or in
such a position as to likely interfere with it.

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There are two different operating modes for the mobile suction and ventilation unit:
 automatic
 manual

these operating modes are explained under paragraph “ISPECTOR CONTROL”

STARTING

The travelling blower is controlled by the switch on the machine control panel at the headstock.

ATTENTION!
After starting, make sure that the cable drag chain smoothly slides in the runway.

STOPPING

Like for starting, the travelling blower stop is controlled by the switch on the machine control panel at the
headstock.

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5.9.5 MAINTENANCE

PREMISE

This chapter is dedicated to the “MAINTENANCE ENGINEER”: he is the technician who is qualified and authorised
by the Customer to service, lubricate and disassemble the machine.

This chapter illustrates the maintenance jobs and programmed lubrication that will ensure regular production
elimination sudden machine shut-downs as far as possible.

This is a recommended preventive maintenance programme. The frequency may differ according to the type of
yarn and the environmental conditions the machines are subject to.

Take note of the precautions as they are mentioned throughout this manual to avoid harming people and damaging
the machine. Remember that incomplete or incorrect maintenance can cause the machine to malfunction. Should
you have any doubts about how to service the machine properly, contact the Savio Assistance Centre.

The Customer must ensure that inspection, repairs, adjustment and maintenance jobs are carried out by qualified
personnel only as explained under paragraph 1.2 "GENERAL SAFETY PROVISIONS"

ATTENTION!
At least once a week and always before any maintenance work is done, it is compulsory to
check the safety circuit and visually verify the soundness of the emergency push button.

ATTENTION!
If, for any reason, it is necessary to remove one or more machine components that have a safety
function, before the machine can be used again for production you must:
- put the safety components back in place;
- make sure they are in proper working order;
- take the keys out of panel and door locks.
Should you have any doubts about how to service the machine properly, contact the Savio
Assistance Centre.

ATTENTION!
Checking, cleaning and lubricating operations should be done when the machine has been
shut-down and its main switch locked in the “O” (zero) position.

ATTENTION!
Only a qualified electrician is allowed to work on the electrical equipment.

ATTENTION!
Do not oil, lubricate, repair or adjust parts while they are moving.
Do not remove the safety devices.

ATTENTION!
The empty oil or grease containers must be disposed of properly. Do not contaminate the
environment: chemical risk.

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ATTENTION!
If, for maintenance purposes, it is necessary to reach the machine higher parts, such as the
travelling blower rails (Electrojet, Savio Belt Blower), the travelling blower outfeed system, the
doffing trolley and its rails, or the lighting system, it will be necessary to use suitable means for
work at height.

Considering that required interventions are rare and occasional, these suitable means could be a
double ladder, complying with EN 131 standard, resting onto a suitable firm and strong support, so as to
ensure a flat position; possibly, the ladder shall be securely fastened to avoid oscillation, skidding or
tipping over.
The operator must use the Personal Protection Equipment (safety clothes, gloves, helmet, shoes).

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5.9.5.1 LUBRICATION

Since all rotating parts feature bearings, it is not necessary to daily lubricate them. The bearings must nonetheless
be periodically serviced (every 500 hours).

The following points fit bearings:

 motor drive shaft
 headstock pulley
 rotor pulley
 differential pulley
 wheels

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Manual tools,
Specific lubricants,
Motor shaft bearing lubrication, the head Personal protection
500 pulley, the pulley rotor fan, differential equipment as required by the
pulley wheels. laws of the country where the
machine is installed.

Manual tools,
Only use grease KLUBER
ISOFLEX NBU15,
Lubricate the bearings using the special
Insert a quantity of grease of
6000 grease nipples. 1.4 to 1.5 gr.
Clean the opening of the bearing (A). Personal protection
equipment as required by the
laws of the country where the
machine is installed.

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5.9.5.2 SCHEDULED MAINTENANCE SHALL INCLUDE INSPECTION OF THE FOLLOWING PARTS

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Check movement of the economiser, Manual tools,
inspect the rotor pulley, the differential Individual protective gear in
500
pulley and the bayonet exchanger. compliance with the laws in
Ensure that the bolts are well tight. force in the country where the
machine is installed

Manual tools,
Check the screws of the transmission
Individual protective gear in
500 pulley and the position of the fork of the
compliance with the laws in
belt and of the screws of the travelling
force in the country where the
device machine is installed

Aspirator,
Individual protective gear in
500 Check alignment of the guides of the
compliance with the laws in
travelling device
force in the country where the
machine is installed

Manual tools,
Individual protective gear in
500 Check the piping of the travelling device compliance with the laws in
force in the country where the
machine is installed

Manual tools,
Individual protective gear in
500 Check the belts of the travelling device compliance with the laws in
force in the country where the
machine is installed

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TRAVELLING BLOWER DEVICES (EVERY 500 HOURS)

 Check economiser movement. The economiser must be open during operation. Make sure that the star
control easily opens and closes the economiser. Remove the part to clean.
 Inspect the rotor pulley, the differential pulley and the bayonet exchanger. Ensure that the bolts are well
tight.

BELT CONTROLS (EVERY 500 HOURS)

Check that the bolts on transmission pulley and motor pulley are not loose, then check the belt fork position and
bolts. Remove any lint remained around the motor.

GUIDES (EVERY 500 HOURS)

Ensure that bolt nuts on the column are not loose, that lug and bolts are tight; make sure that guides are aligned.

PIPES (EVERY 500 HOURS)

Inspect the pipes. Repair and tighten the elbow and angle of the travelling blower pipes. Restore any disconnected
nozzle.

BELT (EVERY 500 HOURS)

Ensure that belt is not peeled off, damaged, twisted or slack. If belt is peeled off or twisted, cut it and rejoin the two
ends. If slack, restore proper tension.

5.9.5.2.1 MONTHLY MAINTENANCE

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Water and mild detergent,

Check the conditions of the filter, clean and Individual protective gear in
160 compliance with the laws in
if need be replace
force in the country where
the machine is installed

CLEANING AND REPLACING THE FILTER (EVERY 160 HOURS).

After a certain period of use, cotton hair obstructs the filter. After machine installation, inspect the filter at short
intervals and determine the required inspection frequency. The filter cleaning and replacement frequency will
depend on the types of devices used in the system, on the operating conditions, on the type of fibre and on the
filter mesh size. Replace the filter with a spare one when you need to clean it. Clean filter with water and mild
detergent, then let it dry naturally in the air. Filter condition greatly affect the machine performance. Replace filter if
necessary.

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5.9.5.2.2 SIX-MONTHLY MAINTENANCE

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator,
Manual tools,
Check the conditions of the pipes of the
1000 Individual protective gear in
travelling device compliance with the laws in
force in the country where the
machine is installed

Aspirator,
Manual tools,
1000 Clean the casing of the travelling device, Individual protective gear in
compliance with the laws in
force in the country where the
machine is installed

Every 1000 Hours

PIPES
Remove and clean the pipes (mainly focus on the blowing pipe). Lint waste often builds up on the pipe top side and
onto pipe welding. Carefully remove all build-up, paying special attention not to damage the pipe. In the same way,
inspect the suction pipe.

TRAVELLING BLOWER BODY

Remove and clean the case. Remove all lint and cotton waste.

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5.9.5.2.3 MAINTENANCE EVERY YEAR

INTERVAL
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED

Aspirator and water-wet

cloth,
Clean the dust and yarn from wheels and
supporting roller unit pins as shown. Manual tools,
2000 Personal protection
Remove the dust and yarn from wheel
surface using a water-wet cloth. equipment as required by the
laws of the country where the
machine is installed

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5.9.5.3 FAULTS, CAUSES AND REMEDIES

The cleaner does not move.

NO
Check the electric
Is the motor
system
turning?

Y
E
S NO
Install the belt correctly.
Is the belt installed? If necessary, join the belt.

Y
E
S
Is the belt running?

Y
E Is the blower
S NO NO
moving when you
Is the belt shifting? manually turn the
driving pulley?

Y
E
S
Y Check the reverse
E fork and its correct
S positioning.

Slacken the belt and ensure that the rotor pulley and the differential pulley turn. If they do not
turn, it is likely that the bearings are faulty; replace if needed.

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When the blower pressure drops, suction power is poor.

Y Y
Is the economiser E E
open? Is the filter Clean the filter
S S
clogged?

NO
NO

Is the suction Y
- Set economiser to E Remove any
nozzle clogged?
open position. S blocking
- Remove any dust or
waste from the
economiser. NO
- It might be necessary
to make economiser
control rotation Are the dust
smoother. Is the filter Y
cleaning pipe collector filters
E
working clogged?
S
properly?

NO
Y
E
S
Adjust the
Clean the
position of filter
filters
cleaning pipe.

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5.11 ISPECTOR CONTROL (VER. 2.0)

5.11.1 TECHNICAL DESCRIPTION

The Ispector Control is a computer controlled system supplied with the machine and enabling:

to set the machine characteristics and the working parameters;

to display/print the data on the production in progress and of the previous shifts;
to display the alarm reasons for the individual peripherals;
to update the software of the machine peripherals.

Data are set and viewed through a “touch-screen” system, so that the windows are activated and the data are set
by lightly pressing the buttons on the display edges.

The main page and a description of the organisation of the different menus follow
in the pages below:

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MANAGEMENT OF OTHER
UNIT MANAGEMENT
PERIPHERALS
Machine configuration,
Configurations Headstock. Trolleys (if any)
Preparer peripheral
Report configurations

Report
Alarms log
Alarms log
Functions
Functions

Advanced functions
Spindle acknowledgement (only I)

HH0276—v02.00—08.31
HOUR COUNTER—SW VERSION-
HOUR

UNIT/MACHINE STATUS

OTHER PC FUNCTIONS Started

Change language Stopped

Other PC functions Energy-save (only I)

USB flash drive In alarm

Print Operator warning

Peripheral status Lot end (only PULSAR E)

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UNIT MANAGEMENT

REPORT

Unit data

Red lights/Technological
alarms

Clearer cuts

Off Standard

FUNCTIONS

Immediate controls ADVANCED FUNCTIONS

Immediate controls (Bobbin Computer aided metering
change) (CAM)
Reset Tension

Remote loading Build-up

Tension Reference
Diagnostics

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MANAGEMENT OF OTHER PERIPHERALS
REPORT

Peripheral data

Hopper station data (only E)

Cleaner

Pick-up (Partial data)

Debug (only I- and E)

FUNCTIONS

(Preparer) Immediate controls

Immediate controls - lot end

(only E)
Code programming (for Savio
use)
Remote loading

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SPINDLE ACKNOWLEDGEMENT (only I-DLS)

SPINDLE ACKNOWLEDGEMENT

Last bobbin discharge

Log

Log-Unit

Data request

Configurations

Code programming (for

Savio use)

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OTHER PC FUNCTIONS

OTHER PC FUNCTIONS

System units

Basic settings

Shift end print settings

Shift setting

System utilities

Network settings

USB FLASH DRIVE

Save Reports

Save Lots

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When the machine is started, the first settings are the machine basic and generic data, such as customer name,

machine serial number, units of measurement, etc. These settings can be accessed pressing the button .
The displayed page enables to set the following parameter groups:

Basic settings

Units of measurement

Shifts

Shift end settings

BASIC SETTINGS
Basic settings
Customer Alphanumeric field dedicated to the customer name.
Serial number Machine serial number
Machine number Machine number within the system
Hour counter Edit machine working hours count. Enter hours and minutes in the
format:
h.mm
Password Edit the passwords for the customer (levels 1 and 2). Fields are
visible ONLY after entering at least level 1 password. To edit the
password: enter it, enter it again in the nearby field and press .
Passwords are encrypted with algorithm md5 and stored in a
database; if the password is lost, you must set a new one.

Initial passwords are:

LEVEL 1: 111111
LEVEL 2: 222222

Date/Time Edit system date and time. Enter date and time in the format:
dd-mm-yyyy hh.mm

Then press

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UNITS OF MEASUREMENT

Units of measurement
Length IS (International Standard)  meters
Weight IS (International Standard)  grams
Possible settings are:
Nm
Count Nec
New
Tex
Possible settings are:
Length/weight m (metres)
g (grams)

SHIFT SETTING.

The daily period can be divided into max. 8 shifts (each one lasting min. 180 min) with the possibility of shifts with
different duration.

SHIFT CONFIGURATION

Equal shifts: field enabling in case of working shifts with the same duration for all the week days.

To set the chart, press on the key corresponding to the day of interest (in case of Equal shifts press on the starting
day) and set:

Start time (hh, mm)

Defines the shift start time, in case of shifts with different duration the system asks for
the start and duration of each single shift. In case of equal shifts, the system automatically assigns the start time of
the following shifts.

Duration (180 ... 720) minutes

Working shift duration.

In case of different shifts, it is possible to add one shift by pressing or delete it using .
The shift chart can be coped from a preset day by checking the option Copy from day and selecting the day from
the drop-down menu.

Press to confirm every change.

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SHIFT END SETTINGS

Printer Enables to select the printer connected on the machine.

Shift end print If the printer is installed, it enables or disables the print of the shift
end report.
Print language The wished language for the print report can be selected; this
selection can be different from the interface one.
Print type Enables to select the wished print report type; the possible settings
are:
Standard
Standard + alarms
Standard + off standard
Complete (Standard + alarms + off standard)
Reduced (unit data only)
Unit stop at shift end for extra- If the "Enable unit stop" option has been enabled, all heads that at
cycle standard off the end of the shift will feature a value of extra-cycles higher than the
 Enable unit stop set "Extra-cycle limit %" will be stopped in "off standard" alarm
 Extra-cycle limit % condition.

SYSTEM UTILITIES - SYSTEM SHUT-DOWN

The Ispector Control (operating system) can be shut down by pressing of System utilities and then to
shut down.

Every time the electric power supply to the machine must be cut off it is previously necessary to shut the Ispector
Control down by this button.

N.B.: do not cut the machine off until a confirmation message appears for the correct finishing of all computer
activities.

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USB FLASH DRIVE

The following symbols allow user to check whether the USB flash drive has been acknowledged by the system:

USB flash drive not inserted

USB flash drive inserted. To remove the flash drive, press

Save shift end reports

Press to transfer the text files created by the PC at shift end to the USB flash drive. While files are copied,
the following image will be displayed, do not remove the flash drive until it goes off.
Files are copied as compressed files to the following directory:
savio_/reports/xxx-xxx-xx
where xxx-xxx-xx is machine serial number, in a file
repyyyymmgg.zip
Save lots
Select the peripheral of interest from the drop-down menu.
When flash drive is not inserted it is possible to view only the list of lots present in the machine.
When user inserts the USB flash drive, the list of all lots currently stored in the flash drive is displayed.

Copy selected lot from machine PC to USB flash drive

Copy selected lot from USB flash drive to machine PC

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LAPTOP

The icon is ONLY displayed when the machine PC is part of a local network (or point-to-point connection)
and access to user interface is performed via any browser (Savio suggests you use Mozilla Firefox) by entering the
IP address of the machine PC as web address.
Save shift end reports

Press to create a compressed file

xxx-xxx-xx__aaaammgg.zip
(where xxx-xxx-xx is the machine serial no., aaaammgg is the year, month and day when file was requested) and a
window appears where user shall specify the local path of the laptop where to save the file.
Save lots
Save
Select the peripheral of interest from the drop-down menu. Select the lot of interest among the available ones and

press . A file lotname.slot is created and a window appears where laptop local path shall be specified.
Recovery
Press Browse to find in laptop HD the file lotname.slot containing data of the lot to be loaded to the machine. Press

to insert the requested lot among the available lots for the peripheral of interest.

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CONFIGURATIONS

The configuration pages are displayed as follows:

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The description of the several available icons is as follows: TECHNICAL DESCRIPTION OF PRODUCT

POSSIBLE OPERATIONS

1 Change confirmation

2 Password setting

3 Entering a new unit group

4 Deleting a unit group

5 Entering a new lot

6 Deleting an existing lot

7 Changing an existing lot

Press on the cell with the

name of the lot currently
being processed
Changing the lot associated with a group or with a Select the lot from the
8
peripheral displayed window
Confirm the operation by
pressing

9 Checking the data associated with the lot

Deleting the changes to the lot data

10 (changes can be made on several structures before
sending data)
Sending the lot (if the lot has been changed, the lot
is sent to each group it is associated with). Sending
11
sub-pages enables to send the involved structures
only.

12 Link to the previous page

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The box can be of different colours, as explained in the table below:

Possible colours of the boxes

The value of a lot parameter has been changed but
1
the confirmation of the changing or sending has not been prompted yet
The value of a lot parameter has been changed and data
2
have not been sent yet
The value of a lot parameter has been changed but it is not valid (outside
3
the range of possible values) – Impossible to send

Creating a new section

To create a new section press a new line will be displayed where it is possible to enter the initial head and

the final head of new section; confirm pressing .

To associate the lot with the new section (or to change the one associate with an existing section) press on the
corresponding Name, select lot name from the list in the window and confirm.

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Creating a lot

To create a new lot it is necessary:

to enter a name for the lot;
to enter a description (optional).

Confirm with the green button : the created lot will contain the default data associated with the peripheral for
which the lot has been created.

To copy a lot:
select the option Copy from lot;
press on the box shown in the picture -> the window of the lot selection is displayed;
select the reference lot and confirm with the green button → the lot selection window closes and the name of the
reference lot is displayed in the marked box;
enter a name to be associated with the new lot;
to enter a description (optional).

Confirm the operation by the green button .

Changing an existing lot (unit)

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Press to open a window where user shall enter name of lot to be modified (o where user can select the lot
through the box listing all existing lots in the machine - not the ones being processed) .

Select lot, press to open data windows. Edit all required values using the button available in every window,

then confirm all changes using the confirmation button next to page header.

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DATA ENTERING

Data are entered through:

a numeric keypad:

an alphanumeric keypad:

The procedure for entering a new value is as follows:

touch the screen next to the field of the data to be modified; if the operation has been performed correctly, the field
shows the keypad suited for the value being modified;

delete the values previously set by the keys or on the keypad from the field;
enter the new value;

confirm the new data item by pressing on the window side.

Use key to close the keypad.

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PASSWORD USE

The PASSWORD setting window is activated by selecting the key .

The Ispector Control has a password to enable the users, depending on preset skills, to access the system at
different levels.
The functions that are not enabled with the used password are displayed as well but cannot be modified.
The enabling obtained through the password (log-in) is cancelled (return to level zero) if the keypad is not touched
for three minutes. Setting an invalid password immediately returns to a zero access level.

The level of the used password is indicated inside the icon on the screen upper section ; obviously the
users of upper level have access to all the functions available to the lower levels.

The following levels of data access are controlled:

Level 0 : data reference, no change possibility. Any data item that can be accessed from an upper level is visible,
but cannot be changed.

Level 1 : Enabling to:

system configuration
simplified working data
(partial) unit setup
auxiliary devices (preparer, searches, package unload belt, etc.)
splicer
other functions, main window

Level 2 : Enabling to:

working shift configuration

(partial) machine configuration
(complete) unit setup
Password
processing data
immediate controls

Level 3 : edit level to be exclusively used by Savio staff.

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ALARMS

The keys on the lower part of the main video page activate the window for the detection of the alarm in progress;
the image on the keys shows the relevant status.

Status Description

Operating peripheral

Peripheral stopped / Peripheral stopped with live alarm

/

Bobbin discharge end / Bobbin discharge end with live alarm 1

/

Peripheral in alarm

Operator warning

The windows that can be displayed involve the alarms of the winding units and the other machine parts (headstock,
preparer, searches): the presence of an alarm is shown by an image of the involved machine unit and by a
description explaining the possible cause, as well as by the switching-on of the machine signalling lamp.

MACHINE STATUS

1 only for Machine I

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Use key to open a window showing the status of all peripherals in the machine (thus according to the type of
machine, PULSAR I or E, there will be a different display for the part relevant to the units and the tailstock and the
part relevant to the other peripherals).

The status of a pheriferal is defined through the colour of its box as indicated below:

OFF LINE
STOPPED
ON
IN ALARM (OR RED LIGHT for the units)
IN PRESENCE OF AN OPERATOR WARNING
CONFIGURATION FAILURE
WAITING FOR CONFIGURATION
CONFIGURATION START
PROGRAMMING IN PROGRESS
WAITING FOR PROGRAMMING

Select a cell to view further information:

 last communication + status
 alarm string (if any)
 operator warning string (if any)

If an alarm is present, the reset key is display to send the command.

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DATA PRINT

The DATA PRINT window is activated by selecting the key

The print option settings are defined by the selections made in the fields inside the window, as shown below:

DATA PRINT
Reference shift 1
Peripheral 2
Data selection 3
DATA PRINT

1 Reference shift (Current; 1, 2, 3, 4)

Select the shift for which data must be printed.

Current
The displayed data refer to the shift currently in progress.

1 …4
Previous shifts stored by the Ispector Control. The data of the just
ended shift are displayed in the shift number 1, the oldest data are
displayed in the shift number 4.
By selecting Reference shift, the window box will show
the date and the shift start and end times.

2 Peripheral All
Prints the data of the units and of peripherals of the preparer.

Units
Prints the data of the units. A further menu allows user to select a
single section.

Preparer
Prints the data on the bobbin preparation efficiency and on the pegs
returning from the winder.

3 Data selection Standard

Working data of the units and list of red lights and alarms. Working
data of the preparer and alarm total.

Standard + alarms
Like Standard + list of the single alarms occurred on the preparer.

Standard + off standard

Like Standard + list of off standard peripherals for production or extra
cycles

OFF STANDARD:Kg=10%-ExC=20%
U Kg J T Spl ExC LR
-----------------------------
05 05.3 138 084 01 01.4* 00
…..

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U BEJ BobW ASys ATec Switch
-----------------------------
05 01 00034 00 00 00000

U Units U Units
Kg Kg Produced BEJ Rejected bobbins
J Splicing BobW Bobbin waiting time
T Cuts ASys System alarms
Spl Splicer Atec Technological alarms
ExC Extra cycles% Switch Switch Stop time
LR Red lights

Complete
Like Standard + list of the single alarms occurred on the preparer +
list of off standard peripherals for production or extra cycles.

Reduced
Working data of the units. Meaningless for the preparer.

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A print report example is the following:

PULSAR I-customer name-0.00.08 HEADING: customer data/shift data

Serial number: 123-456-09 N:5
Shift 1:06:00-14:00
09/02/2009 06:00-14:00(480)

GROUP:1-26 CONFIGURATION DATA + AVERAGE SPEED

Winding speed [m/min] 1400
Count [Nm] 101.60
Package weight[g] 8000.00
-----------------------
Weight 0.0
Produced packages 0
Average speed [m/min] 0.0
-----------------------
UNIT EFFICIENCY 0.0
Red lights 0.0
Techn. alarm 0.0
Cycles 0.0
SYSTEM EFFICIENCY 0.0
Doffing 0.0
Techn. alarm 0.0 HEAD PRODUCTION DATA and EFFICIENCY
Bobbin waiting 0.0 VALUES
Bobbin C. Stop 0.0
MACHINE EFFICIENCY 0.0
Local Stop 0.0
Bobbin discharge end 0.0
Power Off 0.0
Stop Master 0.0
Suction Stop 0.0
Clearer Stop 0.0
Slide Stop 0.0

UNIT DATA
Splicing (No.) 0
Splicing (T) 0.0
Splicing/10 0.0
Cuts (No.) 0
Cuts/10 0.0
Extra cycles 0
Extra Cycles (%) 0.0
Red light 0
Red light (T) 0.0
Red lights (%) 0.0
Alarms (No.) 0
Alarms (T) 0
Doffing (T) 0.0
Bobbin change 0
Rejected bobbins 0

CUT REPORT
Splicing (No.) 0 CUT REPORT (if requested from the interface)
Splicing (%) 0.0
Yarn Fault 0

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Yarn Fault (%) 0.0
Splicer 0
Splicer (%) 0.0
Jump 0
Jump (%) 0.0
Upper Yarn 0
Upper Yarn (%) 0.0
System Cut 0
System Cut (%) 0.0
C6 0
C6 (%) 0.0
C7 0
C7 (%) 0.0
C8 0
C8 (%) 0.0
OFF STANDARD (if requested from the interface)
OFF STANDARD:Kg=10%-ExC=5%
Failed production: list of the units that had zero winding time
Failed production:
for the whole shift.
8
Star indicates when unit is off standard for low production
U Kg J T T10 Spl ExC
or too many extra cycles (or both): supposing that the
----------------------------- reference values are the printed ones: Kg=10%-ExC=5%
04 05.2 201 154 06.6 11 10.9* the unit will be considered off standard for production is its
07 05.5 157 107 04.4 08 07.0* produced Kg are 10% less compared to the section
average; while it will be considered off standard for extra
U RL BEJ BobW ASys ATec SwS cycle% if extra cycle% value is higher than 5.
-----------------------------
04 00 00 00000 00 00 00000
07 00 00 00000 00 00 00000

RED LIGHTS 34
Cut piecing = 10
Failed package tail pick-up=9
Double from package=9
Missing splicing=2 RED LIGHT AND ALARM REPORT (if requested from
Missing yarn from bobbin=4 the interface)

TECHNOLOGIC AL. 9
Clearer: OTHER=5
Clearer: CV=4

SYSTEM AL.
CLEARER-Internal failure=3

PREPARER PREPARER REPORT

Return peg no. 1457
Tot.returned bobbins 29
% returned bobbins 2.1
Returned tube bases 12
% Returned tube bases 0.8
Returned tubes 1378
Inserted tubes 0
% Inserted tubes 0.0

TAIL PICK-UP STATION 1

Foot time [ms] 978

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Cycle time [ms] 4333

Fed bobbins 1437
Bobbins 1 attempt 1312
Bobbins 2 attempt 106
Bobbins, more attempts 0
% Bobbins 98.7
% Bobbins 1 attempt 91.3
% Bobbins 2 attempt 7.4
% Bobbins, more att. 0.0
Bobbins w/out tail 19
% Bobbins w/out tail 1.3

CLEANER
Fed pegs 12
Cleaned tube bases 12
Failed clean.tube bases 0
Rejected bobbins 0
Time in autom.mode 28781
Time in man.mode 0
Time in alarm mode 0
Number of alarms 0

MACHINE ALARMS TOTAL PREPARER ALARMS

MAGAZINE 1 1

---------------------
MAGAZINE 1 PREPARER ALARM DETAILS (if required in
Loading=1 interface)

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HEAD FUNCTIONS

The HEAD FUNCTIONS window is activated by the key on the screen left This window includes the following
functions:

Machine/winding unit immediate controls

Bobbin change card addressing
Reading working data of a unit
Data reset
CAM
Remote loading

UNIT IMMEDIATE CONTROLS

Pressing the button UNIT IMMEDIATE CONTROLS, the following window is displayed:

GROUP UNIT IMMEDIATE CONTROLS

GROUP 1 All Units 2

Reset meter count 3 Empty bobbin change station 11

Knotting cycle 4 Peripheral address change 12
HW reset power 5 Reset modulation cradle 13
Batch start 6 Package unload 14
Bobbin change enabling 7 Doffing force-lot 1 15
Bobbin change disabling 8 Doffing force-lot 2 16
Bobbin change power 9 Clearer test ON 17
Forced doffing 10 Clearer test OFF 18

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UNIT IMMEDIATE CONTROLS

Unit group Sends a control to the range defined in the field (x ÷ y).
(x | y) The value (x) identifies the first unit belonging to the group.
The value (y) identifies the last unit of the group.

All units Sends a control to all units belonging to the machine.

Reset meter count Resets the package meter value in the selected units.

Knotting cycle A splicer cycle is performed.

HW reset power A reset of the cards in the selected units is performed.

Batch start
Bobbin change The bobbin change function is enabled.
enabling Control used after a bobbin change disabling control.

Bobbin change The bobbin change function is disabled, so that the selected units can be fed
disabling manually (e.g. with a package).

Bobbin change A complete cycle of bobbin change is controlled, namely: discharge of the peg
power in feeding and transfer of the second peg from the reserve to the unwinding
station.

Forced doffing A control of reached meter count (doffing) is sent.

Empty bobbin Only the peg discharging from the unwinding station is performed.
change station
Peripheral address Control used to change the address of the selected winding units.
change
Reset modulation If the unit is equipped with electronic modulation, the package-holding cradle is
cradle returned to the zero position.

Package unload Forced doffing with no new tube

Doffing force - Lot 1
Doffing force on the specified lot unit
Doffing force - Lot 2
Clearer test ON Enables the unit stop after a cut
Clearer test OFF Restore the standard operation after the "Clearer test ON" control

BOBBIN CHANGE CARD ADDRESSING

Three controls are available when selecting the Bobbin change card addressing window:

Addressing start
Test addressing start
Test addressing stop

The procedure for the bobbin change card addressing is the following:

Set the machine in STOP

Press the immediate control of “Addressing start” from the operator interface;
On head no. 1, press the STOP key (black button); be careful, as when pressing the head START button (WHITE
button) the head exits the addressing mode.

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Move one of the peg presence sensor levers in bobbin change reserve; the head confirms the performed
addressing by triggering the valve of the unthreading blow for a moment.
Continue with the sequence on all heads returning to point 3.
After performing the sequence on all heads press the control “Test addressing stop” from the operator interface to
save the address in the memory of the cards.
The confirmation of the correct addressing can be made locally, on the individual heads, and pressing 3 times in
fast sequence the head STOP push button; check that the corresponding bobbin pick-up lever is opened.

DATA RESET.

By this window it is possible to reset the productive data of the different units.
It is possible to select:

Complete reset
Complete reset + meter count
Complete reset + meter count + clearers

After having selected the wished option, press the send button; it is now asked to confirm the sending and then the
operation result is communicated.

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MACHINE PERIPHERALS SOFTWARE UPDATE (TELELOAD MANAGER)

Function used only by specialized personnel for updating the software on machine peripherals.

From “Spindle Functions” menù select the software update option (level 2 password is required)

; it appears the following window :

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Select DOWNLOAD button, the following menu will appear:

PULSAR IDLS

Machine Model
MACHINE
AUTOMATICALLY RECOGNIZED
Specify the peripheral to be updated.
The possible options are:
 Yarn End Finder
 Tube Clearer
APPLICATION
 Bobbin loader
 Headstock
 Spindle
 Trolley
Specify the microcontroller model mounted on the peripheral to
MCU TYPE be updated.
Select always AUTO
Specify the firmware file to be used for the update
S-RECORD
Select always DEFAULT
The firmware previously selected is verified and loaded on PC
APPL STATUS memory. If the operation succeed the following message appear
PROGRAM LOADED.
TARGET RANGE Specify the range of peripherals to update

Each menu selection must be confirmed pressing:

.

Once started the update operation is possible to check the working progress pressing:

IF THE UPDATE OPERATION WOULD FAIL OR INTERRUPT (e.g., POWER FAIL)

THE PROCEDURE MUST BE REPEATED FROM THE BEGINNING

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PNP DEVICES INSTALLATION AND CONFIGURATION

Function used only by specialized personnel for the installation and configuration of PNP devices (codes
14064.1656.0 and 14064.1656.1) once installed on machine in replacement of faulty or defected boards

1) EACH PNP DEVICE MUST BE INSTALLED ONE AT A TIME

2) THE DIP SWITCH PRESENT ON PNP DEVICES MUST BE SET IN THE SAME WAY OF
THE REPLACED BOARD

From “Spindle Functions” menù select the software update option (level 2 password is required)

; it appears the following window :

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Select DOWNLOAD PNP button, the following menu will appear:

PULSAR IDLS

Machine Model
MACHINE
AUTOMATICALLY RECOGNIZED
Specify the peripheral to be updated.
The possible options are:
 Yarn End Finder
 Tube Clearer
APPLICATION
 Bobbin loader
 Headstock
 Spindle
 Trolley
Specify the firmware file to be used for the update
S-RECORD
Select always DEFAULT
The firmware previously selected is verified and loaded on PC
APPL STATUS memory. If the operation succeed the following message appear
PROGRAM LOADED.
TARGET RANGE Specify the range of peripherals to update

IN ORDER TO AVOID PNP DEVICE MALFUNCTION, IT IS IMPORTANT TO SELECT THE

CORRECT PERIPHERAL IN THE APPLICATION FIELD

Each menu selection must be confirmed pressing:

.

After that, the PNP device connection is checked

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If the device identification is successful, the following message will appear:

After PNP device identification launch the update operation pressing

It is possible to check the update working progress pressing

ONCE COMPLETED THE UPDATE OPERATION IS NECESSARY TO RESEND THE

CONFIGURATION SETTINGS TO THE INSTALLED PERIPHERAL

If the PNP device identification would fail, the following message will appear

In that case, possible reasons of the message could be

 Update operation already started on PNP device: verify the working progress

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 PNP device already updated and installed: it is recognized as a standard peripheral

PNP device wrongly connected or configured (e.g. Dip Switch configuration)

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CAM – COMPUTER AIDED METERING

The laser presence must be set in the unit configurations: STRUCTURES/VARIOUS/CAM

Any time you need to check the meter count accuracy, or you have mechanically changed the cradle and laser
position, it is necessary to open the CAM configuration window. It is also necessary to use suitable masters to
check package diameters (supplied with the machine) to be positioned on the cradle; it is as well necessary to rely
on the instructions for Laser Adjustment/Calibration 17746.0003.0/0.

CAM parameter configuration window can be opened by pressing Functions and then by pressing of
the CAM:

A B1
C1

C2
B2

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The window is divided into two sections:

Current values2
A. Diameter torque/laser value of the package being processed
B1. Diameter torques/reference laser value
B2. Geometric values
Values present in the database3
C1. Diameter torques/reference laser value
C2. Geometric values

When the window is opened the data are automatically asked for to Unit 1 and are displayed in the boxes A, B1
and B2. If values have been previously saved in the database also fields C1 and C2 will contain values. To analyse
a unit other than number 1, press o .
DATA SAVING IN THE DATABASE
Check you are working on the unit you are interested in.

To save data displayed in B1 and B2, simply press and confirm the request to save data. If the saving is
successful the saved data will be immediately visible in C1 and C2.
SENDING OF DATA SAVED ON DATABASE TO A UNIT
Check you are working on the unit you are interested in.

To send data displayed in C1 and C2 to the unit, simply press and confirm the request to send data. If the
sending is successful the saved data will be immediately visible in B1 and B2 and a message confirms the
performed sending.
DATA CHANGE ON A UNIT
Check you are working on the unit you are interested in.
CHANGE THE VALUE WITH THE ONE OF THE PACKAGE BEING PROCESSED

Select on B1 the diameter you are interested it, scrolling with the keys

Press the key . The new value is displayed in red next to the selected diameter.

2 The presence of a sign --- means the data request to the unit has not been successful.
3 The presence of a sign --- means the data item has never been saved in the database.

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Press to reset the change, if necessary4

Press key to send the new data.

Confirm the sending
A message confirms the performed data sending.

4 The change function with key is not present in the unit until the data are actually sent by pressing the key

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VALUE CHANGE WITH A MANUALLY ENTERED DATA ITEM

Select on B1 the diameter you are interested it, scrolling with the keys

Press to open the window below:

The box relating to the change of the value associated to the previously selected diameter has been
marked in red.
Current: diameter/value of the package being processed.

Suggested: suggested diameter/value (this value is the same that would be obtained using button )
New: the diameter is the one previously selected, the value is the current one in the head but can be modified
using the keypad.
Enter the new value in the field New.

Press to confirm or to cancel the operation. This action closes the window.

If a new value has been entered and button has been pressed, the new value will be displayed in red, next to
the selected diameter.

Press to reset the change, if necessary5

Press to send the new data.

Confirm the sending
A message confirms the performed data sending.

5 The change is not present in the unit until the data are actually sent pressing the button

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CHANGE OF A GEOMETRIC DATA ITEM

As the figure shows, the parameters are:

A Tube tip-LASER beam distance
B Tube tip-yarn deposit distance
C Package rejection
Corr.F. Meter count correction factor

Press the key for changing the data .

Geometrical value change box is highlighted in red

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Enter the new values.

Press to confirm or to cancel the operation. This action closes the window.

If new values have been entered and button has been pressed, the new values will be displayed in red.

Press to reset the change, if necessary6

Press to send the new data.

Confirm the sending

A message confirms the performed data sending.

6 The change is not present in the unit until the data are actually sent pressing the button

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TENSION

This function is exclusively used by Savio technicians.

Short dashes lines ……… Data set for unit configuration

Pressure
Speed
COLOURS Tension
Tension Points
Meter count
POINTS Request to display the intermediate points

Data refresh

Request to activate monitor of 5 bobbins onto selected unit

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BUILD-UP

The growth values calculated for the single units (using the transmission ratio and meter count data item) can be

referred by the key GROWTH VALUES, in the Functions window.

In details, the following values are listed in the activated window:

Growth value for the selected sections (value obtained by the arithmetic average of the values of the units
belonging to the section);

Growth values of the single units.

When a window is activated, the growth numeric key becomes available only after a short period, necessary to
transfer the data from the units to the Ispector Control.
The growth value of a section becomes available only if at least half of the units belonging to the section have a
growth value other than zero.
When the Ispector Control is started all units have a growth value equal to zero and only after a sufficient number
of data the number indicating the growth takes a meaningful value (other than zero).

Press to send an update request of the displayed data.

TENSION REFERENCE DIAGNOSTICS

The tension reference values (sensor calibration) for each single unit can be displayed by pressing in the
Function window.
In details, the following values are listed in the activated window:

 The average reference values for the selected sections (value obtained by the arithmetic average of the
values of the units belonging to the section);

 Tension reference values of the single units.

 Variation percentage with respect to the section average

Press to send an update request of the displayed data.

MACHINE AND PREPARER FUNCTIONS

The MACHINE AND PREPARER FUNCTIONS window is activated by the key on the screen right. This
window includes the following functions:
Preparer immediate controls
Antenna calibration
Machine and preparer peripheral teleloading.

PREPARER IMMEDIATE CONTROLS

The available immediate controls are:

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Preparer station reset: enables to send a reset control to the search and preparer management card.
Cleaner station reset: enables to send a reset control to the cleaner management card.
Trolley 1 code programming: by this control the doffing trolley enters the mode enabling to program the TAGs of the
winding units: this function is useful when the TAG of a head is to be replaced with a new one to be suitably
formatted.
Data reset – preparer: enables to reset the partial acquisition data of the preparer.

CONFIGURATIONS .

The machine can be configured accessing to the icons on the left and on the right of the main video page; as
already shown previously, the left push button enables to access the configuration pages of all head data, while the
2 push buttons on the right enable to access the configuration pages of the machine (headstock machine, trolley,
tube magazine) and of all other peripherals (preparer, searches, cleaners, etc.).
Let’s see in details the organization and meaning of the head settings.

SUCTION CYCLE

The winding head is equipped with a single aspirator, during the winding normally off, to minimize the energy
consumption. During the reattachment cycle, the fan is activated via the following window (see SETTINGS HEAD-
PROCESS):

Can be set:
- Depression suction, the first attempt recovery of the wire from the spool
- Depression recovery, at the second attempt (if the first is unsuccessful)
- Depression realignment coils, to realign the coils before the stop in LR
- Depression maintenance, to transport the thread at the splicer
- Depression in raised, to tighten the wire in the lifting cycle
- Depression dedusting, to remove dust from the winding head (OPT)

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The wire scrap and dust accumulated in the shed lint and dust suction of the winding head, are evacuated in
coordination with the suction header, in order to ensure cleaning of all the heads with the minimum expenditure of
energy, via the following window (see GENERAL SETTINGS MACHINE):

Can be set either:

- A fixed time of cleaning (security) to clean all the heads that have a minimum of fluff
- A cleaning process optimized, linked to the number of heads and the amount of lint accumulated. In this case can
be set, to avoid continuous interventions of the vacuum header:
or the amount of residue maximum containable by each box in order to claim the cleaning cycle
or the minimum number of heads that have reached the maximum amount of fluff

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HEAD CONFIGURATIONS.

Press the button on the left of the main page a video page is displayed showing the subdivision of the heads
in the different machine sections: to access the head configuration parameters it is necessary to choose the section

whose data are to be modified pressing the relevant button .

In this way, a video page is displayed where 3 different pages can be selected with the following meaning:

to access the head simplified data;

to access the HW settings of the heads belonging to the previously selected section;

to access the page for changing all head working data.

The 3 pages are described in details below, starting from the one of the simplified data: to aid the user while setting
the working data, this page summarizes and gathers all parameters most frequently used:

PARAMETER SETTING RANGE

Yarn count ... 300.0

Package dimension [m]7 0 … 1.000.0
Bobbin dimension[m]8 0 … 1.000.0
Winding speed 400 … 2,200
Limit of cuts in the bobbin 0 … 1,000
Limit of package splicing 0 … 10.0
Acceleration 20 … 300
Nominal pressure -1 … 100
Minimum pressure -1 … 100
Minimum speed % 20 … 100
Growth 100 … 60.0

The description of the single parameters follows later.

7 Package dimension[g] if you chose to set g within window Other PC functions/Unit of measurement.
8 Bobbin dimension[g] if you chose to set g within window Other PC functions/Unit of measurement.

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HARDWARE SETTINGS - STRUCTURE.

In the page for the head HW settings the parameters are gathered as follows:

Structure Parameters Description

Other
Options In the corresponding page there are the functions below:
selectable
PACKAGE PACKAGE
SINGLE-STAKE
HAIRLESS
ANTIBUNCH
EXTERNAL BRAKE
ECONOMISED FIXED B.
JUG-SHAPED ITEM SENS.
TYPE Select among the following types:
PULSAR I
PULSAR E

Yarn presence sensor Select among the following types:

type DEFAULT
TYPE A
TYPE B

CAM Selects the presence of the CAM device on the winding unit,
select among the following:
MISSING
BAU AD
BAU 232
BAU 232 B
WO 232

CAD Selects the presence of the CAD device on the winding unit,
select among the following:
MISSING
900KpsFB
CMZ 1Mps

DUO-LOT(double lot) This setting allows user to set double lot (Duo Lot), select
among the following:
MISSING
STANDARD

S.I.S.(spindle This setting allows you to enable spindle acknowledgement

identification) (SAVIO IDENTIFICATION SYSTEM), select among the
following:
MISSING
STANDARD

PACKAGE CRADLE PULSAR

PULSAR+CAP
BALLOON BREAKER STANDARD

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TENSOR MISSING
STANDARD

Cylinder It is possible to select among 7 preset cylinder configurations or to manually set

customised data.
Taper (degrees) It allows you to specify taper of installed cylinder, select among
the following:
0 (94/94)
1.0° (93/98)
-1.0° (98/93)
Diameter (mm) (80 ... 100 mm)
Enter cylinder diameter in mm. Typical diameters are 94, 90,
87, 86. The allowed values range between 80 and 100 mm.
(100 ... 200 mm)
Winding
Set the cylinder displacement in mm. The allowed values range
travel (mm)
between 100 and 200 mm.
Number of screws Select among the following types:
1.5
2
2.5
3
Step Select among the following types:
CONSTANT (1.00)
VARIABLE (0.85)
Tube
Taper (Degrees – Hundredths -20…20)
It indicates cone taper used for take-up, in degrees and
hundredths. Minutes are converted into Hundredths as follows:
Hundredths = (Minutes / 60) x 100
Example:
Used cone: 4° 20’ | 5° 57’
conversion: (20 : 60) x 100 = 33 | (20 : 60) x 100 = 95
result: 4.33 | 5.95
Ф tip (20... 100 mm)
Outside diameter of cone tip, measured at the yarn deposit end
area.
Ф base (20 … 100 mm)
Outer diameter of the cone base, detected in the yarn deposit
start area.
Knotter
Type Possible types:
TWINSPLICER/SPLICER
SPLICER SAVIO
MESDAN 895
MESDAN 8951
MESDAN 692
MESDAN 4982
MESDAN 4101

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HEAD -PROCESS SETTINGS

The page of the head settings logically gathers all parameters connected with the batch being processed and can
be summarized as in the table below:

Structure Parameters Description

Other
Options In the corresponding page there are the functions below:
NO ANTI-KINK AT LOT START: if set, it enables lot start
function between head and trolley with anti-kink open.

DWM AS ALARM: it defines the unit behaviour further to an

alarm DWM (roll formation detected by clearer). Technological
alarm signalled by the unit with the initials t6. If this function is
enabled, the unit stops in alarm and waits for the operator
intervention; if it is not so, the unit carries out a splicing cycle
and resumes processing.

CUT TEST: if set, the head stops after a clearer cut and head
display shows “Ct” to allow for the fault to be analysed.
RFID AL. FOR DMGD TAG: if set, the winding unit generates
an alarm in case the peg has a damaged TAG on board. (only
for I machine)
RFID AL. FOR MISS.TAG: if set, the winding unit generates an
alarm in case the peg has no TAG on board. (only for I
machine)
RFID NO AL. FOR FAULT: if set, the winding unit does not
generate any alarm case of card or reading antenna
malfunction. (only for Machine I).
ANTI-KINK PREOPENING IN CYCLE (PACC): if set, the unit
releases the anti-kink during bobbin nozzle upstroke; it is useful
in case of very thin yarn.
PRODSPLIC.: this function can be used only by Savio staff.

Washer speed (RPM) yarn tensioner washers speed. Possible values to be selected
are: 20 rpm, 25 rpm, 28 rpm, 32 rpm, 38 rpm, 45 rpm, 56 rpm,
75 rpm, 113 rpm.
Trolley advance T (sec.) 0 ... 60 seconds. Advance time for the doffing trolley call time
(sec.) before a winding unit reaches the set meter count.

Doffing type Possible types:

AUTOMATIC
 >160
120 <  <160
70 <  <120
 < 70
NO
NO / W/OUT SPLIC.

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Start delay 8 ... 60 seconds.
It is the maximum time in which heads are restarted randomly
in case of machine status change; such as during machine
start-up.

Work data
Options AXIAL DISPLACEMENT: if set, it enables package formation
with axial displacement.
WAX SENSOR: if set, it enables wax finished probe control.
PACKAGE WITH CAM: if set, it enables the meter count using
the laser sensor.
QUICK START: if set, the winding unit starts with a ramp set to
avoid the first two turns at low speed.
BOOSTER ON: it activates anti-kink booster mode during
winding.

Taper increase (-1° ... 5°)

Gradual package taper increase during its formation, until
reaching the increase value set for final meter count.
(Function only available with units fitted with the electronic
modulation device).
Package dimension [g] 0 ... 42176
Final weight of the package wound on winding units.
Bobbin dimension [g] 0 ... 42176
Weight of the feeding bobbin
Speed 400 ... 2200 m/min.
Winding speed (speed of grooved roll).
Acceleration (20 ... 300)
Revolutions, every 200 ms, of grooved roll acceleration, during
unit acceleration stage, after a splicing cycle.

Slip 0.8 ... 1.2

Correction factor compensating yarn length on package.

Count (Nec) 0.6 ... 177

Count of the yarn being processed.
Limit of cuts in the bobbin It indicates the max. number of clearer cuts possible during one
bobbin.
When reaching the max. set number the unit stops in
technological alarm (t 9) at the restart the bobbin being fed is
ejected.

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Limit of package splicing It indicates the max. number of splicing allowed inside one
package. When reaching the max. set number the unit stops in
technological alarm (t 8).
At the re-start the operator must remove the package manually,
that following to the occurred alarm cannot be discharged
anymore by the doffing trolley and reset the unit meter count.
EXTRA Work data Type of start ramp Possible settings are:
STANDARD
SLOW 1……………
SLOW 2……………
SLOW 3……………

Braking ramp 100 ... 2000

Number of rpm reduction in the speed of grooved roll motor, in
a preset time period, after clearer intervention.
Package start pre-ramp 10 ... 100
Winding speed as a percentage of set speed, and used during
yarn initial deposit onto take-up cone.
Package thickness at 0 … 2.0
reduced speed It specifies thickness (in mm) of the yarn wound on tube at
reduced winding speed.
Anti-kink release speed 0 ... 1000
Release speed for anti-kink activation.
Acceleration factor 50 ... 100
It expresses the reduction (as a % of the Start Ramp) of
cylinder acceleration at package end.
byEXT0 N.A.
byEXT1 N.A.

Cycle
Options No anti-kink in cycle
Large package thread recovery
Small package thread recovery
Delayed braking
Always lift package
Clearer HW reset
No comb tear
Economised fixed nozzle
Test with yarn at standstill
Long suction with cut …………………….
Recover yarn in extra cycle
Recover yarn last package attempt

Inversion speed 40 ... 200

Inversion speed of the grooved roll during the package tail
suction stage, for the following splicing cycle.
Inversion speed, long fault 40 ... 400
Inversion speed of the grooved roll during the suction stage for
removing a defect from the package and defined by the clearer
as ”long”.
Cycle attempts (1 ... 100)
Max. number of consecutive repetitions of the splicing cycle
that the unit can make with thread both in the lower feeler and

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in the clearer. At the end of the set attempts the unit stops in
Red light.
Attempts, double Max. number of attempts for package tail suction in case of
double gripping from package.
Package attempts Max. number of attempts for tail suction made by the package
yarn nozzle before stopping the unit with a Red light to signal a
failed package tail suction
Bobbin attempts Max. number of attempts for tail suction made by the bobbin
yarn nozzle before performing a bobbin change.
Bobbin change attempts Max. number of bobbin changes performed by the unit, before
signalling a red light for failed suction of the bobbin tail.
Bobbin extraction cycles Number of attempts for tail suction by bobbin nozzle to grip a
longer tail.
Bobbin nozzle extra-stroke 10 … 50 steps
Connected to the previous parameter, it defines the length of
tail gripped by bobbin.
Advanced Cycle Package revs 1 … 40
Cut recovery: Type It is possible to select the conditions for the cut recovery cycle
as follows:
CUT TL
CUT YC
CUT CLST
CUT IPI
LR JOINT CUT
Cut recovery: Time (sec) 0 … 255
Technol.alarm recovery: It is possible to select the conditions for the technological alarm
Type recovery cycle as follows:
Count alarm
Cluster alarm
Yarn Fault alarm (NSLT, FF)
Bobbin technological alarm (CMT, IPI, SFI, CV)
Splic. RL alarm
Ejection due to splic.RL
Ejection due to all techn.alarms
Technol. alarm recovery: 0 … 40
attempts
Technol. alarm recovery: 0 …255
Time (s)
Bobbin length for ejection -110 … 110
(%)
Bobbin cleaning: start (s) 0 … 255
Bobbin cleaning: end (m) 0 … 255

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Suction cycle Depression retention (%) 10-100 depression for transport in the wire splicer
Depression intake (%) 10-100 depression on the 1st attempt to capture the wire
Depression recovery (%): 10-100 depression to subsequent attempts to capture
Depression realignment turns 10-100 depression to align the coils before the LR
(%) 0; 10-100 depression to remove dust from the head
depression dedusting 0; 10-100 depression to tighten the wire in doffing
Depression in doffing (%) 0.0 to 20.0 estimate of the length of wire drawn from the spool
Technology: Time (s) in the advanced cycle, for timing the discharge of lint from the
Length suction spool (m) heads.

CAD
Counter-weighing 100% [bar] 0 … 10.0
Nominal counter-weighing value. It expresses the desired
counter-weighing value.
1 -%Package %Counter- It defines the first package counter-weighing range as a
weighing percentage of the meter count and of Counter-weighing
100%.
2 -%Package %Counter- It defines the second package counter-weighing range as a
weighing percentage of the meter count and of Counter-weighing
100%.
3 -%Package %Counter- It defines the third package counter-weighing range as a
weighing percentage of the meter count and of Counter-weighing
100%.
4 -%Package %Counter- It defines the fourth package counter-weighing range as a
weighing percentage of the meter count and of Counter-weighing
100%.
Cycle counter-weighing (bar) … 10.0
It specifies the desired pressure during knotting cycle.
Doffing counter-weighing … 10.0
(bar) It specifies the desired pressure during doffing cycle.
Yarn tensioner
Nominal pressure -1 ...100
It indicates the push exerted on the yarn tensioner peg.
Minimum pressure -1 ... 100
It indicates the lower limit in the pushing decrease by the peg,
to balance the increase of the yarn tensioning detected while
unwinding the bobbin.
Pressure at reduced speed -1 ... 100
It indicates the pressure value applied to the yarn tensioner
pegs during the initial deposit of yarn on the tube at reduced
speed.
Pressure at ramp start -1 ... 100
It indicates the pressure value applied to the yarn tensioner
pegs during the unit re-start and is maintained till the winding
speed has reached the operating value.
Pressure for splic.pull -1 ... 100
It indicates the pressure value applied at the re-start after a
cycle and is approximately maintained for a time equal to a
few revolutions of the winding cylinder.
Doffing pressure -1 ... 100
It indicates the pressure value applied to the yarn tensioner
pegs during the doffing cycle.

Tensor
MODE The following modes are available:

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ROLL CHECK
PRESSURE CHECK
SPEED CHECK
SPEED RECOVERY
Traversing max. stage 0 … 179

Tension check +% 0 ... 100

This parameter is also called Upper check limit (see diagram
1) and defines the max. tension the yarn can reach while the
bobbin is unwound. The set number is expressed in
percentage with respect to the Reference tension, which is
autonomously calculated by the system at each batch
change.
partita. For values over the one identified in this way, the yarn
tensioner starts reducing the pushing applied to the peg.
Example:
Reference tension = 50 (Average tension of bobbin unwinding
measured by the sensor)
Check max. limit = + 10 %
Tension values beyond which the yarn tensioner starts
reducing the push on the peg: 55.
Tension check -% 0 .. 100
This parameter is also called Lower check limit (see diagram
1) and defines the yarn min. tension that can be measured
while the bobbin is unwound. The set number is expressed in
percentage with respect to the Reference tension, which is
autonomously calculated by the system at each batch
change.
For values below the one identified in this way, the yarn
tensioner starts increasing the pushing applied to the peg till
the value defined in the setting of the field Nominal pressure.
Example:
Reference tension = 50 (Average tension of bobbin unwinding
measured by the sensor)
Check min. limit = − 10 %
Tension values below which the yarn tensioner starts
increasing the push on the
peg: 45.
Bobbin analysis from % 0 ... 100
This parameter, (diagram 3) is also called Lower limit of the
bobbin to be checked, defines the percentage quantity of yarn
that must be unwound before the system starts acquiring the
values for defining the parameter Reference tension from the
start of bobbin unwinding.
(see diagram 1).
Bobbin analysis to % 0 ... 100
This parameter (see diagram 3), also called Upper limit of the
bobbin to be checked, defines - from the point indicated with
the Lower limit of the bobbin to be checked, the quantity of
yarn that must be unwound and for which Reference tension
values will be defined.
Minimum speed % 20 ... 100
It indicates the percentage of winding speed (see diagram 2).
The percentage value is calculated according to the set
Winding speed.

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Example:
Set PS: 1200 m/min
Max. speed var.: 70 %
Resulting PS: 840 m/min
Antiwrap device sensitivity 0 ... 255
The set value defines the reference threshold beyond which
the activation of the antiwrap alarm in the unit occurs.
Value meaning:
0: nearly zero sensitivity (1024)
1: max. sensitivity
255: min. sensitivity
Traversings to be ignored at 0 ... 100
the start It indicates the number of traversings of the winding cylinder
ignored by the sensor, when the unit re-starts, before
activating the Antiwrap device.
Wrong traversing 1 ... 5
seriousness Penalty used by the system to consider a failed traversing in
the yarn being wound.
Wrong traversing limit 1 ... 100
It indicates the max. number of consecutive events for which
the traversing signal impressed to the yarn by the grooved roll
is not detected.

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By this page it is possible to divide the package in 12 ranges to be wound with a different rated pressure of the yarn
tensioner.

Package tension
1 %Meter count 0 ...100 0 ... 100
%Pressure First range.
Specifies the percentage with respect to the final meter count to
which the percentage of the nominal pressure must apply.
2 %Meter count 0 ...100 0 ... 100
%Pressure Second range.
Specifies the percentage with respect to the final meter count to
which the percentage of the nominal pressure must apply.
…. ….
….
….
12 %Meter count 0 ...100 0 ... 100
%Pressure 12th range.
Specifies the percentage with respect to the final meter count to
which the percentage of the nominal pressure must apply.
Anti-flaw formation
Options Active in PRERAMP
ON/OFF at package end
Avoid all critical points

Type It is possible to select the type of desired modulation:

ON/OFF (standard)
C.A.P. C.A.P. (only if the head is preset).
Ratio tolerance 0 ... 100
Max. percentage difference between the detected ratio and the
ratio calculated with the growth.
Growth 1 ... 60.0
It is an index that represents the increase in package diameter
compared to the length of yarn taken up. In the case of a lot
change, the approximate package build up value to set is found
with the following formula:

Growth = 23000·10 / Count (Nm)

After a few complete doffings the correct value to be set can be

detected by activating the button Growth.

ON/OFF MODULATION: ANTI-FLAW FORMATION PARAMETERS

Anti-fl.form. Param.
Period (ms) 1,000 ... 5,000 ms
It defines the time of a complete ON/OFF cycle, consisting of a
roller acceleration phase and deceleration phase (see diagram
1).
Time ON % 10 ... 50
Percentage of time during which speed increases (ON phase)
in relation to the total ON/OFF period (see diagram 1).
ON Speed 1 ... 6 %
increase % Percentage increase of winding speed during acceleration (ON
period), with anti-ribboning mode ON/OFF (see diagram 1).

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K % Period 0 … 100
It indicates Period variation as a percentage corresponding to
transmission ratio 2. Parameter variation linear from ratio 1 to
ratio 2 and continues for the other ratios.
K % Time ON 0 … 100
It indicates Time ON variation as a percentage corresponding
to transmission ratio 2. Parameter variation linear from ratio 1 to
ratio 2 and continues for the other ratios.
K % Increase 0 … 100
It indicates Increase speed ON variation as a percentage
corresponding to transmission ratio 2. Parameter variation
linear from ratio 1 to ratio 2 and continues for the other ratios.

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C.A.P. MODULATION: ANTI-FLAW FORMATION PARAMETERS

Anti-fl.form. Param.
% jump 1 .. 99
It represents the point where the cradle sloping is inverted while
checking the flaw; thus, the driving goes from the tip to the
bottom of the package.
The inversion point is defined in percentage of the whole check
time.
Step limit at infeed No. of steps toward tip
Step limit at No. of steps toward base
outfeed
Hysteresis band Non-controlled band close to critical band
Zero return speed Speed at which it returns to zero position at ribbon end
KP SI 10 … 10000 Jump at infeed
KP SU 10 … 10000 Jump at outfeed
KP CTRL 10 … 10000 Infeed control parameters
KI CTRL 10 … 10000

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Base splicer or Twin-Splicer

Rotation time (ms) 800 ... 2000

Specifies the knotting cycle time.

SPLICER 895
Tail preparation (T1) (1 ... 12)
Time of the blow sent on the two thread ends to arrange the fibres in parallel and then to prepare
the ends for the following splicing.

Tail collection (L) (1 ... 12)

Quantity of overlapping in splicing chamber of the thread ends.

Blow in chamber (T2) (1 ... 12)

Time of the blow sent to the mixing chamber, that mixes
the fibres and splices the ends.

Intermediate stop YES (1)/NO (0)

Additional function to enable an advanced cycle stop, without
splicing, to check the quality of tail preparation.

MESDAN 8951
Adjustments: Tail preparation, Tail collection, Blow in chamber, Intermediate stop, as on 695, with:
- Water cycles: number of water pump strokes per cycle. Selection available: 0, 1.
A kit for the application of an added solenoid valve in retrofitting (OPT) is also available in order to enable 2 pump
strokes (for extremely thick yarns, only).

MESDAN 4982 (device derived from Polar)

Adjustments as on 695, with:
- Heating time (minutes): time required to take the device to the right temperature (approximately 25
minutes). During this period the winding head is inhibited.
- Fork activation: determines the position of the fork throttling the chamber outlet air. It takes three positions:
0 – always closed; 1 – always open; 2 – close at 1st blow, open at 2nd blow (position 2 is usually used)

MESDAN 692 (device derived from Polar)

Adjustments as for 695. The tail length adjustment is directly carried out on the device.

KNOTTER 4101 (device derived from Polar)

Depending on the device chosen in the HW configuration of the current section, the page has a different content:
for this purpose, the parameters to be set depending on the knotter type are listed here below.

N.B.:
The value setting guide diagrams are shown in the window “Jointair approximate adjustments”.

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MACHINE GENERAL SETTINGS.

The window for the machine general settings can be accessed pressing the button at the top right; the
following parameter groups can be set:
Machine
Headstock
Trolley

The different settings of each of these groups are detailed here below:

Machine
Model Select the machine model; the possible choices are:
PULSAR I
PULSAR E
Type Select if it is a right or left machine.
Unit number Specify the number of winding units of the machine.
Trolley number Select the number of doffing trolleys on the machine. Possible
settings are 0 ... 4.
S.I.S. (Spindle identification) Select the enabling/disabling of the spindle acknowledgement
function. Function only available on Pulsar I machines.
DUO-LOT (double batch) Select the enabling/disabling of the machine with double batch. For
Pulsar E machines only.
Search number Specify the number of installed tail pick-up stations. Possible
settings are: 1 … 3.
Slow search Specify if the additional search station is Installed/Not installed (only
Pulsar I).
Cleaner Specify if the tube cleaner (OPT) is Installed/Not installed. For
Pulsar E or Pulsar I machines only.
Tube loader Specify if the tube loading station (OPT) is Installed/Not installed.
For Pulsar I machines only.
Hopper stations Specify the number of present hopper stations. For Pulsar E
machines only. Possible settings are: 0 .. 2.

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Headstock
Other Options Select/deselect present options:
Water pressure switch
Water tank
Dust remover number (0 ... 8)
Specify the number of present dust remover
devices.
Interval time (min) Specifies the time in minutes after which a
cleaning cycle must be performed
Cleaning time (sec) Specifies cleaning time
Blower type Specify the type of blower installed; possible
settings are:
Electrojet
Savio by Magitex
SBB
Blower: stop time (0 ... 10 min)
Determines the waiting time of the headstock
blower between two transfers (in the
Simplified case) or between two cleaning
intervals (in case of Savio by Magitex or
Electrojet).
Blower: cycles (0 ... 10)
It indicates the number of transfers performed
by the blower without discharging the dust
sucked at the machine headstock.
(Setting used only when using Savio by
Magitex and Electrojet equipment)
MAG
Magazine number (0 .. 2)
Number of cone magazines the machine is
equipped with.
Type Select the item STANDARD.
Division Set number of take-up units to which the
second magazine feeds its cones.
NSR
Number (0 ... 2)
Number of package unloading belts the
machine is equipped with.
Type Function activating the package unload mode.
Possible settings are:
Manual
Automatic
Robotised
Robotised UTIT
Robotised Neuenhauser
Null
Shunters (0 ... 8)
Number of shunters the machine is equipped
with.
Package number, belt 1 Determines the number of packaged unloaded
on the first belt; when reaching this number the
belt starts automatically

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Package number, belt 2 Determines the number of packaged unloaded
on the second belt; when reaching this number
the belt starts automatically
Last unit, package belt 1 It indicates the last winding unit served by the
first belt.

DRAIN WIRE SCRAP

Period filter cleaning Determines the space of time cleaning
devices security, in minutes, all of us a heads who
have passed the minimum threshold
Minimum time ignition Determines the time window in which to
engine intake proceed to any cleaning edlle heads
Minimum number Determines the number of heads that have
peripherals cycle start reached the maximum threshold to start a
cleaning cleaning cycle
Number cycles cleaning Measures cleaning cycles that precede the
cycle exhaust discharge of fluff
Duration breath Determines the duration in seconds puff filter
separation lint dust for separating dust from lint
Duration exhaust damper Determines the length of the bottom of the filter
opening dell'aperura to download the lint in box
Cleaning time head Determines the millisecond shutter opening
head cleaning, which must be added the
evacuation time multiplied by the head position
Evacuation time Determines the time of translation of the fluff in
the exhaust pipe between two successive
heads
Dimensions warehouse Determines the maximum grams of fluff
containable by the head
Warehouse minimum (%) Determines the minimum threshold above
which the head is empowered to wipe
Warehouse maximum (%) Determines the maximum threshold beyond
which the head requires cleaning. After the
size of the stock, the head, in the absence of
cleaning, it stops.

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DOFFING CARRIAGE SETTINGS.

The settings for the doffing carriage have been divided in 3 categories, namely:
HW configurations: configurations linked to the machine structure;
Technological data: parameters adjusting the group positions in the cycle;
Working data: parameters defining the doffing cycle mode.

All setting parameters are explained in details here below.

Trolley Fig.aaa
HW Configurations
Trolley general map It is the working area for each trolley (defined
by a min. head and by a max. head) that is to
be made physically accessible for the trolley.
For a single trolley system, just the first and the
last head are indicated, while for a multiple
trolley system the configuration must be made
so that (at least) the lower and upper limits of
each trolley are on different sections than the
others. For example:
64-head system, 1 trolley: [1.64] /
64-head system (sections by 8), 2 trolleys: first
trolley [1, 56], second trolley [9, 64]
64-head system (sections by 8), 3 trolleys: first
trolley [1, 48], second trolley [9, 56], third trolley
[17, 64]
64-head system (sections by 8), 3 trolleys
without overlapping: first trolley [1, 16], second
trolley [17, 48], third trolley [49, 64]

Priority map A subset of the general map is defined for

each trolley where the trolley has working
priority, namely it will always try to serve first
the doffing heads of this subset and then those
in the rest of its accessible area. In case of
multiple trolley system there cannot be any
overlapping of single priority maps. For
example:
64-head system, 1 trolley: [1.64]
/
64-head system (sections by 8), 2 trolleys: first
trolley [1, 32], second trolley [33, 64]
64-head system (sections by 8), 3 trolleys: first
trolley [1, 16], second trolley [17, 48], third
trolley [49, 64]
64-head system (sections by 8), 3 trolleys
without overlapping: first trolley [1, 16], second
trolley [17, 48], third trolley [49, 64]

Indicates if it is a Standard trolley or a Q

Trolley type /
symmetrical version trolley.
Tube feeding Enables to choose the tube feeding; the
possible selections are:
/
Magazine;
Baskets;

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Magazine without reserve: for managing
multiple batches: the trolley does not move
with the cone in reserve on board, rather
requests it at each doffing (slower doffing
cycle).
Version Enables to select the type of group installed on
the trolley. Introduced to manage the version of 663/6
the group with anti-fall brake.
Enables to select the type of TAG reading card
installed on the trolley. Possible settings are:
DEFAULT;
TAG card type /
SAVIO.

Technological data
Indicate the value [0÷5] of taper increase with
which the head cradles have been configured
Taper increase 610/6
in the trolley working area. In heads with
C.A.P. indicate 0 as value. Initial value: 0.
Increase in steps of the package unloading
value. For positive values the cradle goes
Package unload value beyond the rated value, while for negative
657/6
offset [steps] ones it stops before it. A step corresponds to a
movement by about 1.5 [mm] at the cradle tip.
Initial value: 0.
Increase in steps of the value where the empty
Tube load value offset tube is loaded. For positive values, the cradle
654/6
[steps] remains higher than the rated value, while for
negative values it lowers. Initial value: 0.
Increase in steps of the tube pick-up value.
Positive position offset values make the
Tube pick-up position
gripping position lower, while (steps) negative 659/6
offset [steps]
values make it rise. A step corresponds to a
movement by about 0.5 [mm].
Increase in 1/10 of mm with respect to the
Wheel rev./space
rated value (253.0 [mm]) of the wheel 652/6
offset [1/10mm]
circumference. Initial value: 0.
Variation in steps of the position where the
reserve is positioned with respect to the live
centre. Positive values move the reserve
toward the movable tailstock, while negative
Reserve position offset
values move it farther. A step corresponds to a 683/6
[steps]
movement by about 0.8 [mm]. Initial value: 0.
Note: Note: with this parameter the yarn
threading position in front of the live centre is
controlled.
increase, in steps, of the position where yarn is
clamped and cut. Positive values bring the
Yarn clamping position
scissors nearer the head, while negative 675/6
offset [steps]
values bring them farther. A step corresponds
to about 1.5 [mm]. Initial value: 0.
Yarn loading position offset: increase, in steps,
Yarn loading position
of thread load position behind the centre. 677/6
offset [steps]
Positive values bring the scissors farther the

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centre, while negative values bring them closer

to it.
Offset on tube: variation in steps of the
movement extent by the reserve cradle when
the centre closes. Positive values move the
reserve toward the movable tailstock, while
negative values move it farther. A step
corresponds to a movement by about 0.8 [mm].
Offset on tube 683/6
Initial value: 0.
Note: Note: with this parameter the reserve
position on the tube is controlled. The final
position is determined by the sum of this
parameter and of the previous one, that must
be set first.
Support position offset: increase, in steps, of
the value for supporting start on Cradle lifting
Support position offset
unit. For (steps) positive values it is lower, 661/6
[steps]
while it rises for negative values. Initial value:
0.
Notch search position offset: increase in [mm]
Notch search position
of the distance of the centring notch slow 651/6
offset [mm]
search start. Initial value: 0.
Work data
Yarn binding Number of yarn binding revolutions to be made
revolutions before the doffing. Set 0 to disable the binding. /
Initial value: 0.
Enable tail winding Enables the winding of the yarn segment left
/
after the cutting by the scissors. Initial value: 1
Reserve revolutions Min. number of tube revolutions for the
reserve. The true number of wound turns could
be higher as, after having reached the min. 683/6
number, there is the cylinder stop time. Set 0 to
disable the reserve. Initial value: 0
Speed override [%] Percentage [10÷100] of the rated transfer
speed (60 [m/min]) to be used for positioning. 652/6
Initial value: 100.
Options Enable batch start: instructs the trolley to
enable the control of the batch start cycle in
/
the manual controls (manual control P03) and
upon request by the heads. The control is
totally effective only if the heads have the
corresponding option installed and enabled.
Initial value: disabled.
Binding enabling: if enabled, while the reserve
683/6
is formed, the arm makes a small movement to
overlap the turns and to bind them

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PERIPHERAL SETTINGS

The setting window for the machine peripherals can be accessed pressing the second button on the upper
right; the operating parameters of the following machine peripherals can be set:
Preparer
Pick-up
Slow pick-up (Pulsar I/E machines)
Link
Cleaner
Hopper station
(Pulsar E machine)

The parameters of each of these peripherals are detailed here below:

Peripherals
Preparer
(Pulsar I / E) Options Lint cutting: select the lint cutting function.
Pick-up
(Pulsar I / E) Lint breaker: enable/disable this function;
Options
Anti-kink: enable/disable this function;
Specifies the number of the first unit to be fed
First unit
with the prepared bobbins.
Specifies the number of the last unit to be fed
Last unit
with the prepared bobbins.
100 ... 1200
Bobbin in suction speed Specifies the bobbin rotation speed during the
tail suction stage.
100 ... 1200
Bobbin speed with foot Specifies the bobbin rotation speed during the
tail breaking foot downstroke.
100 ... 1200
Suction start speed Specifies the bobbin rotation speed during the
first N slow revolutions in the suction stage.
1 ... 30
Specifies the max. number of revolutions made
Max. rev. number (suction)
during the tail suction step without the yarn
check sensor feeling its presence.
1 ... 30
Initial slow rev. number Number of slow revolutions made in the initial
step of the tail suction.
1 ... 4
Cycle attempt no. Number of cycle repetitions before rejecting the
bobbin.
Bobbin type Specify S or Z bobbin type.
This window enables or disables the foot
Foot cycle enabling
function in the single attempts of tail gripping.
Recover Pick-up
(Pulsar I/E)  Lint breaker: enable/disable this function;
Options
 Anti-kink: enable/disable this function;
100 ... 2000
Bobbin in suction speed Specifies the bobbin rotation speed during the
tail suction stage.

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100 ... 2000

Bobbin speed with foot Specifies the bobbin rotation speed during the
tail breaking foot downstroke.
100 ... 2000
Suction start speed Specifies the bobbin rotation speed during the
first N slow revolutions in the suction stage.
1 ... 30
Specifies the max. number of revolutions made
Max. rev. number (suction)
during the tail suction step without the yarn
check sensor feeling its presence.
0 ... 30
Initial slow rev. number Number of slow revolutions made in the initial
step of the tail suction.
1 ... 4
Cycle attempt no. Number of cycle repetitions before rejecting the
bobbin.
Bobbin type Specify S or Z bobbin type.
10…200
Specifies the stretch height in millimetres. Such
Stretch height
value is taken as reference during the cycle of
the tail pick-up in the stretch area.
CYCLES Number of cycles with brush in Number of bobbin revolutions
contact (Reserved1)
No. of bobbin's extra-revolutions Bobbin's revolutions after that the scissors yarn
(Reserved2) presence sensor has detected the yarn.

The cycle consists of maximum eight phases

performed in sequence.

It is possible to select a type of cycle in the

Phase1 curtain menu for each phase.
Phase2
Phase3 The base setting can be the following:
Phase4 Phase1 - Suction
Phase5 Phase2 – Bobbin's detection
Phase6 Phase3 – Pick-up on bobbin
Phase7 Phase4 – Pick-up on stretch
Phase8 Phase5 – Pick-up upon winding
Phase6 – Pick-up on bobbin
Phase7 – Pick-up with blow
Phase8 – Pick-up on bobbin

Link
(Pulsar I) Spinning frame type
Spindle number
Number of spindles in head
Number of spindles in tail Specify the number of pegs in spinning frame
tail
Waiting time from spinning frame Time by which the heads still work after the
(min) bobbin discharge end signal.

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Hopper station Bobbin detection sensor type Select the type of bobbin detection sensor
(Pulsar E) being used

Algorithm enabling Select the types of algorithms to be used to

detect the bobbin
Bobbin Length Currently used bobbin length

Vibrating scroll maximum Maximum percentage of the loading reference

frequency value
Vibrating scroll minimum Minimum percentage of the loading reference
frequency value
Proportional constant System adjustment parameters
Integral constant System adjustment parameters
Operating mode Enables the self-calculated/constant operation
check
Belt On time (sec.) Specifies the time required for activating the
bobbin spacing belt in case of feed request.
Belt Off time (sec.) Specifies the spacing belt stop time required
after ON time elapses.
Belt scissors cut ON time Specifies scissors closing time
Tube cleaner
(Pulsar I/E) Tube initial millimetres Value identifying the distance between tube
base and yarn deposit start point (see figure 1).
The set value must not be below 9 mm.
Tube length (180 ... 310 mm)
Parameter defining the quantity of stroke made
by the trolley with stripper strut. The required
value is the length of the bobbin tube used in
the winder.
Tube base height (30… 100 mm)
Tube base reference height
Router
(Pulsar E ) Step time 1200 … 5000 ms
Specifies the frequency with which pegs enter
the preparer.
Feeling options Possible options are:
Release multiple peg: if selected, it allows
releasing all pegs of the parking section;
otherwise a single peg is released at a time.
Height sensor Dirty/Clean: if selected, it
specifies the presence of a height sensor. It is
selected by default.
Pick-up
(Pulsar E) The following options are available:
Foot at cycle 1;
Foot at cycle 2;
Foot at cycle 3;
Bobbin S/Z;
Options
Bobbin unthreading;
Anti-mariage;
Equivalent search (only with PULSAR E DUO -
LOT);
Threading extra-time;
Bobbin in suction speed 200 ... 1200

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Specifies the bobbin rotation speed during the

tail suction stage.
10 ... 20
Specifies the max. number of revolutions made
Suction rev. number
during the tail suction step without the yarn
check sensor feeling its presence.
1 ... 3
Cycle attempt no. Number of cycle repetitions before rejecting the
bobbin.
Hopper station
(Pulsar E) Belt ON time (sec) Specifies the time required for activating the
bobbin spacing belt in case of feed request.
Belt OFF time (sec) Specifies the spacing belt stop time required
after ON time elapses.
Scissors cut time (s)
Options Possible options are:
Low drum speed
Low roller speed
Low conveyor speed
Threading
station
(Pulsar E) Options Possible options are:
Slow profile
Simult. start
Tube cleaner
(Pulsar E) Gap length A Value identifying the distance between tube
base and yarn deposit start point (see figure 1).
The set value must not be below 9 mm.
Tube length A (mm) 180 ... 310
Parameter defining the quantity of stroke made
by the trolley with stripper strut. The required
value is the length of the bobbin tube used in
the winder.
Gap length B Value identifying the distance between tube
base and yarn deposit start point (see figure 1).
The set value must not be below 9 mm.
Tube length B (mm) 180 ... 310
Parameter defining the quantity of stroke made
by the trolley with stripper strut. The required
value is the length of the bobbin tube used in
the winding unit.
Minimum speed 50 … 300 steps/s

Up speed 100 … 1000 steps/s

Down speed 100 … 1000 steps/s
Speed in manual mode 100 … 600 steps/s
Options Possible options are:
Enable cleaner;
Enable tube A cleaning
Enable tube B cleaning
Code antenna presence

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14.5 SPINDLE IDENTIFICATION SYSTEM – ONLY I MACHINES

The spindle identification system is able to:

Intercept bobbins with long stretches of yarn with technological defects (e.g., CV, IPI) coming from a Ring Spinning
frame linked to a winder. The technological defects may be produced during spinning or from processes upstream.
Identify the specific spindle that produced the bobbin with a technological defect.
Attempt recovery of the technological alarm automatically through the suction of short stretches (~ 10 metres) of
defective yarn directly on the winding unit and/or recycle the defective bobbin in the tail search unit for the suction
of long stretches (~50 meters) of defective yarn.
If preferred by Customer, it can also stop the winding unit with the defective bobbin on board or unload the
defective bobbin and park it in a dedicated section of the preparer to recover it manually and intervene on the
spinning frame.
The system also allows to:
Intercept bobbins with short stretches of thick or thin yarn (caused by manual re-connections on the Ring Spinning
Frame) that generate Red Lights due to continuous cuts of the clearers (Clearer Red Lights or Splicing Red Lights).
Attempt recovery of the Clearer Red Lights through the suction of short stretches of defective yarn directly on the
winding unit and/or recycle the defective bobbin in the tail search unit for the suction of long stretches of defective
yarn.
If preferred by Customer, it can also stop the winding unit with the defective bobbin on board or unload the
defective bobbin and park it in a dedicated section of the preparer to recover it manually.
Generally speaking, recovery from the tail pick-up station is preferable because the winding unit can remove only
short stretches of yarn with low efficiency.
Each technological alarm is associated to a different coloured Flag, in order to make it easier to understand and
manage the defects requiring a prompt intervention on the spindles of the Ring Spinning Frame:
Black Flag - indicates that the bobbin cannot be recovered. The decision not to recover a technological alarm
automatically but to intervene manually on the spinning frame instead is the Customer's responsibility (the
technological alarms that are not selected with a check symbol generate a Black Flag, otherwise they are
recovered automatically).
Yellow Flag - indicates a technological alarm that can be recovered
Red Flag - indicates a technological alarm that has not been recovered after the set number of attempts
Green Flag - indicates a technological alarm that has been recovered
In the same way, different coloured circles are associated to the clearer Red Lights:
Black circle - used when the alarm Splicing Red Light has not been selected and a manual intervention is required.
Yellow circle - indicates a Clearer Red Light that can be recovered
Red circle - indicates a Clearer Red Light that has not been recovered (defect of the yarn - too long) after the set
number of attempts
Green Circle - indicates a Clearer Red Light that has been recovered
The system comprises a number of TAGs mounted on the bobbin transport peg and a series of antennas installed
on the machine for peg identification and management.
The technological alarm threshold must be set on the clearer control unit. The technological alarms are:
Count, Cluster, Yarn defects (Neps, Short, Long, Thin, Foreign Fibres), Bobbin alarm (IPI, Hairiness, CV, CMT)
The signals of the technological alarms are sent, once they have been intercepted by the clearers, to the relative
winding unit (for more details see the Instruction Manual of the clearer).
The bobbin preparer has a dedicated section for technological alarms in which bobbins that can no longer be
worked are stored.
The bobbin preparer also has an additional yarn slow search station (OPT) to remove long stretches of yarn without
keeping yarn search stations along the machine busy.

The instructions to set and use the S.I.S. (spindle identification system) are indicated below:

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S.I.S. ACTIVATION ON THE WINDING UNITS

In the figure below, click on the "head icon":

Head icon

Click on the "unit icon" in the figure below:

Unit icon

Click on the "structure icon" in the figure below:

Structure icon

Click on the “misc. icon" in the figure below:

Misc. icon

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Then set S.I.S. to "normal" (spinning frame identification) check box in the following window:

standard

ENABLING THE SYSTEM

Click on the "peripherals icon" (in the figure below, on the left) A new window will open: click on the "machine icon".

Peripherals icon

Machine icon

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The following window will open. On the S.I.S (spindle identification system) select NORMAL

STANDARD

S.I.S. icon

Click on the “S.I.S. icon”. The following window will appear. click on the “Set up icon”.

Set up icon

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The "Spinning Frame Spindle Recognition" window will open. Enable the spinning frame spindle recognition
system by selecting the check box "Enabled".
Then set the desired cut reference number: Cuts/10 km (recommended), or Cuts (per bobbin)

Last 4 bobbin
discharges
window

First line

Second line
Set the reference value after checking the head reports
Third line

First line (for the current and 3 previous doffing operations) - used to set an absolute Number or a Value based on
10km of yarn
For this line, the Customer must choose whether to use absolute values (for instance, using the most recent doffing
operations as a reference) or to use values based on 10km of yarn.
Second line - used to select "Number or Cuts/10Km"
Third line - used to set a Value based on 10 Km for Historical data (from the last Historical data reset).

The reference values selected by the Customer must be greater than the values found in the head reports. In this
way, the system will identify the bobbins exceeding the set values:
note: when entering an absolute Number, the value found on the head report is a total (referred to the selected
shift), therefore the Number should be obtained by dividing the value found by the total number of bobbins
processed in the shift.
Historical data are given only as a general picture of what happens over long time periods. Users are
recommended to monitor closely the last 4 doffing operations of the spinning frame, to reach a better
understanding of how the spinning frame itself behaves and, if necessary, for a prompt technical intervention.

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The entered Reference Numbers are used by the system in the PC window (last 4 bobbin discharges) to indicate
when the limits have been exceeded (scissors icon and red horizontal line)

Click on the “head icon” to open a new window. Click on the chosen "unit icon".

Head icon

Unit icon

The following window will open. Click on the "process icon" and then on the "advanced cycles" icon.

Process icon

Advanced cycles
icon

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The following window will open.

Yarn alarm recovery icon

Click on the "yarn alarm recovery icon" to open the Technological Alarms and Red Lights window.

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Select the desired Technological Alarm or Red Light and behaviour of the winding unit (rejection or non-rejection of
the defective bobbin).

Savio Engineers Only

Important:
1) do not select the EXP check boxes - these are for Savio Engineers only
3) the "Unload with all alarms" option can be used to force bobbin unload with all splicing Red Lights or alarms.

If a bobbin triggers an alarm that had not been selected by the Customer, the bobbin is marked with a Black Flag
(this means that the manual intervention of the operator is required), and if rejection has not been selected either,
the head will stop with the bobbin on board. The bobbin is rejected only once the stop-start button has been
pushed, but the operator must immediately remove it manually or it will be recycled again. On the contrary, if
unload is selected, the bobbin is rejected automatically and will be moved to the technological alarms section of the
preparer, waiting for a manual intervention.

If a bobbin triggers an alarm that had been selected, the bobbin is marked with a Yellow Flag (automatic attempts
to recover the bobbin will be activated), and if rejection has not been selected, the bobbin is processed with the set
number of recovery attempts (both on the winding unit and on the tail search). When the max. number of attempts
is reached unsuccessfully, the bobbin is marked with a Red Flag and the head stops with the bobbin on board as
above. On the contrary, if unload is selected, the bobbin is rejected automatically and will be moved to the
technological alarms section of the preparer, waiting for a manual intervention.

The Splicing Red Lights, which are associated to coloured circles instead of flags, follow the same procedure.

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Please refer to the following three-step flow chart:

STEP 1: The bobbin triggers a technological

alarm.
The head tries to recover the alarm with the
set number of attempts.
In case of failure, the bobbin is rejected and
marked with a Yellow Flag

STEP 2: the bobbin is sent to the tail pick-

up station, where a longer stretch of yarn
is suctioned to remove the defect

STEP 3: the bobbin is once again sent to

the machine to be unwound by a head

YES IS THE AMOUNT OF YARN NO

REMOVED SUFFICIENT TO AVOID
THE SAME TECHNOLOGICAL
ALARM?

THE UNWINDING CONTINUES BOBBIN - RECYCLED AGAIN IN THE TAIL SEARCH

ONCE THE MAX. NUMBER OF ATTEMPTS IS
THE BOBBIN IS MARKED WITH A GREEN FLAG REACHED UNSUCCESSFULLY, THE BOBBIN IS
(TECHNOLOGICAL ALARM REMOVED) MARKED WITH A RED FLAG AND SENT TO THE
TECHNOLOGICAL ALARMS SECTION

SETTING THE NUMBER OF TAIL AND WINDING UNIT SEARCH ATTEMPTS

NOTE: NOTE: THE YELLOW FLAG IS

TRANSITIONAL, EVERY BOBBIN WILL BE
MARKED WITH A GREEN OR RED FLAG IN
THE END

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Click on "head icon", "unit icon", "process icon" and "advanced cycle" icon as shown above. The number of
attempts and the suction time for the attempts of the winding unit can be set in the following window:

The first digit indicated the number of attempts of the head

The second digit indicates the number of tail search attempts
Head suction time (s).
E.G.: 12 = 1 tail search attempt and 2 head attempts

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CURRENT AND LAST 3 DOFFING OPERATIONS DATA
Instructions for obtaining data from the system are given below:

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Click on the "S.I.S. icon" to open the following window, which shows the last 4 doffing operations (Last Spinning
Bobbin Ends):

Current doffing
operation

Reports of the 3
previous doffing
operations

Single cell

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The window displays the conditions of the Ring Spinning frame spindles, with Technological Alarms, Splicing Red
Lights, Cuts, starting from the worst, together with the status of the alarms (green=recovered, red=failure,
yellow=processing). Clicking on a single cell, the corresponding Ring spindle window opens, offering more detailed
information.

Technological alarms for each

bobbin

Yarn defects cuts on the single

bobbin

The red columns represent data for each single bobbin, the green columns represent the average values for the
entire doffing operation.
The horizontal red lines indicate pre-set values for the cuts Reference Number.

The scissors icon indicates the presence of too many cuts on a certain ring spindle, exceeding the pre-set
limits.

Example:
In this case, winding unit no.19 intercepted a technological defect on spindle no. 834 (type CV, for 2563.5 metres).
The bobbin was unloaded, marked with a YELLOW FLAG, sent to the tail search station to eliminate the defect,
and then processed by winding unit no. 3. This winding unit reached the max. number of attempts without
eliminating the defect (after further 67.9 metres) and the bobbin was finally unloaded and marked with a RED
FLAG.

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HISTORICAL DOFFING OPERATION DATA

The following windows show the history of technological alarms and Red Lights for each ring spindle and each
winding unit. Clicking on the "spindle historical data icon" or the "head historical data icon"), it is possible to view
the history since the last system reset.
Head historical data
Ring spindle historical data icon
icon

Single cell

Clicking on a single cell will open a window displaying historical data, as shown above.

History of technological alarms for all bobbins

produced by spindle no.361 from the last
Defect cuts for all bobbins manual reset.
produced by spindle no.361
from the last manual reset

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Clicking on the "interrogation icon" it is possible to view/verify the history of each single ring spindle. Enter the
spindle number and click on the "refresh icon" to see the spindle historical data. Follow the same procedure for the
winding unit. To view the historical data of the alarms for the bobbins parked in the technological alarms section
click on the "parked bobbins refresh icon".

Interrogation icon

Spindle refresh icon

Parked bobbins refresh icon

Head refresh icon

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5.12 MAINTENANCE PROGRAMME

INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

OPERATIONS NOT Hand Tools 5.2.5.1 MACHINE

BODY GENERAL
ORDINARY andwarnings shown
CLEANING
inparagraphchargebel
Replacement and Handling of
ow.
electronic boards
0 Personal protectionas
requiredby the rulesin
force in thecountry of
installationof the
machine.

Disassembly of single Compressed air 5.1.5.1 MAIN

SUCTION FILTER
cyclone filter cover, visual system (gentle blow), CLEANING
check of mesh filter and Personal protection
8 cleaning using downwards
equipment as required
blowing
by the laws of the
country where the
machine is installed

Cleaning the cooling grilles of Aspirator, 5.1.5.2 ELECTRIC

COMPONENT
electric material housings in
Compressed air COOLING GRIDS
the headstock system (gentle blow), CLEANING

8 Personal protection
equipment as required
by the laws of the
country where the
machine is installed

Peg conveyor belt brush Aspirator, 5.2.5.1 MACHINE

BODY GENERAL
cleaning Personal protection CLEANING
8 equipment as required
by the laws of the
country where the
machine is installed

Bobbin preparer path Compressed air 5.5.5.1 BOBBIN

PREPARER
cleaning system (gentle blow),
GENERAL
Personal protection CLEANING
8 equipment as required
by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Unit general cleaning Compressed air 5.6.5.1 GENERAL

CLEANING GROUP
system (gentle blow),
RESEARCH
Manual tools, BRANCH ROLL
TOP COP
8 Personal protection
equipment as required
by the laws of the
country where the
machine is installed

Package cone magazine Aspirator, 5.7.5.1 PACKAGE

CONE MAGAZINE
general cleaning
Compressed air GENERAL
system (gentle blow), CLEANING

8 Personal protection
equipment as required
by the laws of the
country where the
machine is installed

Clean the ratiomotor, reserve Aspirator, 5.7.5.1 PACKAGE

CONE MAGAZINE
compartment and cone
Manual tools, GENERAL
conveyor tail CLEANING
Personal protection
8
equipment as required
by the laws of the
country where the
machine is installed

Pegs conveyor belt top and Aspirator. 5.1.5.5 PEG

CONVEYOR BELT
bottom brushes cleaning
Manual tools, BRUSH CLEANING

Personal protection
24
equipment as required
by the laws of the
country where the
machine is installed

Carefully clean any wax Brush, 5.3.5.1

PACKAGING UNIT
residues on ceramics and
Personal protection GENERAL
pins in the waxing unit area equipment as required CLEANING
24 and on the square axis of the by the laws of the
wax container.
country where the
machine is installed.

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Cleaning of external groups, Aspirator, 5.8.5.1

AUTOMATION
transfer guides and blade-
Personal protection TROLLEY
lifter control piston of GENERAL
24 equipment as required
automation carriage CLEANING
by the laws of the
country where the
machine is installed

Bobbin preparer path Compressed air 5.5.5.1 BOBBIN

PREPARER
complete cleaning. system (gentle blow). GENERAL
Operation to be carried out Manual tools, CLEANING
removing the lateral guards.
24 Personal protection
Check the general operation equipment as required
of the search cycle. by the laws of the
country where the
machine is installed

Complete cleaning of tail pick- Compressed air 5.6.5.1 GENERAL

CLEANING GROUP
up unit path system (gentle blow), RESEARCH
 Operation to be Personal protection BRANCH ROLL
TOP COP
24 carried out removing equipment as required
the lateral guards by the laws of the
 Check the general country where the
operation of the machine is installed
search cycle

Cleaning, by a cloth, of the Cotton cloth, 5.6.5.1 GENERAL

CLEANING GROUP
reading area (2) of the sensor
Manual tools, RESEARCH
(1) for thread presence on the BRANCH ROLL
economizer. Personal protection TOP COP
24
equipment as required
by the laws of the
country where the
machine is installed

Visual check, from the Manual tools, 5.6.5.1 GENERAL

CLEANING GROUP
transparent inspection
Personal protection RESEARCH
windows, of the cleaning of BRANCH ROLL
24 equipment as required
the peg conveyor belt pulleys. by the laws of the TOP COP

country where the

machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Cleaning of package Aspirator. 5.1.5.3 PACKAGE

UNLOADING BELT
unloading belt driving and idle
Personal protection ROLLER
rollers and belt control motor CLEANING
equipment as required
cooling fans.
by the laws of the
150
country where the
machine is installed.
Compressed air
system (gentle blow).

Peg cleaning Aspirator. 5.2.5.1 MACHINE

BODY GENERAL
Personal protection CLEANING
150 equipment as required
by the laws of the
country where the
machine is installed

Manually remove any flocks Aspirator, 5.3.5.1

PACKAGING UNIT
on the taper engaging lever Personal protection GENERAL
150 (1). equipment as required CLEANING
by the laws of the
country where the
machine is installed.

Cleaning suction nozzles on Aspirator. 5.5.5.1 BOBBIN

PREPARER
pegs conveyor
Personal protection GENERAL
equipment as required CLEANING
150
by the laws of the
country where the
machine is installed

Peg detecting photocell and Cotton cloth, 5.5.5.1 BOBBIN

PREPARER
tube laying down unit
Personal protection GENERAL
cleaning CLEANING
150 equipment as required
by the laws of the
country where the
machine is installed

Extrusion area reflector and Compressed air 5.5.5.2 TUBE

CLEANER
photocell cleaning system (gentle blow). MAINTENANCE
Cotton cloth,
150 Personal protection
equipment as required
by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Cone conveyor cleaning Brush with hard 5.7.5.1 PACKAGE

CONE MAGAZINE
bristles,
GENERAL
Personal protection CLEANING
150 equipment as required
by the laws of the
country where the
machine is installed

Automation carriage dust Aspirator, 5.8.5.1

AUTOMATION
brushes and wheels cleaning Personal protection TROLLEY
equipment as required GENERAL
150 CLEANING
by the laws of the
country where the
machine is installed

Bobbin preparer conveyor Aspirator. 5.5.5.1 BOBBIN

PREPARER
belt pulley cleaning (the top
Manual tools, GENERAL
guard must be removed to CLEANING
perform this operation). Personal protection
150
equipment as required
by the laws of the
country where the
machine is installed

Peg rotation unit cleaning in Aspirator. 5.5.5.1 BOBBIN

PREPARER
the tail search and insertion
Manual tools, GENERAL
station (this operation CLEANING
requires the removal of the Personal protection
150 equipment as required
upper guards; when working
with paraffin wax we by the laws of the
recommend to clean the unit country where the
at closer intervals). machine is installed

Inserting station complete Manual tools, 5.5.5.1 BOBBIN

PREPARER
cleaning (this operation Compressed air GENERAL
requires the removal of the CLEANING
system (gentle blow).
guards).
150 Personal protection
equipment as required
by the laws of the
country where the
machine is installed

Check a complete tube Personal protection 5.5.5.2 TUBE

CLEANER
cleaning cycle equipment as required
MAINTENANCE
150 by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Cleaning of the belt pulleys Aspirator, 5.6.5.1 GENERAL

CLEANING GROUP
transporting bobbin tail
Manual tools, RESEARCH
section search unit. BRANCH ROLL
Personal protection TOP COP
150 This intervention needs the equipment as required
upper guards to be removed. by the laws of the
country where the
machine is installed

Peg rotation group cleaning. Aspirator, 5.6.5.1 GENERAL

CLEANING GROUP
This intervention needs the Manual tools, RESEARCH
upper guards to be removed; BRANCH ROLL
Personal protection TOP COP
150 when working with paraffin equipment as required
wax we recommend to clean by the laws of the
the unit at closer intervals.
country where the
machine is installed

Cleaning of peg conveyor Aspirator, 5.1.5.6 PEG

CONVEYOR BELT
belts control ratiomotors,
Manual tools, UNIT CLEANING
drive and transmission rollers
Personal protection
150 equipment as required
by the laws of the
country where the
machine is installed

Check integrity and Manual tools, 5.5.5.2 TUBE

CLEANER
functionality of the emergency
Personal protection MAINTENANCE
push button located on the
equipment as required
150 control panel. When the push
by the laws of the
button is pressed it must stop country where the
all activities in progress in the machine is installed
tube cleaner.

Check the conditions of the Water and mild 5.9.5.2.1 MONTHLY

MAINTENANCE
filter, clean and if need be detergent,
replace Individual protective
160 gear in compliance with
the laws in force in the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Yarn cutting and threading Compressed air 5.5.5.1 BOBBIN

PREPARER
presence units cleaning and system (gentle blow).
GENERAL
lubrication. CLEANING
Spray oil Contrakor
WARNING: Be very careful Fluid H1, Klüber,
when lubricating the yarn Manual tools,
300 presence scissors and do not
let any oil get on the electronic Personal protection
feeler. equipment as required
by the laws of the
country where the
machine is installed

Yarn cutting and threading Compressed air 5.6.5.1 GENERAL

CLEANING GROUP
presence units cleaning and system (gentle blow), RESEARCH
lubrication BRANCH ROLL
Lubricate with spray oil
TOP COP
 Clean the unit Contrakor Fluid H1,
scissors: Yarn Kluber,
presence and cut Manual tools,
300 and threading.
Personal protection
WARNING: Be very careful equipment as required
when lubricating the yarn by the laws of the
presence scissors and do not country where the
let any oil get on the electronic machine is installed
feeler.

Package tail cutting and pick- Compressed air 5.8.5.1

AUTOMATION
up scissors cleaning and system (gentle blow), TROLLEY
lubrication spray oil Contrakor GENERAL
Fluid H1 Kluber, CLEANING
350 Personal protection
equipment as required
by the laws of the
country where the
machine is installed

Check movement of the Aspirator, 5.9.5.2

SCHEDULED
economiser, inspect the rotor Manual tools, MAINTENANCE
pulley, the differential pulley SHALL INCLUDE
and the bayonet exchanger. Individual protective INSPECTION OF
500
Ensure that the bolts are well gear in compliance with THE FOLLOWING
the laws in force in the PARTS
tight.
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Check alignment of the Aspirator, 5.9.5.2

SCHEDULED
guides of the travelling Individual protective MAINTENANCE
device gear in compliance with SHALL INCLUDE
500 INSPECTION OF
the laws in force in the THE FOLLOWING
country where the PARTS
machine is installed

Check the piping of the Manual tools, 5.9.5.2

SCHEDULED
travelling device Individual protective MAINTENANCE
gear in compliance with SHALL INCLUDE
500 INSPECTION OF
the laws in force in the THE FOLLOWING
country where the PARTS
machine is installed

- Make sure live centre (1) Aspirator, 5.3.5.1

PACKAGING UNIT
and fixed centre (2) axial Compressed air GENERAL
movement is smooth and system (gentle blow), CLEANING
free from dust and possible Personal protection
wound yarns; equipment as required
- Make sure yarn tensioner by the laws of the
country where the
unit (3) axial movement is machine is installed,
smooth; if not, clean the
500 Brush.
internal side of the sliding
bush (4).
- Make sure the wax
cartridge movement is
smooth; remove dust, wax
residues and lints from the
ceramics and the contact
points (5).

Motor shaft bearing Manual tools, 5.9.5.1

LUBRICATION
lubrication, the head pulley, Specific lubricants,
the pulley rotor fan,
differential pulley wheels. Personal protection
500 equipment as required
by the laws of the
country where the
machine is installed.

Check the screws of the Manual tools, 5.9.5.2

SCHEDULED
transmission pulley and the Individual protective MAINTENANCE
position of the fork of the belt gear in compliance with SHALL INCLUDE
500 INSPECTION OF
and of the screws of the the laws in force in the THE FOLLOWING
travelling device country where the PARTS
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Check the belts of the Manual tools, 5.9.5.2

SCHEDULED
travelling device Individual protective MAINTENANCE
gear in compliance with SHALL INCLUDE
500 INSPECTION OF
the laws in force in the THE FOLLOWING
country where the PARTS
machine is installed

Compressed air system filter Compressed air 5.1.5.7

COMPRESSED AIR
cleaning system (gentle blow), SYSTEM FILTER
Personal protection CLEANING
750 equipment as required
by the laws of the
country where the
machine is installed

Belt guide cleaning Aspirator, 5.7.5.1 PACKAGE

CONE MAGAZINE
Personal protection GENERAL
equipment as required CLEANING
750
by the laws of the
country where the
machine is installed

Doffing cycle complete check Personal protection 5.8.5.1

AUTOMATION
equipment as required TROLLEY
750 by the laws of the GENERAL
country where the CLEANING
machine is installed

Check the lubrication unit oil Oil HM 46, 5.5.5.1 BOBBIN

PREPARER
level (top up if necessary) Manual tools, GENERAL
CLEANING
Personal protection
750
equipment as required
by the laws of the
country where the
machine is installed

Tube extraction ramp pinion Manual tools, 5.5.5.1 BOBBIN

PREPARER
cleaning Personal protection GENERAL
equipment as required CLEANING
750
by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Check the conditions of the Aspirator, 5.9.5.2.2 SIX-

MONTHLY
pipes of the travelling device
Manual tools, MAINTENANCE

Individual protective
1000 gear in compliance with
the laws in force in the
country where the
machine is installed

Clean the casing of the Aspirator, 5.9.5.2.2 SIX-

MONTHLY
travelling device,
Manual tools, MAINTENANCE

Individual protective
1000 gear in compliance with
the laws in force in the
country where the
machine is installed

Photocell cleaning "Electronic Soft cloth, 5.3.5.1

PACKAGING UNIT
yarn detection and movement
Personal protection GENERAL
feeler". CLEANING
equipment as required
WARNING: This by the laws of the
intervention requires the country where the
separation of the plastic machine is installed.
guard from the photocell
casing.
The cleaning of the emitter-
receiver (photocells) surface
and of the plastic guard must
1000 be carried out only using a
soft cloth, without
compressed air and/or
aggressive products such as
solvents and similar products.
PHOTOCELL ASSEMBLY
POSITION: the take-up yarn
must move through the yarn
presence detection race
without interfering with the
detection surface (vertical
walls).

Check inserting station chain Manual tools, 5.5.5.1 BOBBIN

PREPARER
lubrication, it should feel
Personal protection GENERAL
partially greasy. CLEANING
1500 equipment as required
by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Clean the dust and yarn from Aspirator and water- 5.9.5.2.3
MAINTENANCE
wheels and supporting roller wet cloth,
EVERY YEAR
unit pins as shown.
Manual tools,
Remove the dust and yarn Personal protection
2000
from wheel surface using a equipment as required
water-wet cloth.
by the laws of the
country where the
machine is installed

Cleaning movable conveyors, Aspirator. 5.5.5.1 BOBBIN

PREPARER
yarn suction at peg base
Personal protection GENERAL
equipment as required CLEANING
4000
by the laws of the
country where the
machine is installed

Cleaning movable conveyors, Aspirator, 5.6.5.1 GENERAL

CLEANING GROUP
yarn suction at peg base Personal protection RESEARCH
equipment as required BRANCH ROLL
4000 TOP COP
by the laws of the
country where the
machine is installed

Automation carriage general Aspirator, 5.8.5.1

AUTOMATION
internal cleaning
Manual tools, TROLLEY
GENERAL
Compressed air CLEANING
system (gentle blow),
4000
Personal protection
equipment as required
by the laws of the
country where the
machine is installed

Bobbin tail suction nozzle lukewarm water and 5.5.5.1 BOBBIN

PREPARER
cleaning. Remove the bobbin. sodium hydrate
GENERAL
solution (40°C), CLEANING
NOTE: Avoid using
tools that could scratch
the inside surface of
4000
the nozzle.
Personal protection
equipment as required
by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Bobbin tail suction nozzle lukewarm water and 5.6.5.1 GENERAL

CLEANING GROUP
cleaning sodium hydrate
RESEARCH
solution (40°C),
 Bobbin tail suction BRANCH ROLL
TOP COP
nozzle disassembly Personal protection
4000 and cleaning. When equipment as required
cleaning, do not use by the laws of the
tools that could country where the
scratch the inside machine is installed
surface of the nozzle

Checking trolley alignment Personal protection 5.8.5.1

AUTOMATION
with the units below equipment as required TROLLEY
4000 by the laws of the GENERAL
country where the CLEANING
machine is installed

Checking the torque value at Personal protection 5.8.5.1

AUTOMATION
which the doffing cycle control equipment as required TROLLEY
4000 ratiomotor clutch kicks in by the laws of the GENERAL
country where the CLEANING
machine is installed

Dust suction from automation Aspirator, 5.8.5.1

AUTOMATION
carriage electric parts
Personal protection TROLLEY
equipment as required GENERAL
4000 CLEANING
by the laws of the
country where the
machine is installed

Check conditions of the tail Manual tools, 5.5.5.1 BOBBIN

PREPARER
pick-up lever profile (foot)
Personal protection GENERAL
where it usually touches the CLEANING
4000 equipment as required
bobbin body; make sure the
by the laws of the
lever axial movement is country where the
smooth. machine is installed

Checking tension of peg Manual tools, 5.5.5.1 BOBBIN

PREPARER
conveyor belts to preparer Personal protection GENERAL
equipment as required CLEANING
4000
by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Cleaning and checking Compressed air 5.5.5.1 BOBBIN

PREPARER
tension of control chain of the system (gentle blow).
GENERAL
peg conveyors to preparer. CLEANING
Lubricant Asportec 70-
This intervention needs the
07 – Metaflux,
upper and lower guards to be
4000 removed. Manual tools,
Personal protection
equipment as required
by the laws of the
country where the
machine is installed

Check of the tube extraction Compressed air 5.5.5.1 BOBBIN

PREPARER
station belt tension. system (gentle blow). GENERAL
Manual tools, CLEANING

4000 Personal protection

equipment as required
by the laws of the
country where the
machine is installed

Clean and lubricate the spring Lubricant Molykote Dx, 5.5.5.2 TUBE
CLEANER
(1) that locks the peg on the
Manual tools, MAINTENANCE
elevator trolley edge
Personal protection
4000 equipment as required
by the laws of the
country where the
machine is installed

Check tail pick-up lever profile Manual tools, 5.6.5.1 GENERAL

CLEANING GROUP
(foot) where it usually touches
Personal protection RESEARCH
the bobbin body; make sure BRANCH ROLL
4000 equipment as required
the lever axial movement is TOP COP
by the laws of the
smooth. country where the
machine is installed

Greasing cams, gears and Lubricant paste 5.8.5.1

AUTOMATION
automation carriage shafts MolykoteDx, TROLLEY
Manual tools, GENERAL
CLEANING
4000 Personal protection
equipment as required
by the laws of the
country where the
machine is installed

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INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Lubricate the bearings using Manual tools, 5.9.5.1

LUBRICATION
the special grease nipples.
Only use
Clean the opening of the greaseKLUBER
bearing (A). ISOFLEX NBU15,
Insert a quantity of
6000 grease of 1.4 to 1.5
gr.
Personal protection
equipment as required
by the laws of the
country where the
machine is installed.

Visual check of the cyclone Aspirator, 5.1.5.1 MAIN

SUCTION FILTER
filter. Suction activation of
Manual tools, CLEANING
possible residue and cleaning
of internal surface with a Personal protection
8000 equipment as required
damp cloth.
by the laws of the
country where the
machine is installed

NOTE: Usually it is not Aspirator, 5.1.5.4 MAIN

SUCTION ROTOR
necessary to clean the side
Manual tools, CLEANING
channel suction unit inside.
Personal protection
If suction is not enough, first
equipment as required
check the vacuum value
by the laws of the
indicated on the vacuometer,
country where the
then check that waste
machine is installed
evacuation duct seals all
along the machine are in
8000 their seats and operating
properly.
If vacuum is still low, it is
necessary to disassemble
and clean the side channel
suction unit: while doing so,
carefully follow the
instructions indicated by the
manufacturer in the machine
documents.

Check peg integrity Manual tools, 5.2.5.1 MACHINE

BODY GENERAL
Personal protection CLEANING
8000 equipment as required
by the laws of the
country where the
machine is installed.

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MACHINE UNIT INFORMATION, USE INSTRUCTIONS AND
02 MAINTENANCE

INTERVAL CHAPTER
(HOURS) OPERATOR TYPE OF MAINTENANCE MATERIAL USED REFERENCE

Securing the cableson Manual tools, 5.2.5.1 MACHINE

BODY GENERAL
electrical equipmentand Personal protection
CLEANING
8000 motors equipment as required
by the laws of the
country where the
machine is installed

Clean the inside of the Compressed air 5.3.5.1

PACKAGING UNIT
cylinder support box (toothed system (gentle blow), GENERAL
belt and disk for speed CLEANING
Silicone-based
detecting probe). lubricant (Parker
Super O-Lube type).
8000
Check smoothness of the Personal protection
counter weight piston (1) and equipment as required
lubricate it if necessary. by the laws of the
country where the
machine is installed.

Checking operation of the Manual tools, 5.5.5.1 BOBBIN

PREPARER
tube selecting combs
Personal protection GENERAL
equipment as required CLEANING
8000
by the laws of the
country where the
machine is installed

Replacement of the pegs Manual tools, 5.5.5.1 BOBBIN

PREPARER
spacer lever
Personal protection GENERAL
equipment as required CLEANING
8000
by the laws of the
country where the
machine is installed

Check the stretch value of the Manual tools, 5.5.5.1 BOBBIN

PREPARER
clamp supporting chain, and
Personal protection GENERAL
replace it if it is no longer equipment as required CLEANING
8000 possible to keep the required by the laws of the
deflection value.
country where the
machine is installed

Clean tension of the belt of Manual tools, 5.7.5.1 PACKAGE

CONE MAGAZINE
the pin chain’s command
Personal protection GENERAL
motor CLEANING
8000 equipment as required
by the laws of the
country where the
machine is installed

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6 - OF MACHINE START AND STOP

Modification table
Revision Date Drafter: Revision Date Drafter:
01 26/01/2016 Tweddle

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INDEX :
6.0 GENERAL SAFETY PROVISIONS ............................................................................................ 3
6.0.1 RESPONSIBILITY ON THE QUALITY OF YARN AND PACKAGES PRODUCED ........................... 4
6.1 WORKING AREA ....................................................................................................................... 5
6.2 MACHINE START-UP ................................................................................................................ 6
6.2.1 MACHINE START-UP AND OPERATION .......................................................................................... 7
6.3 MACHINE STOP ...................................................................................................................... 16
6.3.1 MACHINE ORDINARY STOP ........................................................................................................... 17
6.4 WORK INSTRUCTIONS AND TECHNOLOGICAL NOTES ...................................................... 18
6.4.1 BOBBIN FEATURES......................................................................................................................... 19
6.4.1.1 DIMENSIONS.......................................................................................................................... 19
6.4.1.2 CONFIGURATION .................................................................................................................. 20
6.4.2 SELECTING THE WORK PARAMETERS........................................................................................ 22
6.4.2.1 PNEUMATIC ADJUSTMENTS ............................................................................................... 22
6.4.2.2 UNIT MECHANICAL ADJUSTMENTS ................................................................................... 22
6.4.2.3 ISPECTOR CONTROL SETUP .............................................................................................. 28
6.4.4 DEFINING THE NUMBER OF PEGS IN THE MACHINE................................................................. 29
6.4.5 FAULTS, CAUSES AND REMEDIES ............................................................................................... 30

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6.0 GENERAL SAFETY PROVISIONS

The manual, together with the wiring, pneumatic and installation diagrams and the manuals of use and
maintenance of systems not designed by SAVIO (see the clearing, blower/aspirator, splicer systems, etc.), as well
as the spare parts catalogue, is kept inside a case provided with the machine.

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6.0.1 RESPONSIBILITY ON THE QUALITY OF YARN AND PACKAGES PRODUCED

The quality of yarn and packages produced on the machine is on the responsibility of the user. A careful reading
and a proper consultation of this Manual and of the Manuals and media supports supplied with the machine
(clearers, splicers) allows achieving the qualitative and quantitative performance expected.
In order to maintain a consistent quality of the wound yarn and the packages, it is required to make continuous
tests in the Quality Laboratory as below.

Reference should always be made on the historical data-base related to counts and blends of the consolidated
processed lots, and in lack of this, to build it gradually.
With reference to the historical data-base, please refer to the machine computer appropriate qualitative reports of
the current and previous shifts, to detect any abnormalities of the devices of the machine and check every day (*),
through your Textile Quality Laboratory, and according to the magnitude of the lots in production, at least:
- Level of yarn clearer cuts / 100 km
• In case of clearer cuts/100 Km in excess to the consolidated standard it is suggested to make a
Classimat, in order to individuate the reasons for the defects (preparation, carding, draw frames, rowing
frame, spinning).
- Quality of the joints (appearance and resistance in compliance with the consolidated standards)
- Package building
- Quality of the yarn

(*) The frequency is daily. If you have not yet adequately trained workers, it is appropriate to increase the
frequency.

In order to identify problems of the winding heads, and act upon them, it must be checked once a month (or more
frequently, if necessary):
- Good winding out of the packages
• for this purpose it is advisable to number the packages coming from the machine to be checked and re-
wind them at high speed on a manual type winder, preferably equipped with mechanical yarn clearer or
electronic clearers (excluding suctions), so that the defects can be collect, and corrective actions on the
related winding head can be made.

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6.1 WORKING AREA

ATTENTION!
Do not place any materials or cumbersome objects that could obstruct the operator’s escape
path.

ATTENTION!
Do not place materials or anything else that could hinder correct ventilation of the electric
motors and consequently compromise cooling.

ATTENTION!
When using the machine normally, it is forbidden to dwell or carry out any jobs in the work areas
that have not been mentioned in this manual.

The people trained for the ordinary use of the machine will be working in the work areas shown in the figure below,
where:

A = WORK AREA
F = MACHINE FRONT
R = MACHINE BACK

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6.2 MACHINE START-UP

This operation must be performed by qualified personnel, having proven experience and previously duly
trained.

While performing this operation, all personal protection must be worn, in compliance with the laws in force
in the country where the machine is installed.

The operator can start the machine proceeding as follows:

1. Check that the main headstock switch

(1) is ON, marked with the letter "I", and
that the winding unit's alphanumeric
display is activated.
The main switch is located on the side of
the machine headstock.

2. Verify the pneumatic supply to the

system’s control unit, on the headstock,
via the gauge on board.

3. Make sure that no emergency stop

push buttons have been pressed on the
peripheral units and that the automatic
functioning mode has been selected.

4. Check that all the panels accessing

the inside of the peripheral units are
closed with the lock provided.

5. Press the START push button (2) on

the headstock unit main panel.

6. When the whole machine has been started, the resulting condition should be:
 Headstock: suction working (the value can be read on the vacuometer).
 Winding unit: if working, with the red light off and the number of units shown on the display; if not working,
with red light on and the display showing the reason why.
 Bobbin preparer: peg conveyor belts moving and alarm signalling lamp on the headstock off.
 Package cone magazine: the Start push button has its lamp on and the cone belt is working.
 Doffing trolley: start push button with its lamp on and the display showing the number of units it is hooked
to.
 Mobile suction unit: if the device is activated (from the control panel - switch (3), it begins moving along
the machine.

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6.2.1 MACHINE START-UP AND OPERATION

YARN TENSIONER PRESSURE

Yarn tensioner adjustments

The Customer shall find the most suitable rated pressures for a proper processing, considering the actual bobbin
formation and the desired package.
Following are the most common adjustments.

Nominal pressure
Packages for warping - weaving:
Cotton Ne 6 – 20 >>> nominal pressure 80% - 40%
Cotton Ne 30 – 60 >>> nominal pressure 60% - 20%
Cotton Ne 80 – 120 >>> nominal pressure 20% - 10%
Soft packages:
the winding speed determines the yarn tensioner pressure; for speed around 700 - 800 m/1’:
rated pressure >>> 10% - 20%
for higher speed, around 1,000 m/1’
rated pressure >>> 6% - 15%

Minimum pressure
While the bobbin is being unwound the yarn tensioner reduces the pressure to compensate the winding tension
increase; the minimum pressure the yarn tensioner can reach should never be set below 6%. Following are
indicative values:
Packages for warping - weaving:
Cotton Ne 6 – 20 >>> minimum pressure 25%
Cotton Ne 30 – 60 >>> minimum pressure 10%
Cotton Ne 80 – 120 >>> minimum pressure 6%
Soft packages:
the winding speed determines the yarn tensioner pressure; for speed around 700 - 800 m/1’:
Minimum pressure >>> 10%
for higher speed, around 1,000 m/1’
Minimum pressure >>> 6%

Minimum speed %
Once the yarn tensioner minimum pressure has been reached the speed progressively decreases (if active) up to
the set value. We recommend to set the following values at first:
Minimum speed % >>> 30% – 40%
To obtain the maximum production and the best packages the speed shall be reduced on the tube base only. After
all settings we recommend to check the unwinding tension trend on the machine PC to optimise the adjustments
(access with password, green gear on screen left side).

Pressure at reduced speed (winding starting phase with empty tube)

for the first 2 mm of yarn wound on the tube (especially tubes for dyeing or oval tubes) set a reduced speed to limit
the cradle vibrations and compensate the winding low tension, by increasing the yarn tensioner pressure. We
recommend to set the following values:
Reduced speed >>> 40% - 60% (according to the tube)
Pressure at reduced speed >>> increase the rated p. by 40% - 20%

Pressure at ramp start (restart phase after one splicing cycle)

We recommend to increase the pressure according to the low starting speed, to better bind the coils on the
package.
Pressure at ramp start >>> increase the rated pressure by 5% - 10%

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Pressure for splic. pull (start phase after one splicing cycle)
In case of medium-thick counts Ne 6 – 30 we recommend increasing the pressure to reject weak splices:
Pressure for splic. pull >>> increase the rated p. by 30% - 20%

Doffing pressure (during doffing phase)

During automatic doffing we recommend reducing the pressure to facilitate the trolley operations.
Doffing pressure >>> 25% - 30%

PACKAGE TENSION

Double gear white/process/package tension.

This function is used especially with stretched yarns or yarns that tend to form skirted packages. In these cases to
obtain the best formation the yarn tensioner must be adjusted so as to form the package at stratified density, where
the first layers are harder than the following ones. It is possible to set up to 12 successive layers, even if on
average 4 different layers are sufficient. This function is useful when the rated pressure level is over 60%, since to
obtain the desired effect it is necessary to have a significant tension difference between the first and the last layers.

Following is the most common setting:

referring to the yarn tensioner rated pressure already set

Package length % % of rated pressure

40% 100%
60% 70%
80% 40%
100% 40%

CAD
Double gear white/process/CAD.
This OPT is recommended for dyeing packages or yarns with high stretch (wool, extra-twisted) to be processed at
low rated pressure. The CAD does not work on the yarn tensioner but on the cradle weight adjusting the counter-
weighing.
4 adjustment steps and two cycle and doffing counter-weighing values (to ensure the cradle does not lift up and is
not too heavy) are available. Following are some relevant settings:

Soft or wool package:

referring to the counter-weighing already set (for example 5 bars)

Package length % % of rated pressure

40% 60%
60% 70%
80% 80%
100% 100%

Cycle counter-weighing = 4.5

Doffing counter-weighing = 4.5

Obviously the CAD can be used together with the "Package tension” function.

RED LIGHTS
The machine PC provides several functions to reduce the red light number according to the reports on the causes
of the RL (red lights) activated during the processing.

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All following improving options are intended for use with efficient headstock suction (make sure the filters are not
clogged and in case of SPL > 10 for 10 km activate the management-inhibition function of the cycles with the
current threshold) and with package - package nozzle position according to the manuals.

Consecutive cycles and

RL for cut splice >>> activate the forced Bobbin Change
RL for missing splice >>> activate the forced Bobbin Change
This function is activated when RL turn on due to clearer cuts on consecutive cycles (yarn count, long
faults, faulty splices), or when the bobbin tail does not go up because of a difficult unwinding due to
wrongly packed bobbin or stuck yarn.

Consecutive cycles and

RL for cut splice >>> activate clearer Reset HW
In case of a lot of unjustified splice cuts the system activates the clearer reset function. Sometimes the
clearer looses its adjustment and in this case the control unit restores it. Available in case of Loepfe
clearers only.

RL for failed package tail pick-up >>> activate Delayed Braking

This functions serves to reduce the yarns stuck to the package by rotating the tail at high speed. This
prevents the tail from being squashed between package and cylinder upon braking. This is particularly
effective with thick stretched yarn counts.

RL for failed package tail pick-up >>> activate Always Package Lifting
With this function the package is lifted upon all cycle repetitions preventing the tail from remaining stuck.

RL for failed package tail pick-up >>> activate Recover yarn in extra cycle
>>> Recover yarn in extra cycle
upon last attempt
This function is used when the yarn coils in the package tend to ruffle in the ramp after a knotting cycle. It
is useful to prepare the tail for the suction before starting the inversion.

RL for failed package tail pick-up >>> activate Test with yarn at standstill
Use of yarns that do not slide properly and form kinks and/or coils in the package during the inversion. It
allows having a tensioned yarn before its threading in the clearer cell. This also allows reducing the
reading of double gripping by the clearer.

RL for failed package tail pick-up >>> activate Long suction with cut
This shall be used where the system detects many count faults (C and CC) and the presence of yarn cuts
or stuck on the clearer introducer and/or yarn retainer when the AR nozzle returns up to suck the faulty
parts (C and CC). This function activates the clearer cut after the "picked-up tail" check and before the AR
nozzle return to the package.

RD for splice cuts >>> activate Quick Start

To be used to avoid kinks upon cylinder start after the cycle, with snapping and/or extra-twisted yarns.
Direct start from the ramp without 2 cylinder turns at low speed.

RL for failed package tail pick-up >>> activate package turn no.
Particularly useful with thin yarns and/or yarns that do not stuck against the package.
This setting consists of two values: the first number indicates the package turns carried out with suction
nozzle with package diameter twice bigger than the cylinder one; the second indicates the package turns
carried out with suction nozzle with package diameter equal to the cylinder one. This function allows the
tail to pass in front of the suction nozzle a sufficient number of times to be sucked.

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RL for failed package tail pick-up >>> activate No comb tear
Used if no package nozzle combs are used.
This function excludes the package nozzle double movement upon tail suction.

YARN REJECTION REDUCTION

If the yarn rejection is 0.5 % higher than the produced kg, proceed as follows:
 Check for no excessive count faults. If the headstock is active for long fault suction the rejection percentage
increases.
 Check that the technical faults of the bobbins are not recovered by the winding units.
 Check that the anti-kink device is active during the cycle phase.
 Check that the package inversion turns are adequate (not over 4 turns with small package and 2 turns with
big package).

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MACHINE OPERATION CHECK

Following are the general instructions to check the machine operation referring to the reports drafted at the end of
the working shift. To carry out this analysis the machine must have processed a certain yarn quantity on all units
(better if for one entire shift).

ECO PULSARS I-DLS-Customer name First check the MACHINE EFFICIENCY, which should
Serial number: 123... always be very high, nearly 97-98%. In case of lower
09/02/2009.... efficiency find the main issues and intervene
Shift 1:06:00.... accordingly (the bobbin discharge end must not be
considered as inefficiency but as possible margin for
the winding unit).
UNIT: 1-26
Winding speed (m/min) 1000 Then check that the SYSTEM EFFICIENCY is > 95-
Count (Nm) 27.09 97%:
Package weight (g) 2100.00 This indicates
----------------------------------------------------------  that the machine automatic functions (doffing
Average speed (m/min) 0.0 trolley, bobbin automatic feed) work properly
---------------------------------------------------------- (check the driving parts efficiency and remove
any lint);
UNIT EFFICIENCY 0.0
 that the clearer setup is correct and the yarn
Red lights 0.0
has no faults that could generate technical
System al. 0.0
alarms.
Cycles 0.0
SYSTEM EFFICIENCY 0.0
Doffing 0.0 Finally check the UNIT EFFICIENCY: an insufficient
Techn. al. 0.0 production when the machine works correctly is mainly
Bobbin wait 0.0 due to the cycles (nearly 80%) than to the Red Lights
Bobbin c. stop 0.0 (20%) and the System Alarms (0%). Of course it will be
MACHINE EFFICIENCY 0.0 necessary to assess if the loss per cycles is due to
Local stop 0.0 standard working conditions (Cuts/10 Km + Bobbin
Bobbin discharge end 0.0 Changes), or to cycle errors (Extra-cycles).
Power off 0.0 It is important to check following the sequence below:
Master stop 0.0
 Cuts/10 Km
Suction stop 0.0
Clearer stop 0.0  Extra-Cycles (%)
Slide stop 0.0
Weight 0.0  Red Lights (%)
Produced packages 0.0  Ejected bobbin
Splices (No.) 0.0
Splices (T) 0.0
Splices/10 0.0 Cuts/10 Km: for a normal working they should be below
Cuts (No.) 0.0 10.
Cuts/10 0.0 Value 15 indicates a poor yarn quality or too precise
Extra-cycles 0.0 clearer settings; value 20 leads for sure to a low
Extra-cycles (%) 0.0 efficiency. The Splices/10 Km value includes all
Red light 0.0 parameters as well as the Cuts/10 Km and the bobbin
Red light (T) 0.0 changes, the yarn natural breaks, the clearer bunches
Red light (%)0.0 and any winding laps.
Alarms (No.) 0.0 Note: the Cuts/10 Km include both clearer and other
Alarms (T) 0.0 types of cuts (see below).
Doffings (T) 0.0
Bobbin changes 0.0 Extra-cycles (%): up to 5% indicates a good operation
Rejected bobbins 0.0 of the heads. Above 10% it is necessary to follow the
DIAGNOSTIC instructions on the machine PC to find
the heads featuring more extra-cycles and the two

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reasons of such extra-cycles (cut or not performed
splice), and work on the concerned heads.

Red Lights (%): up to 0.8% indicate a good operation.

Above 1.0% it is necessary to check the DIAGNOSTIC
instructions on the machine PC to understand if the
problem is a faulty tail pick-up, mechanic or due to the
workers; then intervene accordingly on the heads
featuring more red lights.

Ejected Bobbin: up to 3% of bobbin change indicates a

good operation. Above 5%, for machines with manual
bobbin loading (M/L), it is necessary to check:
 that the operator constantly feeds the bobbin
magazine
 that the operator properly inserts the tail in the
magazine
 that the passage from magazine to head is
correct
 that the head scissors are efficient
 that the yarn feeler reads correctly.

For the machines with automatic bobbin loading (E/I)

check:
 that the bobbins are separated with properly
inserted tail (to this end, check the head pick-up
efficiency)
 that the travelling blower does not interfere with
the bobbins during their handling along the
machine
 that the bobbin change parts are efficient
 that the tail pick-up by the head occurs correctly
(yarn feeler and tail suction nozzle)

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CUT REPORTS The detailed CUT REPORT can be set always visible
through the PC (recommended). In this section the cuts
Splices (No.) 0 are divided into two categories:
Splices (%) 0.0  ìcuts due to yarn real faults (Yarn Fault)
Yarn Fault 0
Yarn Fault (%) 0.0  other cuts (for splice, winding laps, double
gripping, bunch).
Splicer 0
Splicer (%) 0.0 This subdivision allows to analyse separately the cuts
Jump 0 according to the yarn fault (we recommend to analyse
Jump (%) 0.0 them referring to the clearer reports), and the service
Upper Yarn 0 cuts linked with the winding unit or the clearer.
Upper Yarn (%) 0.0 In case of cuts due to splicer:
System Cut 0  if concerning single heads check the clearer
System Cut (%) 0.0 and/or the splicer
C6 0
 in case of a general fault, check that the setting
C6 (%) 0.0
of the splicing control channel is not too
C7 0
precise.
C7 (%) 0.0
C8 0 In case of cuts due to Upper Yarn:
C8 (%) 0.0  if there is a real double gripping (to check it
monitor the machine) check the package nozzle
and comb position
Extra-cycles (%) 0.0
 in case of false double gripping detected by the
Splices (T) 0.0 clearer check the double gripping channel
Extra-cycles (%) (+) 0.00 (1) adjustment.
Extra-cycles (%) (-) 0.00 (0)
Splices (T) (+) 0.00 (1) In case of cuts due to Jump:
Splices (T) (-) 0.00 (0) the yarn vibrates strongly in the reading cell, so
 check the balloon breaker position and the
unwinding bobbin centring
 try to increase the yarn tensioner adjustment
 in case of fancy yarns, activate the OPT device
to keep the yarn in the clearer
In case of cuts due to System Cut:
 they are additional cuts generated by the
clearer for internal needs. They can not be
removed.
In the Red Lights section check what follows.
 Failed package tail pick-up: check the tail pick-
up settings, the suction power and the distance
of the nozzle from the package as well as its
parallelism. In case of a high number of cuts
activate the number limitation of heads
operating at the same time in the same cycle
RED LIGHTS 34
Cut splice = 10  missing splicing: it is due to the dirt on some
Failed package tail pick-up = 9 parts, especially the splicer, to improper splicer
Double gripping from package = 9 adjustments, or to a faulty introduction of
Missing splice = 2 bobbin and package tails.
No yarn from bobbin = 4
 cut splice: it is due to improper splicer
TECHNOLOGIC AL. 9 adjustments (long yarn ends, thick splicing), too
Clearer: OTHERS = 5 precise settings of the clearer splice channel, or
Clearer: CV = 4

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to flocks stuck in the clearer.
SYSTEM AL.
 missing yarn from bobbin: the operator does not
CLEARER-internal failure = 3
feed the yarn or other consecutive errors during
the bobbin change.
 double gripping from package: it can be due to
lateral falls of the tail, to a package nozzle
adjustment with combs too near to the
package, or to too precise settings of the
clearer double gripping check channel.
In the Technical Alarm section check if the causes are
real or if the clearer setup is too precise. Find the
technical problems and act on the machine upstream
line (spinning frame, preparation)

TAIL PICK-UP 1 In the section dedicated to the bobbin preparation

Foot time (ms) check:
Cycle time (ms)
Entered bobbins  % of bobbins upon first attempt: it is the tail
Bobbins 1 attempt pick-up efficiency upon first attempt. If > 95% it
Bobbins 2 attempt indicates a good operation. If lower, check:
Bobbins other attempts 1) the suction level
% Bobbins 1 attempt
% Bobbins 2 attempt 2) the nozzle-bobbin distance
% Bobbins other attempts 3) the centring of the tail pick-up foot on the
Bobbins without tail bobbin and its efficiency
% Bobbins without tail
4) in case change the adjustment parameters
SLOW PICK-UP (turns, downstroke time, etc...).
Foot time (ms)
Cycle time (ms)  % bobbins with failed tail pick-up: these are the
Entered bobbins bobbins the operator shall manually pick-up; in
Bobbins 1 attempt case of slow pick-up (IDLS only) consider the
Bobbins 2 attempt datum "Bobbins without tail". If < 3% it indicates
Bobbins other attempts a good operation. If higher check the bobbins
% Bobbins 1 attempt and the reasons of the failed tail pick-up; the
% Bobbins 2 attempt causes can be as follows:
% Bobbins other attempts
1) failed binding: the bobbins must be complete
Bobbins without tail and feature 2-2.5 binding turns.
% Bobbins without tail
2) Lint: check the spacing on the hopper station
PREPARER and the nozzle and scissors efficiency. If the
No. of return pegs bobbins are already bound, carefully prepare
Total return bobbins the bobbins on the spinning frame and the
% total return bobbins transfer to the compartments
Returned tube bases 3) Half bobbins: since they come from the
% of returned tube bases spinning frame, only a tail pick-up dedicated to
Inserted tubes the faulty bobbins can minimise the manual
% of inserted tubes intervention; in this case the slow pick-up can
Bobbin wait time be useful (IDLS only)
Spinning frame alarm time 4) Lint and dirt on preparer: clean and check the
brushes on the belts

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MACHINE ALARMS
MAGAZINE 1
 % of return tube bases: if < 2% indicates a
good operation. If higher check:
1) the number of breaks/1000 spindles on the
-------------------------------------------------------- spinning frame and that the manual restarts
MAGAZINE 1 with empty tubes on the spindles are properly
Loading = 1 carried out
2) The yarn winding start on the spinning frame
must be at least 10 mm from the tube base
3) The adjustment of the cross cut chisel that
breaks the yarn end on the preparer
4) The adjustment of the tail pick-up foot
5) The alignment of the unwinding bobbins on the
balloon breakers of the heads.

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6.3 MACHINE STOP

The ECO PULSARS I-DLS machine can be stopped with the following procedures:
- Ordinary stop
- Emergency stop

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6.3.1 MACHINE ORDINARY STOP

To stop the machine normally proceed as follows:

1. Press the Stop push button (1) on the control panel

and wait until all the peripheral units have been
stopped in sequence.
2. Now that the machine is completely still, the
resulting condition should be:
 Winding unit not working with yarn cut by
the clearer and display on. The red light can
be on but only if it was already on before the
machine was stopped.
 Doffing trolley and cone magazine: not
powered.
 Travelling cleaner: if this device is on it will have
stopped in the headstock.
 The following devices are powered as usual:
Ispector Control, clearer system, hopper station
(bobbin trolley loading platform), preparer and
alarm signalling lamp.

Carry out the following manoeuvre only in the case of prolonged stops:
3. Open the main switch on the headstock.
Before doing this, close all running applications on the Ispector Control in the proper sequence.
4. Open the compressed air on/off valve located on the inlet pipe on the headstock.

WARNING!
When the machine is stopped normally the emergency push button or main switch should never
be used.

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6.4 WORK INSTRUCTIONS AND TECHNOLOGICAL NOTES

ATTENTION!
Do not place any materials or cumbersome objects that could obstruct the operator’s escape
path.

ATTENTION!
Do not place materials or anything else that could hinder correct ventilation of the electric
motors and consequently compromise cooling.

ATTENTION!
When using the machine normally, it is forbidden to dwell or carry out any jobs in the work areas
that have not been mentioned in this manual.

The people trained for the ordinary use of the machine will be working in the work areas shown in the figure below,
where:

A = WORK AREA
F = MACHINE FRONT
R = MACHINE BACK

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6.4.1 BOBBIN FEATURES

6.4.1.1 DIMENSIONS

The bobbins used to feed the machine must conform to the dimensional characteristics given in the table.

MACHINE VERSION Length (mm) Width (mm) Diameter (mm)

ECO PULSARS I-DLS 180 ÷ 280 281 ÷ 310 32 ÷ 67

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6.4.1.2 CONFIGURATION

A Loops wound with ascending ring-support unit

B Loops wound with descending ring-support unit

C Bobbin binding coil

D Bobbin diameter

E Starting point of binding

H1 Top of cone

H2 Bottom of cone

L Bobbin lenght

A stretch is the length of yarn deposited on the bobbin tube during every up and down movement of the spinning
frame ring-support unit.
The stretch length is approximately 3 ÷ 6 m: it should be lower when using thick yarn and higher when using fine
yarn.
In the above figure, the stretch is the yarn length corresponding to section A plus section B.

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CROSS-WINDING RATIO
The ratio between the number of loops wound on the bobbin during the ascending phase of the ring-support unit
and the number of loops wound during the descending phase of the ring-support unit must be 2:1. That is, the
rising movement of the ring-support unit must be slow (A) and its descending movement must be fast (B). If this is
not the case, problems may occur during the unwinding of the bobbins (D).

X= ascending of the ring-support unit

Y= descending of the ring-support unit

BOBBIN TAPER
The ratio between length H1 of the top cone and diameter D of the bobbin must be at least 1.2 or more. In this case
angle α is less than 11°.
The ratio between length H2 of the bottom cone and diameter D of the bobbin must be 1 or more.

YARN DEPOSIT ON THE TUBE

Cones that are too short or rounded could cause simultaneous yarn coil getups.
Yarn deposit on the tube by the ring-support unit must begin at a distance of 30 to 40 mm from the base of the tube
(point X, Ref. A). This prevents the yarn end from escaping at the start of bobbin winding, prevents the ravelling of
the tube base during handling, and assures uniform and complete unwinding.
A section of at least 12 mm from the two ends of the tube must be free of yarn (C).
Bobbins without underwinding are recommended. However, bobbins with a maximum of three underwound loops
(L1) are acceptable.
The winding coil must be made with about 1.5 ÷ 2 turns of yarn winding on the cylindrical part of the bobbin.

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6.4.2 SELECTING THE WORK PARAMETERS

Selecting the work parameters includes those general adjustments or settings that are done each time a new yarn
lot is started.
The work parameters are susceptible to both yarn and bobbin characteristics as well as to the subsequent use of
the prepared packages. For this and other reasons, the recommended work data are to be taken only as
approximate and not as a reference.
The work parameters can be divided into:
 pneumatic adjustments
 mechanical adjustments
 Inspector Control set-ups.

6.4.2.1 PNEUMATIC ADJUSTMENTS

COUNTER-WEIGHING THE PACKAGE CRADLE

With a higher working pressure there is a lightening of the cradle which means the package is less dense.
The counterweight value is set within a range of 1 ÷ 4 kPa (1 ÷ 4 bar).

SPLICER FEEDING
This set-up is only necessary when compressed air splicers are used (JOINTAIR).
Feeding pressure to the splicers depends on the features of the materials being processed;
the value recommended is given on the Ispector Control under CONFIGURATIONS, in the APPROXIMATE
SPLICER ADJUSTMENTS folder.

6.4.2.2 UNIT MECHANICAL ADJUSTMENTS

TAPER INCREASE

This determines a progressive increase in take-up package taper as package diameter increases.
The taper increase can vary from 0° to 5°.
Paragraph "ISPECTOR CONTROL" describes the adjustment procedure (mechanical taper increase); each time
taper increase is modified, the cone-cylinder parallelism also needs adjusting.

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If the taper increase is electronic [OPT], the system self-calibrates and so the cone-cylinder parallelism needs no
adjusting when the increment parameter setting is altered.
The increase value set-up field on the Ispector Control is under CONFIGURATIONS in the WORKING DATA
folder.
Adjustment/setting of the taper increase value depends on the size of the package produced and on its subsequent
use. The suggested values are:
 cylindrical packages or low taper: 0°
 packages 4° 20’, 5° 57’, for warping and weaving: 3° ÷ 5°
 packages 4° 20’, 5° 57’, for dyeing: 0°

INSTRUCTIONS FOR A CORRECT WAXING

To select the paraffin wax, consider the conditions below:

 Yarn type;
 Temperature;
 Requirements of each yearn (paraffin wax deposits, quantity, etc.).

It is necessary to choose different types of paraffin wax according to the season to best stand the ambient
temperature variations. We recommend using paraffin wax rollers with the following features:

Colour Roller softening Needle Application NOTES

point penetration in
the roller at
25°C (in mm)
Yellow 60-62°C 10-11 Universal for cotton, synthetic Soluble in the finish with
fibres, wool and their mix. emulsifying additives added
Suitable for fine yarns and during the cleaning cycle
high ambient temperature
(approx. 30°C)
Green 59-61°C 19-20 For wool, cotton, polyester Soluble in the finish with
and their mix. Recommended emulsifying additives added
when a high quantity of during the cleaning cycle
paraffin wax is required.
Blue 56-58°C 24-25 Suitable for low tension Soluble in the finish with
yarns, yarns bleached at low emulsifying additives added
tension. during the cleaning cycle
Do not use with temperature
higher than 30°C
Red 56-58°C 22-25 For items to be bleached or Directly soluble in water
dyed after winding thanks to emulsifying
additives of the paraffin wax.

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ROLLER DIMENSION

ROLLER WEIGHT: 37.5 grams

Wax roller specifications:

 the faces must always be rounded
 The central hole must be perpendicular to the faces to avoid roller wobbling
 The roller body must be free of blowholes

Roller suppliers:

Pellizzari S.r.L., Viale Trento, 55 36078 Valdagno (VI) Italy [email protected]

Reseda-Binder, Mazmannstrasse, 38 D-72458 Albstadt-Ebingen Germany [email protected]
Yamashiro Wax Ltd, 3-9-5, Shimagashira Kadoma, Osaka 571-0016 Japan
Boeglin Paraffine, rue Géneral de Gaulle, 84 10000 Troyes France [email protected]

for a correct use of the waxing unit and to avoid cutting wax pieces, the wax roller must rotate with no obstacles
and slide smoothly inside the cartridge. Operate as follows:
 Check the roller driving needles and clean them from paraffin wax residues, if necessary.
 Make sure the cartridge spring moves freely and remove dirt and dust from the cartridge, if necessary.
 Before inserting the roller in the cartridge it is necessary to grind the faces using the tool supplied with the
machine (see following figure):

 if possible, use rollers with 5/6 m-long driving notches on one end, which ensure its rotation as indicated in
the drawing below. In this case, pay attention to position the notches on the roller driving needles' side.

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CORRECT DEPOSIT OF PARAFFIN WAX ON YARN

The yarn is suitable waxed when the paraffin deposit is approximately 0.08 to 0.18%. Outside this range the friction
increases because of an insufficient paraffin wax deposit on the yarn or paraffin accumulation on the yarn sections
on the knitting machine.
With a suitable waxing the yarn friction coefficient becomes a 40 to 50% lower than that of the non-waxed yarn, see
figure below:
Friction coefficient

A: after waxing
B: before waxing

YARN FRICTION COEFFICIENT

To understand the yarn waxing conditions it is important to know the friction coefficient variation according to the
paraffin deposit, which is represented in the diagram below:
Friction coefficient

paraffin wax %

At the beginning the friction decreases, whereas it increases as the paraffin wax deposit increases: therefore, an
excessive waxing does not lead to good results as far the friction coefficient is concerned.
There are no fixed rules on how to determine the right quantity of paraffin wax because it depends on the fibre
features, the winding speed, the type of paraffin wax and the humidity (see graphic below):

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Friction coefficient
Deposit in gr/km of yarn

% of yarn humidity before winding

A: Non-waxed yarn
B: Waxed yarn
C: Paraffin wax coating

Following are the friction coefficient for some yarns:

Type of yarn and count Friction coefficient of the Friction coefficient of the % reduction of the
not-waxed yarn waxed yarn friction coefficient
Polyester Nm 40 0.42 0.21 50
Carded cotton Ne 30 0.28 0.13 55
Wool/polyester Nm 1/42 0.35 0.16 54
Acrylic Nm 1/32 0.35 0.18 48
Wool Nm 36 0.34 0.16 53
Worsted cotton Ne 50 0.28 0,145 48
Wool/acrylic Nm 40 0.33 0.18 45

ADJUSTMENT

After determining the ambient temperature, humidity, the type of paraffin wax, the user must perform a test to
obtain a yarn featuring the minimum friction coefficient.
On the basis of many tests performed on different yarns, the best results are achieved with a paraffin deposit of
approximately 0.08-0.22%. With lower values the paraffin deposit can be insufficient thus leading to the formation
of dust in the following passages. On the other hand, higher values will lead to a higher friction coefficient with
paraffin wax deposit on the devices of the knitting machines.

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Friction coefficient

Quantity of paraffin wax g/kg yarn

A: 100% acrylic Nm 1/32

B: Carded cotton Ne 30
C: Wool Nm 1/42

PARAFFIN WAX QUANTITY REGULATION

The paraffin is deposited by interference of the yarn path on the paraffin roller. The interference value can be
adjusted with shims measuring 0.15 mm to be inserted in the base (2) of the ceramic guide (1).

The recommended interference, reached using the 2 shims, is of 0.3 mm and is suitable to obtain a deposit from
0.08 to 0.22% for most of the yarns; this interference can be reduced or increased according to the type of yarn and
the friction coefficient tests carried out on yarn samples.
If the waxing unit is not used, remove the wax containers to avoid damaging the driving supports on the movable
bottom of the containers themselves.

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6.4.2.3 ISPECTOR CONTROL SETUP

All the general set-ups and the ones which are usually subject to changes when a new lot is started, are collected
in the main CONFIGURATIONS programme in the SIMPLIFIED WORK DATA folder.
If alterations have to be made to the remaining set-ups/configurations, refer to the relative sections under
"ISPECTOR CONTROL".

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6.4.4 DEFINING THE NUMBER OF PEGS IN THE MACHINE

The number of pegs present at the same time on ECO PULSARS I-DLS is obtained with the following formula:

Number of pegs per winding unit = 20 + (15 x number of tail pick-up units) + (4 x number of winding units)

NOTE: It is not useful to insert a higher number of pegs since there is the risk to clog the runways; at the same
time, it is not useful to inset a lower number of pegs in the machine since there is the risk of not supplying the
winding units correctly.

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6.4.5 FAULTS, CAUSES AND REMEDIES

Following is a table to identify the main faults, causes and remedies during the package working and winding.

CAUSES REMEDIES
SKIRTING
1. TOO MANY REVOLUTIONS OF 1. REDUCE THE NO. OF
CYLINDER SCREW. CYLINDER SCREW
REVOLUTIONS

2. EXCESSIVE WINDING 2. CHECK THE WINDING

TENSION. TENSION:
YARN TENSIONER, SPEED.

3. TOO HEAVY BOBBING 3. INCREASE COUNTER-

HOLDER CRADLE WEIGHING
CURLINESS
1. INADEQUATE WINDING 1. REDUCE THE TENSION
TENSION AND/OR CRADLE AND/OR PACKAGE HOLDER
PRESSURE CRADLE

2. TOO HIGH TAPER INCREASE

2. REDUCE INCREASE
3. LOW GRIP OR FAULTY CONES

4. CONE DRAGGING ON ITS TOP 3. REPLACE THE TYPE OF CONE

5. UNSUITABLE CAP 4. CHECK PARALLELISM

MODULATION PARAMETERS BETWEEN CRADLE AND
CYLINDER

5. CHECK THE INCREASE AND

CONTROL VALUE
UNTIDY WINDINGS
1. THE PACKAGE IS NOT STILL 1. CHECK LIVE CENTRE SEALS
BEFORE INVERSION AND BLOCKS

2. PACKAGE NOZZLE TOUCHES 2. ADJUST THE NOZZLE

THE RETAINER AND/OR
PACK AND/OR IS TOO NEAR IT PARALLELISM, SUITABLY SPACE
DURING SUCTION PHASE THE NOZZLE ACCORDING TO
THE YARN

3. TOO LIGHT PACKAGE HOLDER 3. REDUCE THE COUNTER-

CRADLE WEIGHING

4. TOO HIGH CYLINDER

ACCELERATION AFTER 4. BY MEANS OF A PC REDUCE
KNOTTING CYCLE THE ACCELERATION

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CAUSES REMEDIES
LONG AND SHORT FALL
FOR THIS KIND OF PROBLEM IT a1. CHECK YARN TENSIONER
IS NECESSARY TO WITH RELEVANT WASHERS,
UNDERSTAND IF THE FALL HAS MAKE SURE THAT ON THE PEG
OCCURRED AFTER A SPLICING THERE IS THE BOBBIN TUBE
CYCLE OR DURING WINDING RETAINING SPRING, THAT THE
PHASE ANTI-KINK DEVICE RETAINING
SCREW IS NOT LOOSEN, CHECK
a) IF DURING WINDING: THAT THE PEG TUBE IS NOT
1. WINDING TENSION WITH BENT, AND THAT THE BOBBIN
SUDDEN CHANGES HOLDER STAKE IS CENTRED.
SPECIAL CASES:
YARNS EXTRA-TWISTED, NOT
STEAMED OR JUST SPUN, CAN
CREATE KINKS UNDER THE
YARN TENSIONER, THAT OPEN
IT DURING THE RUN CAUSING
TENSION CHANGES.
REMEDY: FIT SUITABLE
WASHERS OR FIT A
PRETENSIONER

a2. MODIFY THE CAP

PARAMETERS (CHECK THE
INCREASE) OR ON-OFF
PARAMETERS (REDUCE THE
2. CAP MODULATION SPEED JUMP)
PARAMETERS OR UNSUITABLE
ON-OFF a3. ENSURE A RELATIVE
HUMIDITY IN THE WINDING
ROOM OF AT LEAST 60%

3. TOO LOW HUMIDITY

b1. CHECK THE BOBBIN BRAKE

b) IF DURING A SPLICING CYCLE, EFFICIENCY
DEFINE IF THE FALL HAS b2. CHECK ACCELERATION
OCCURRED BEFORE OR AFTER CHECK BUSTER OPERATION (SO
THE SPLICING THAT IT DEACTIVATES AT LOW
1. BEFORE THE SPLICING SPEED)

CAUSES REMEDIES

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YARNS INSIDE PACKAGE FRONT 2. AFTER THE SPLICING:
SIDE 1. PACKAGE NOZZLES (WITH
1. AFTER FALL OF YARN- COMBS) TOO NEAR TO THE
PACKAGE ON DEAD CENTRE, PACK.
THE PACKAGE NOZZLE HAS
SUCKED ONE END. 2. REMOVE LINT FROM THE
DEAD CENTRE.

3. NO “HOOK” RETAINING THE

YARN ON THE DEAD CENTRE.

CREASING
SYNCHRONISATION BETWEEN 1. WITH ON-OFF MODULATION
PACKAGE AND SPEED. THE ACCELERATION VALUE
INCREASES.

2. WITH CAP MODULATION

CHECK THE INCREASE
PARAMETERS, CHECK ENTRY,
EXIT AND JUMP.

WRAP
LINT BREAK INSIDE THE 1. TENSION NOT SUITABLE TO
GROOVED GUIDES OF THE THE TYPE OF LINT.
CYLINDER DURING WINDING
PHASE. 2. SCRATCHED/DAMAGED
CYLINDER.

3. JUMP ON CLEARER WITH

EXCLUDED CUT.

CONCAVE PACKAGE
1. PACKAGE PACK WITH 1. WINDING SPEED AND/OR
EXCESSIVE WINDING TENSION. YARN TENSIONER EXCESSIVE
VALUES.

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CIRCULAR SIGNS
1. SIGNS NEAR CYLINDER 1. ADJUST CAP SETTINGS
MULTIPLE Ø (e.g. with Ø94 mm (reduce jump %) CHECK THE
cyl. to 94, 125, 188) INCREASE VALUE

2. CIRCULAR SIGNS NEAR 2. TENSION CHECK NOT

BOBBIN CHANGE ACTIVATED AND/OR BOBBIN
WRONG NET WEIGHT

CAUSES REMEDIES
WIDE SKIRTING
1. WINDING TENSION LOWER 1. CHECK THE UNIT ELECTRIC
THAN LOWER AND UPPER OPERATION, CHECK FOR NO
LAYERS; THE YARN TENSIONER MECHANICAL JAMS DUE TO
WASHERS DO NOT WORK FLOCKS AND/OR LINT, CHECK IF
CORRECTLY. THE YARN COMES OUT OF THE
WASHERS AFTER THE SPLICING
CYCLE; ACTIVATE OR EXTEND
THE ANTI-KINK DEVICE
OPERATION

PRESENCE OF TANGLES
1. TOO HIGH WINDING SPEED
FOR BOBBING BEING WORKED
(COIL UPWARD MOVEMENT
2. CHECK BALLOON BREAKER
POSITION
3. THE YARN DOES NOT REMAIN
TENSIONED DURING CYCLE
INVERSION PHASE (IT DOES
NOT SLIDE AND/OR REMAINS
STUCK IN THE NOZZLE OF THE
PACKAGE)
PACKAGES WITHOUT BUFFER
ON CONE 1. CHECK THE SPINDLE RUBBER
ELEMENTS STATE
2. BUFFER MOTOR OF DOFFING
TROLLEY NOT OK
3. THE GROOVED ROLL FOR THE
YARN BUFFER OF THE DOFFING
TROLLEY IS NOT ABLE TO MAKE
THE YARN PASS OVER THE
TUBE THICKNESS. (YOU NEED
THE "LEAF" TYPE)
4. NO BINDING (adjust the reserve
lever)

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YARN DEPOSIT ON THE TOP

1. CHECK PARALLELISM
BETWEEN CONE AND CYLINDER
2. INITIAL DRAGGING (TOOTH ON
CYL.) IS OK?
3. TOO HIGH PACKAGE START
PRE-RAMP, TOO LOW YARN
TENSIONER TENSION
4. PACKAGE TUBE NOT NAPPED
AND/OR TOO SLIPPERY
PACK STARTING RIBBONING
1. CHANGE DIAMETER OF
DRIVING RUBBER ELEMENT

Long ans short falls. Falls are due to high tension

changes, and kinks that could open
the yarn tensioner (extra-twisted,
snapping yarns).

Small falls are due to tension check the bobbin holder stake
changes: centring and remove any dirt or fault
on the yarn tensioner and anti-kink
device.
Falls on top of package. They occur after the clearer cut or at Cylinder with more screws (lower
bobbin end at on side end of the windup angle), if the cylinder with
yarn. On the taper packages short less screws has been used
falls are more frequent on top than the centre retainer, that prevents the
on tail. free tail windup on the centre, keeps
it detached so that it is easier to
suck it.

Gassed compact, slipping yarns on In case of short falls. It is possible to solve this problem
R/R machines. by means of the steaming process
of the packages being fed since it
stabilises the yarn. Alternatively it is
possible to apply a mechanic
pretensioner.

In case of skirting with hard It is possible to solve this problem

packages after steaming process, with CAD, for example by lightening
possible with medium worked count the last package layers, in 12
on cylinder screws at 2.5 rev. successive steps with parabola
trend.

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DISMANTLING AND WASTE DISPOSAL
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9 - DISMANTLING AND WASTE DISPOSAL

Modification table
Revision Date Drafter: Revision Date Drafter:

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00
INDEX :

9.1 OPERATIONS TO BE CARRIED OUT BY THE CUSTOMER .................................................... 3

9.1.1 DEMOLITION AND DISPOSAL .......................................................................................................... 3

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9.1 OPERATIONS TO BE CARRIED OUT BY THE CUSTOMER

Before starting to demolish the machine check its physical condition accurately, verifying whether or not there are
parts of its structure that could collapse or break during demolition.
The Customer must work observing current laws in force in his country, regarding environmental protection.

ATTENTION!
Only qualified personnel should be allowed to dismantle the machine, wearing suitable
individual protective gear (safety shoes and gloves) and using suitable tools and auxiliary
means.

9.1.1 DEMOLITION AND DISPOSAL

ATTENTION!
All disassembly operations for dismantling must be done when the machine has stopped and
after the electricity source has been cut off (lock the main switch on the control headstock on
position “O” - Zero).

ATTENTION!
Disconnect the compressed air and steam units and discharge any surplus energy prior to
carrying out any disassembly work.

ATTENTION!
Only a qualified electrician is allowed to work on the electric equipment.

It is recommended, before demolishing the machine, rendered harmless all those parts likely to cause a source of
danger, and then:
- Remove all the electrical equipment in accordance with the laws governing disposal;
- Scrap the structure of the machine by the authorized companies;
- Separate from the rest of the materials, accumulators present in the electronic cards, which must then be
disposed of in accordance with regulations of the country of use of the machine;
- Recover separately oils and fats, to be disposed of by authorized companies, in accordance with regulations
of the country of use of the machine.

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00
To comply disposed of separately according to the regulations of the country of use of the machine, completely
disassemble the parts and divide all commodities components:

1 Separe plastic parts marked with the recycling symbol according to the type of material indicated (PA, PA66 +
50% GF, POM, ABS, ABS + 17% GF, PP + 50FV, Tritan). For tubes, to separate the pipes for the compressed
air which are made of PVC, by connecting hoses to tire made of PU.
2 Separate the grommets, seals paravolvere, and Pneumatic Seals, in POS, and keep them separate from
plastics.
3 Remove with forceps ceramic thread guides incolati on introducers sheet, and keep them separate from the
other materials.
4 Removes the scissors, which are made by sintering of carbides of refractory metals dur (tungsten carbide,
titanium carbide, chromium carbide, cobalt), and to keep them separate from the remaining materials.
5 Remove the fluorescent tubes and signal lamps, and keep them separate from the remaining material.
6 Separate the metals according to the type (iron, stainless steel, aluminum, brass, cast iron).
7 Separate the electronic cards from the rest of the electrical equipment; then challenged wise to recognize the
codes of the cards made with the lead-free solders, so as to keep them separate from the other tabs.

At the time of the demolition of the machine the CE marking, this manual and other documents
must be destroyed.

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APPENDIXES
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10 - APPENDIXES

Modification table
Revision Date Drafter: Revision Date Drafter:
04 01/11/2016 Badiali Roberto

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APPENDIXES
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INDEX :

10.1 LIST OF INFORMATION DOCUMENTS SUPPLIED WITH THE MACHINE .............................. 3

10.2 LUBRICANTS ............................................................................................................................ 4

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10.1 LIST OF INFORMATION DOCUMENTS SUPPLIED WITH THE MACHINE

The table below indicates the codes and descriptions of the documents attached to the machine technical
documentation.

Code Description
006526.0.2 Right machine installation scheme
006527.0.2 Left machine installation scheme
10-2-001 Lubricants

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10.2 LUBRICANTS

It is important that products in the recommended ISO class be used for lubricating (indicated in the text with an
acronym: XM2, HM46..). This acronym, according to the ISO standards, is the symbol of certain common product
characteristics of the various Companies given in the comparative table.

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SPECIAL LUBRICATING PRODUCTS
Lubricant Commercial Manufacturer
description acronym
Silicone−based greases Super O-Lube Parker
Molybdenum−based greases (*) (a) Molikote G-n Molykote
(b) Unimoly Plus Klüber
(c) Molykote G-n Plus Molykote
Special greases TURMOGREASE PP300 Lubcon
Lubricating paste (a) Molykote Dx Molykote
(b) Altemp Q NB 50 Klüber
Special oils Lubriclens (spray) Savio
Invarol 46 Esso
Contrakor Fluid H1 (spray) Klüber
Staburags NB 8 Klüber
Special oils for Jointair 4924 Texiclens (spray) Mesdan
Chain lubricants Asportec 70-07 Metaflux
Synthetic oils PG220 (a) Blasia S220 Agip
(b) Sintheso D 220 EP Klüber
(c) Glygoyle 30 Mobil
(*) Products (b) and (c) can be used as an alternative to product (a); product (a)
cannot be used as an alternative to products (b) and (c).

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