AVL Industrial Dobby Loom User manual

Industrial Dobby Loom
User's Manual
AVL Looms
2360 Park Ave.
Chico, CA
95928-8305 U.S.A.
530 893-4915
530 893-1372 (fax #)
[e-mail] www.avlusa.com
Copyright © 2018
All Rights Reserved Worldwide

Industrial Dobby Loom User's Manual Introductory Information
Introductory Information Page | 3
Introductory Information ................................................................................................................ 1
Safety .......................................................................................................................................... 2
Warnings: ................................................................................................................................ 2
Safety Features: ....................................................................................................................... 3
IDL Setup ........................................................................................................................................ 5
Introduction ................................................................................................................................. 6
About This Manual ..................................................................................................................... 6
Preparations................................................................................................................................. 6
Safety .......................................................................................................................................... 6
Stopping your loom safely ...................................................................................................... 8
Restarting After an "Emergency Stop" ................................................................................... 9
Additional Loom Setup ............................................................................................................. 10
Square and Level the Loom .................................................................................................. 10
Flexible Air Link ................................................................................................................... 11
Floor Brackets ....................................................................................................................... 11
Power Supply ........................................................................................................................ 11
Setup Your Computer ............................................................................................................... 11
Setup the Air System ................................................................................................................ 12
Compressor ........................................................................................................................... 12
Filter-Regulator (FR) ............................................................................................................ 12
Regulators ............................................................................................................................. 13
Cylinder Flow Controls (Speed Controls) ............................................................................ 14
Testing The Loom ..................................................................................................................... 14
Pre-Operation Checklist ............................................................................................................ 15
Normal Loom Firing Sequence ................................................................................................. 15
Using the IDL ............................................................................................................................... 17
Operating the Loom .................................................................................................................. 18
Manual Loom Control ........................................................................................................... 18
Automatic Loom Control ...................................................................................................... 19
Reversing Cloth Direction ........................................................................................................ 19
Adjustments .............................................................................................................................. 22
Synchronized Loom Motion ................................................................................................. 22
Automatic Cloth Advance Speed Adjustment ...................................................................... 22
Automatic Advance and Cloth Beam Gear Adjustment ....................................................... 23

Introductory Information Industrial Dobby Loom User's Manual
Page | 4 Introductory Information
Dobby Cylinder Speed Adjustment (controls harness lifting) .............................................. 25
Shuttle Box Adjustment ........................................................................................................ 26
Cloth Storage Power Control ................................................................................................ 33
Establish Picks Per Inch (P.P.I.) ............................................................................................... 34
Pressure Roller .......................................................................................................................... 36
Temple System (To Prevent Draw-In) ...................................................................................... 37
Setting the Temple Rollers .................................................................................................... 37
Temple Rings ........................................................................................................................ 38
Warp Tension ............................................................................................................................ 38
Set Tension ............................................................................................................................ 39
Troubleshooting Tip.............................................................................................................. 39
Shuttle Box System ................................................................................................................... 40
Normal Mode ........................................................................................................................ 41
Special Mode ........................................................................................................................ 43
Extra Mode............................................................................................................................ 44
Maintenance .................................................................................................................................. 47
Maintenance .............................................................................................................................. 48
General .................................................................................................................................. 48
Square and Level the Loom .................................................................................................. 48
Maintenance .......................................................................................................................... 49
Trouble-shooting ........................................................................................................................... 51
Basic Troubleshooting Tips ...................................................................................................... 52
Shuttle Doesn't Fire ............................................................................................................... 52
Shuttle Won't Stay On Race .................................................................................................. 52
Shuttle Doesn't Box Completely ........................................................................................... 52
Loom Fires on Empty Box .................................................................................................... 52
Loom Stops -- Red Light Is On ............................................................................................. 52
Loom Stops -- Green Light Is On ......................................................................................... 52
Harnesses Drop or Don't Lift ................................................................................................ 53
Automatic Cloth Advance Inoperable ................................................................................... 53
Inconsistent Pick Count ........................................................................................................ 53
Loose Shed ............................................................................................................................ 53
Adjusting the Compu-Dobby .................................................................................................... 53
Adjusting the Shuttle Sensors ................................................................................................... 55

Industrial Dobby Loom User's Manual Introductory Information
Introductory Information Page | 5
To make the adjustment ........................................................................................................ 55
Troubleshooting the Picker Cylinders ...................................................................................... 56
Diagram of the PLC .................................................................................................................. 57
The Fine Print ............................................................................................................................... 59
AVL Customer Service ............................................................................................................. 60
AVL Warranty .......................................................................................................................... 60
AVL Returns Policy .................................................................................................................. 61

Industrial Dobby Loom User's Manual Introductory Information
Introductory Information Page | 1
INTRODUCTORY
INFORMATION
INTRODUCTORY INFORMATION

Introductory Information Industrial Dobby Loom User's Manual
Page | 2 Safety
SAFETY
Before Getting Started:
Please read the entire manual before using the loom.
Warnings:
WARNING:
EQUIPMENT SHOULD ONLY BE USED FOR TEXTILE MANUFACTURING. IF
THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE
MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY
BE IMPAIRED.
WARNING:
ELECTRICAL SHOCK HAZARD. DO NOT TAMPER WITH ELECTRICAL WIRES
OR OPERATE THE LOOM WITH SAFETY PANELS OPENED OR REMOVED.
WARNING:
PINCH, CRUSH, AND FINGER CUT-OFF HAZARDS. DO NOT OPERATE THE
LOOM WITH SAFETY PANELS OPENED OR REMOVED. DO NOT PLACE
HANDS IN MOVING MECHANISMS OR SCISSORS.

Industrial Dobby Loom User's Manual Introductory Information
Safety Page | 3
WARNING:
EQUIPMENT PANELS ARE AWKWARD AND HEAVY. TO AVOID MUSCLE
STRAIN OR INJURY, USE PROPER LIFTING TECHNIQUES AND A HELPER.
WARNING:
DO NOT POSITION EQUIPMENT IN A WAY TO BLOCK OR IMPEDE ACCESS
TO DISCONNECTING DEVICES, EMERGENCY STOPS, OR ON/OFF BREAKER
SWITCHES
WARNING:
USE OF CONDUCTIVE FIBER OR YARN ON OR AROUND THIS EQUIPMENT
WILL VOID WARRANTY AND MAY DAMAGE EQUIPMENT.
WARNING:
THIS EQUIPMENT IS CLASSIFIED FOR LIGHT INDUSTRIAL ENVIRONMENT
ONLY. OPERATION OF HIGH-CURRENT DRAW EQUIPMENT (EX. MIG
WELDER) ON THE SAME ELECTRICAL CIRCUITS MAY CAUSE EQUIPMENT
FAILURE.
Safety Features:
Covers and shielding separate weaver from moving components where pinch
hazards exist. Do not reach under covers and shielding while the loom is
operating.

Industrial Dobby Loom User's Manual IDL Setup
IDL Setup Page | 5
IDL SETUP
IDL SETUP

IDL Setup Industrial Dobby Loom User's Manual
Page | 6 Introduction
INTRODUCTION
Your Industrial Dobby Loom (IDL) is designed to be low-maintenance and
easy to use. If you are an experienced power loom weaver, you may initially
think this loom is a little quaint. If you’re more familiar with handlooms, it
may seem impossibly busy and complicated. With a little hands-on
experience, however, you’ll find that the IDL is just right. Considerable
attention has been paid to the needs of the weaver. In addition to those
things we know you’ll need, we’ve provided features that we think you’ll
want. For example, the cloth beam can be removed so that you’ll have more
working room when sleying the reed and we’ve placed the main operating
controls conveniently front-and-center. Feature for feature, you’ll soon
discover that the IDL is the best loom in its class.
ABOUT THIS MANUAL
While the IDL is simple to use, there is some information you need to know,
like how to start the IDL, how to make adjustments, and what you’ll need to
do to keep your loom in top working condition.
We have provided detailed steps to follow and illustrations to guide you.
You will also find a Maintenance and Troubleshooting section in the back of
the manual.
PREPARATIONS
Your IDL will have been assembled and tested before it left the factory. An
AVL technician will, in most cases, have uncrated and installed the loom at
your facility, run it, and made any necessary adjustments. It is also likely
that someone on your staff will have been oriented to the loom.
SAFETY
The first part of this manual shows the safety warnings and features that
apply to the IDL. Anyone who has access to the IDL must be aware of these
warnings.
Let’s talk about some safety rules that you need to follow to safely use the
loom. Remember that any piece of equipment, from a hammer to a buzz
saw, can be hazardous if it’s misused or misunderstood. The IDL is fitted
with a variety of safety devices, but the critical element in using this
machine safely is your ATTENTION TO THE RULES. The rules are:

Industrial Dobby Loom User's Manual IDL Setup
Safety Page | 7
.
1. Never, under any circumstances, remove or disable one of your
loom’s safety devices.
2. Err on the side of caution: if something seems wrong, assume it
is. Stop the loom until you’ve figured it out.
3. Don’t take chances — be particularly careful about your hands.
4. Disconnect both electrical power and air before you do any
maintenance on your loom.
5. Don’t guess. If you’re unsure about anything, and this manual
doesn’t help, call our technical support number at 800 626-9615.
6. Never stand at the end of the shuttle boxes when the loom is in
motion.
BE SAFE!!! You’ll come across other safety tips as you read more about your
IDL. PLEASE, if you read nothing else in this manual, read this safety
information!

IDL Setup Industrial Dobby Loom User's Manual
Page | 8 Safety
Stopping your loom safely
It is important to understand how to stop your loom safely, especially if an
emergency occurs. Always pay attention to where you are in relation to the
moving parts of the loom. Normally, you will use Stop or Pause to stop the
loom when weaving.
In an emergency where the loom needs to be stopped immediately, you
should use the Emergency Stop. However, anything that has already been
placed in motion will complete that motion. For instance, if the shuttle has
been thrown, it will not stop until it hits something.
1) There are three ways to stop your loom:
a.
Press STOP
b.
Press PAUSE
c. Press EMERGENCY STOP
Figure 1 - Control Panel
Each of these actions will bring the loom to a standstill; but, different
situations call for different methods.

Industrial Dobby Loom User's Manual IDL Setup
Safety Page | 9
Control Application What Happens
STOP To stop the loom at the
end of the present cycle.
Can be used for any
reason.
Loom works to the end
of the cycle and stops.
To resume, press RUN. The new cycle will begin
properly.
PAUSE To pause the loom mid-
cycle for any reason.
Interrupts the loom,
mid-cycle.
Press PAUSE to resume. The cycle should resume
with the next action.
Check to make sure the
next expected action
occurs.
EMERGENCY
STOP
To stop the loom
immediately.
Stops the loom at the
current action. The cycle
will not complete.
Turn the loom on, and
press RUN.
The loom resets to the
beginning of the next
cycle. This may result in
a flaw in the fabric
if it is
not accounted for.
Restarting After an "Emergency Stop"
If you’ve used this mode, your loom will have stopped somewhere mid-
cycle; that is, anywhere between a cloth advance and a beater return.
However, when you re-start the loom, it will re- set automatically to the
beginning of the next cycle. Whatever weaving operations were yet to go
when it was shut down will not be completed. If you continue weaving in the
AUTO mode, you’ll develop a flaw in the fabric.
Note:
Before re-starting the loom, make sure the shuttles are firmly in their boxes
and the warp yarns are correctly in place.
1) Switch the loom to Manual at the Control Panel.
2) Determine where you are in the weaving sequence.

IDL Setup Industrial Dobby Loom User's Manual
Page | 10 Additional Loom Setup
3) Use the hand control to advance through the remaining steps of the
cycle. As a reminder, each cycle consists of the following sequence
of steps:
ADVANCE —> DOBBY —> SHUTTLE —> DOBBY —> BEATER —>
BEATER
4)
Return the loom to Auto , press Run , and continue.
ADDITIONAL LOOM SETUP
Normally, the IDL is setup by an AVL technician. Depending on the
circumstances of your particular installation, you may need to provide some
additional setup.
Square and Level the Loom
Please make a note of this process, as it is an important part of the
maintenance of your loom. Your loom will perform better and give more
years of service if this process becomes a part of your regular loom
maintenance.
1) Using a tape measure, note these measurements:
a. The distance from the inside corner of the rear left vertical to
the inside corner of the front right vertical.
b. The distance from the inside corner of the rear right vertical
to the inside corner of the front left vertical.
2) These two measurements should match. If they do not, you will
need to adjust the frame slightly.
3) Now, using a level, check to see if the frame is level front-to-back,
place a carpenter’s level along the top of each Top horizontal.
4) Check side-to-side by placing the level along the length of the Cloth
beam and, again, along the Lower back framing member.
5) Depending on the flooring, you may need to use shims under the
four corner verticals in order to achieve level.
6) Once the loom is square and level, check and tighten all bolts and
nuts that connect the frame pieces.

Industrial Dobby Loom User's Manual IDL Setup
Setup Your Computer Page | 11
Over time, due to the shaking and movement the loom experiences during
use, these connections will shake loose, requiring periodic checking and
tightening. Make a check of these components a regular part of your loom
maintenance.
Flexible Air Link
If the air line from your compressor is made of a rigid material (steel pipe,
PVC, copper), we suggest that you provide a flexible link between it and the
loom. Simply connect a foot or more of ½” air hose between the FR and the
end of the compressor line. This link will dampen vibration between your
loom and the incoming air line, lessening the possibility of loosened fittings.
Floor Brackets
Your loom is equipped with special shock absorbing pads which will retard its
tendency to “walk”. In some situations, the loom may need to be anchored
to the floor. Brackets made for this purpose are available from AVL.
If you opt to bolt your loom to the floor, be sure to first check that it is
square. Bolting the loom to the floor will, over time, reduce the need to
adjust the loom for square. It will also reduce the need to make adjustments
to the flyshuttle boxes.
Power Supply
AVL strongly recommends that you use a surge protector and an
Uninterruptable Power Supply (UPS) with your loom. These will protect the
electronics in your loom from power outages and fluctuations.
Note:
If the IDL stops unexpectedly due to a power outage, check the loom
carefully for any damage before restarting. Also check the warp and the
woven cloth to make sure nothing was damaged.
SETUP YOUR COMPUTER
Your AVL technician should have installed the software for the IDL on your
computer and connected it to the Compu-Dobby.
There are several ways to connect the Compu-Dobby to the computer. The
most common is with a USB cable.
For complete information on using the software, please see the software
manual.

IDL Setup
Page | 12
SETUP THE AIR S
YSTEM
Compressor
Your
compressor must be able to deliver a minimum of 2
per minute at 115
pounds per square
Filter-Regulator (FR)
The FR (Filter,
Regulator) is mounted on the back of the
This is where the air line coming from the compressor
The primary function of this device is to
the system.
Air pressure is measured in pounds
familia
r with pneumatic systems, just think of air as
car. More air equals more
power.
You’ll
see a gauge on the FR and an adjustment knob
Turn
this knob clockwise to increase pressure.
from
the FR at 105+ p.s.i. The operating pressure
around 120 p.s.i.
Figure 2 -
FRL (may vary)
Industrial Dobby Loom User's Manual
Setup the Air System
YSTEM
compressor must be able to deliver a minimum of 2
5
cubic
pounds per square
inch.
Regulator) is mounted on the back of the
Computer
This is where the air line coming from the compressor
connects to the loom.
The primary function of this device is to
control
the air pressure coming into
Air pressure is measured in pounds
-per-square-inch (P.S.I.). If
you’re not
r with pneumatic systems, just think of air as
you think of gas in your
power.
see a gauge on the FR and an adjustment knob
immediately above it.
this knob clockwise to increase pressure.
You
should start pressure
the FR at 105+ p.s.i. The operating pressure
should
generally
FRL (may vary)
Industrial Dobby Loom User's Manual
Setup the Air System
cubic
feet of air
Computer
Cabinet.
connects to the loom.
the air pressure coming into
you’re not
you think of gas in your
immediately above it.
should start pressure
generally
be

Industrial Dobby Loom User's Manual
Setup the Air System
Regulators
In addition to the FR, there are other regulators that control the
air that is delivered to the di
component board in the computer cabinet in
of the FR. Each regulator has a
REMEMBER:
Regulators co
ntrol power. FLOW CONTROLS, discussed below, control the
speed at which your systems operate.
Each regulator controls one system and is labeled on the air board
computer cabinet. Consult the chart below to determine
values for each system.
You
Industrial Dobby Loom User's Manual
In addition to the FR, there are other regulators that control the
air that is delivered to the di
fferent loom systems. These
are located on the
component board in the computer cabinet in
the
Component box, to the left
of the FR. Each regulator has a
gauge labeled with the name.
Figure 3 - Regulators
ntrol power. FLOW CONTROLS, discussed below, control the
speed at which your systems operate.
Each regulator controls one system and is labeled on the air board
computer cabinet. Consult the chart below to determine
initial
operating
You
may find that these
settings need to be
IDL Setup
Page | 13
In addition to the FR, there are other regulators that control the
amount of
are located on the
Component box, to the left
ntrol power. FLOW CONTROLS, discussed below, control the
Each regulator controls one system and is labeled on the air board
in the
operating
settings need to be

IDL Setup Industrial Dobby Loom User's Manual
Page | 14 Testing The Loom
modified, depending on the weight of your yarns, operating speed, and other
factors.
System P.S.I. Setting
Beater 60
Cloth Storage 10-20
Dobby 60
Right picker (shuttle) 50
Left picker (shuttle) 50
Cylinder Flow Controls (Speed Controls)
The speed at which each of the loom systems operates is regulated by “flow
controls” located at various points on the loom:
Loom System Flow Control
Cloth Advance Automatic Advance Cylinder
Harness Lifting Dobby Cylinder
Box Changing Box Changing Cylinders
Cloth Storage Cloth Storage Cylinder
These different systems will operate according to the choreography which
you establish. You’ll want the loom to lift, beat, and pick according to your
weaving needs at a particular moment. This means you’ll need to set the
controls for each of the systems. It sounds much more complicated than it
really is and, once you’ve made your initial setting, you won’t need to
change them for the balance of your warp. Your installer will make the initial
settings. We describe how to adjust these and what they control in more
depth later in the manual.
TESTING THE LOOM
You will want to test the loom before beginning to weave the first time, and
anytime it has been sitting idle for a long time. Generally when your loom is