Loepfe WEFTMASTER FALCON-i User manual

WEFTMASTER ® FALCON-i
Optical Yarn Defects Sensor
Instruction Manual
46867003 en
Version 1.03 / 10.2015

Loepfe Brothers Ltd.
Kastellstrasse 10
P. O. Box
8623 Wetzikon/Switzerland
Phone [phone]
Fax [phone]
E-Mail [e-mail]
Internet www.loepfe.com
Document title: WM_FALCONi_Manual_46867003_en
Version: 1.03
Date: 10.2015
This instruction manual is copyrighted and exclusively meant for
internal purposes.
Disclosures to any third party or reproduction of any kind – even
in form of excerpts – as well as the use and/or disclosure of the
contents without written approval from Loepfe Brothers Ltd.,
except for internal use, are prohibited.
WeftMaster®and FALCON-i are registered trademarks of Loepfe
Brothers Ltd. for Switzerland and other countries.
© 2015 Loepfe Brothers Ltd., Switzerland

5 FALCON-i
Tabel of Contents
Tabel of Contents
1 General 7
1.1 About this Manual 7
1.2 Explanation of Symbols 7
1.3 Liability 8
2 Safety 9
2.1 Responsibilities 9
2.2 Personnel Requisitions 9
2.3 Usage 9
3 Product Description 11
3.1 Application 11
3.2 Components 11
3.3 Functions 11
3.4 Technical Data 12
4 Operation 13
4.1 Sensitivity Adjustment 13
4.2 Display 14
5 Checks and Maintenance 16
5.1 General 16
5.2 Safety 16
5.3 Inspections and Maintenance Work 16
6 Troubleshooting 18

7
General
FALCON-i
For your safety in case of any insecurity, please contact your
supplier.
1 General
1.1 About this Manual
1.1.1 General This manual assures a safe and efficient handling of the optical yarn defects
sensor FALCON-i.
1.1.2 Obligation to Read The personnel is obligated to read and understand these instructions, specifi-
cally the safety instructions, prior to all works.
1.1.3 Depository This manual is an integral part of the optical yarn defects sensor FALCON-i
and must be deposited within striking distance to the installation and avail-
able to the personal at all times.
In case of a resale of the installation this manual must be included.
In these instructions, safety information is marked with symbols and signal
words which point out the extent of the hazard.
The safety information has to be strictly observed to prevent accidents, per-
sonal injuries and damage to property.
1.2 Explanation of
Symbols
1.2.1 Symbols General hazard
Electrical hazard
Flammable
Property damage
DANGER Indicates an imminently hazardous situation
which will result in death or serious injury.
WARNING Indicates a potentially hazardous situation
which could result in death or serious injury.
CAUTION Indicates a potentially hazardous situation
which may result in minor or moderate injury.
ATTENTION Indicates a potentially hazardous situation which may result
in damage to property.
1.2.3 Tips and Hints Useful tips and recommendations
1.2.2 Signal Words

8
General
FALCON-i
1.3 Liability
Information and safety instructions within this manual have been implement-
ed under consideration of valid standards and guidelines as well as the cur-
rent state-of-the-art based on our long-standing experience.
1.3.1 Information within
this Manual
1.3.2 Delivery Besides the contractual obligations terms of business and delivery by the
supplier apply.
1.3.3 Technical
Modifications
Loepfe Brothers Ltd. herewith excludes liability for damages and accidents
due to following occurrences:
unauthorized rebuilds or modifications of the optical yarn defects sensor
usage of unauthorized spare parts / reproductions / modification parts not
provided by Loepfe Brothers Ltd.
1.3.4 Improper Application or
Usage
Loepfe Brothers Ltd. herewith excludes liability for damages and accidents
due to following occurrences:
usage not according to intended purpose of the equipment
failure to observe the information given within this operation manual
1.3.5 Inadequate
Maintenance
Loepfe Brothers Ltd. herewith excludes liability for damages and accidents
due to following occurrences:
deferred or inadequate maintenance
not following the instructions described in chapter “Maintenance”

9
Safety
FALCON-i
Inadequate qualifications may cause serious injury
and material damage!
ZInstallation, operation and maintenance shall only be con-
ducted by qualified technical staff.
WARNING
2 Safety
2.1 Responsibilities The customer must rule the responsibilities for installation, operation and
maintenance of the optical yarn defects sensor FALCON-i and appoint rele-
vant persons in charge.
2.2 Personnel Requisitions
2.2.1 Inadequate
Qualifications
2.2.2 Qualified Personnel Following qualifications are listed in this manual for the different task areas:
Foreman and User are qualified and trained staff for the operation and
maintenance of the optical yarn defects sensor.
Installation Engineer and Service Engineer are qualified personnel
being familiar with all safety checks, installation and service guidelines.
Repair Technician is a qualified and trained employee of Loepfe
Brothers Ltd. or a technician specifically appointed therefore by Loepfe
Brothers Ltd.
2.3 Usage
2.3.1 Designated Use The optical yarn defects sensor FALCON-i is designed and constructed for
the detection of yarn defects, knots, loops and impurities in weaving.
The optical yarn defects sensor FALCON-i must be installed and operated
in compliance with the provisions listed in installation and operating instruc-
tions.

11
Product Description
FALCON-i
3 Product Description
Yarn Guide
Yarn Guide
Digital display
Optic
Function button
The optical yarn defects sensor FALCON-i is capable of detecting small
yarn imperfections, knots, loops, and lint (dirt) created during the textile
manufacturing process in
Monofilament and multifilament yarns, regardless of yarn color.
3.1 Application
The optical yarn defects sensor FALCON-i consists of the following compo-
nents:
Chemical resistant housing made of a conducting material (ESD protection)
Optional: especially sealed for use with conducting material such as carbon
and similar fibers
Evaluation electronics
Optical sensor for measurement of yarn thickness
Digital display (7 segment-display)
Function button to adjust sensor sensitivity, to display the fault cause and
reset after an error
3.2 Components
Constant measuring of yarn thickness for yarn counts between 20 dTex
and 3000 dTex
Fault display and stop signal in case of textile faults / imperfections
Fault display and stop signal in case of excess lint / dust on the optical
sensor
3.3 Functions
The FALCON-i is not capable to detect thin places!

12
Product Description
FALCON-i
Max power 500 mW
Supply voltage 24 Vdc
PNP output 2.7 mA ±8% constant current
NPN output max. 25 mA
Ambient temperature Operation 0 – 50°C
Ambient temperature Storage -20°C – 85°C
Humidity 5 – 90% non-condensing
Degree of protection IP50
Housing Chemical resistant, made of conducting material
Evaluation electronic Shielded against electrostatic or magnetic interference
Sensor Optical measuring principal
Application Monofilament or multifilament yarns, regardless of yarn color
Yarn speed Up to 30 m/sec
Yarn count 20 – 3000 dTex
Adjustment range 10 sensitivity levels, manually and automatically adjustable
3.4 Technical Data

13
Operation
FALCON-i
In case of a power failure, the sensor automatically adjusts
to the previously selected level.
4 Operation
4.1 Sensitivity Adjustment
4.1.1 Manual / Automatic
4.1.2 Select the Sensitivity
Level
1. Push the function button briefly for 1 second.
»The actual sensitivity level is now displayed.
2. Push the function button for 3 seconds.
»The display starts blinking.
3. Select the Sensitivity level: Push the function button briefly, repeat until
the desired sensitivity level (from 0-9) is displayed.
»The selected sensitivity level blinks for 4 seconds. Then the setting is
saved.
»Yarn diameter and degree of pollution are registered.
»After 5 more seconds the display goes dark and returns to „Normal“.
Adjusting the sensitivity manually: The sensitivity of the sensor can
be adjusted from level 0 to level 9.
Automatic: The sensor adjusts itself automatically and keeps checking
continuously.
4.1.3 Change in Yarn Diameter
(New Article)
1. Insert new yarn in the sensor.
2. Push the function button for 3 seconds.
»The display starts blinking.
»The new yarn diameter is registered.
»Once the display stops blinking, the new yarn diameter is read
and stored.

14
Operation
FALCON-i
4.2 Display Lowest Sensitivity level
Highest sensitivity level
Automatic sensitivity level
Mode „Normal“, Yarn is running and the sensor is active
Textile faults
»Fault display erased after yarn starts running again
»Fault display can be re-set, by pushing the function button briefly
Fault caused by excessive contamination on the optical sensor
»Fault display can be re-set, by pushing the function button briefly

15
Operation
FALCON-i
Schema (7 Segment Display)
Mode: Normal (Yarn is running)
Fault display
Textile fault
blinking Sensor is active Yarn is running Fault caused by contamination flashing = warning blinking = fault
Mode: Sensitivity adjustment
Button Button Button
Lowest sensitivity level
1 s 3 s 1 s >
. . . 1 s > 1 s >
4 s time-out = setting is saved5 s time-out
Highest sensitivity level
Sensor adjusting itself automatically
Display of sensitivity level
(example: 5)
Display of sensitivity level blinking (example: 5)
Changes between the different settings (blinking)
Manual adjusting of sensitivity (0–9)
. . .

16
Checks and Maintenance
FALCON-i
Risk of injuries!
Maintenance on the running machine may lead to serious
personal injury.
ZBefore performing maintenance, stop the machine and
wait until the machine has come to complete standstill.
WARNUNG
5 Checks and Maintenance
5.1 General Regular inspections of the optical yarn defects sensor FALCON-i ensures
a reliable and trouble-free operation.
5.2 Safety Maintenance work may only be performed by authorized and trained
personnel.
All maintenance NOT described in chapter 5.3 “Inspection and Maintenance
Work” has to be done by service engineer.
5.3 Inspections and Maintenance Work
5.3.1 Yarn Flow Check the yarn flow.
»In order to ensure proper function, the yarn flow has to smooth and
should be positioned in the center of the yarn guide.
If necessary, the mounting position of the sensor / yarn guides has to be
checked and corrected.
5.3.2 Sensors Check the sensors for contamination.
»Excessive lint and contamination in the sensor area could cause false
stops of the optical sensor. The sensor may not work reliably.
»A contaminated optic is indicated with „d“ on the display.

17
Checks and Maintenance
FALCON-i
Gasoline is highly inflammable!
ZObserve warning notices on container!
DANGER
The substances listed below must be avoided by all
means, as their use will destroy the optical system!
XAromatic hydrocarbons, e.g. benzene, benzol, toluol
XAll kinds of alcohol, e.g. methanol, ethanol
XSpirit, Acetone
XAutomobile and aviation gasoline
ATTENTION
Suitable cleaning agents:
Light contamination:
»Cleaning agent TK-Clean from LOEPFE
Heavy contamination
»“Zippo Premium Lighter Fluid”
»“Ronsonol Lighter Fluid”
»Medical grade benzine
»n-Heptane (C7H16)
»Cypar 7, Cycloaliphat (C7) (a SHELL product)
Loepfe will not be liable for damage claims resulting from the use of
unsuitable substances!
In case of heavy contamination, all the sensors have to be
cleaned after every machine stop.
Risk of damage to the sensors!
The sensors could become damaged by improper cleaning!
ZClean the sensors with utmost care.
XDo NOT immerse the sensing head in cleaning agent!
XDo NOT spray cleaning agent directly in the optical system!
XDo NOT use any hard/sharp objects!
ATTENTION
Cleaning of contaminated sensors
Gently blowing off with air pressure
Remove contamination with a vacuum cleaner
Clean the area on the left and right side of the white ceramic of the yarn
guide carefully with cotton swab or cloth and 1–2 drops of detergent.

18
Troubleshooting
FALCON-i
6 Troubleshooting
Fault Possible Cause Solution
Fault display, but current
yarn has no fault
The knot was inserted one insertion
earlier.
It is necessary to use the pick finding device
once more.
The point in the display
is illuminated („Normal“
mode) but the yarn is not
running
Faulty electrical ground connection. It could be necessary to insulate the sensor,
install rubber dampers.
Several false stops The sensitivity level is set too high. Set the sensitivity level lower.
Yarn is not flowing smoothly (uncon-
trolled)
Adjust the yarn guides to create a smooth
yarn flow or install an additional brake
before the optical sensor.
Machine does not stop
after an imperfection
Increase Sensitivity level until the machine
stops all the time, then lower the sensitivity
by 2 levels.
Example: Machine stops at level 7 all the
time, then set the sensitivity to level 5.

Loepfe Brothers Ltd.
8623 Wetzikon / Switzerland
Phone [phone]
Fax [phone]
[e-mail]
www.loepfe.com
Subject to technical modifications