MEMMINGER-IRO MRA 2 User manual

Operating Instructions
english
027-920-000-01
27.05.09
MRA 2

1
Introduction
Congratulations and thank you for choosing a quality product from MEMMINGER IRO. To ensure that you get top
performance from this product you should be fully familiar with all its features and functions.
This is why we ask you to read this instruction manual carefully before starting to use the product. The manual contains
precautions, operating instructions and other useful information about how to make the best use of this product. Keep
this manual where it will be readily available for reference.
Introduction / Contents
Table of contents
Introduction................................................................................................................................................................ 1
Contents ..................................................................................................................................................................... 1
Safety.......................................................................................................................................................................... 2
Permitted uses.............................................................................................................................................................2
Safety precautions.......................................................................................................................................................2
Warranty ...................................................................................................................................................................... 2
Disposal.......................................................................................................................................................................2
Symbols used in this manual.......................................................................................................................................2
Description................................................................................................................................................................. 3
Unit components..........................................................................................................................................................3
Function.......................................................................................................................................................................3
Components ................................................................................................................................................................3
Installation options.................................................................................................................................................... 4
Single motor on one diameter ring with one toothed belt ............................................................................................ 4
Single motors on two different diameter rings with two toothed belts.......................................................................... 4
Single motors on two same diameter rings with two toothed belts.............................................................................. 4
Twin motor on one diameter ring with two toothed belts ............................................................................................. 5
Twin motors on two different diameter rings with four toothed belts............................................................................ 5
Single motor and twin motors on three different diameter rings with ve toothed belts .............................................. 5
Preparing for installation..........................................................................................................................................6
Setting the hollow shaft encoder ratio ......................................................................................................................... 6
Setting the toothed belt length.....................................................................................................................................6
Removing the toothed belts, the tensioning devices and the quality adjustment pulleys............................................ 6
Assembly.................................................................................................................................................................... 7
Fitting the hollow shaft encoder...................................................................................................................................7
Fitting the control unit .................................................................................................................................................. 8
Fitting the capacitor batteries (optional) ...................................................................................................................... 8
Connecting up the step-down transformer (optional) .................................................................................................. 8
Fitting the MRA 2 motors ............................................................................................................................................. 9
Fitting the tensioning device...................................................................................................................................... 10
Fitting the toothed belts ............................................................................................................................................. 10
Fitting the GT 3 console ............................................................................................................................................ 10
Terminal connection diagram................................................................................................................................. 11
Control unit ................................................................................................................................................................ 11
Electrical connections................................................................................................................................................ 11
Operation.................................................................................................................................................................. 12
Layout of GT3 console display .................................................................................................................................. 12
Access level menu.....................................................................................................................................................12
Conguration menu ................................................................................................................................................... 13
Setting the hollow shaft encoder for the set yarn feed rate ....................................................................................... 15
Fabric press-off rectication ...................................................................................................................................... 16
Device information menu...........................................................................................................................................16
Fault and status message menu ............................................................................................................................... 17
Console menu ...........................................................................................................................................................17
Technical data.......................................................................................................................................................... 18
Troubleshooting ...................................................................................................................................................... 18
Dimensions .............................................................................................................................................................. 19
MRA 2 motor..............................................................................................................................................................19
Control unit ................................................................................................................................................................20
GT3 console ..............................................................................................................................................................21
Hollow shaft encoder................................................................................................................................................. 21
Declaration of Manufacturer................................................................................................................................... 22

2
Safety
Permitted uses
The MRA 2 system is designed solely for feeding yarn to textile machines. All other uses are not permitted. The manu-
facturer will not accept any liability for damages resulting from non-permitted uses. The user is liable for damages
resulting from non-permitted uses.
Safety precautions
No special training is required to operate an MRA 2 system.
The operator is responsible for ensuring that all instructions regarding the electrical installation, tting, operation and
maintenance of the MRA 2 are implemented.
The MRA 2 must only be installed and serviced by qualied electricians working in accordance with current electrical
engineering practices and regulations.
The MRA 2 has electronic components which are sensitive to interference from electrostatic charges. Before
you open the equipment housing, you should take precautions to prevent electrostatic charges. You can
discharge any electrostatic charges beforehand by touching an earthed object such as the machine or the
earth contact of a socket.
The MRA 2 system is designed for operation with a 3 x 400 V AC power supply. The power supply for the MRA 2 must
be taken from the circular knitting machine. The power supply to the MRA 2 must be switched on and off from the
main switch of the circular knitting machine. This means that the MRA 2 can only be powered up when the machine
is powered up. When the machine is turned with the hand lever, the unit must be ready for operation.
Before you start any adjustments, even small ones, you must power down the knitting machine. Power up the equip-
ment only after you have completed these adjustments.
In the interests of your own safety, please enter all the necessary data on the GT3 console.
Before you start any adjustment of the unsprung tensioner device, power down the circular knitting machine.
Only use original spare parts and accessories.
Warranty
Failure to follow the instructions in this manual will void your warranty. The manufacturer will not accept any liability
for damages or operating faults resulting from failure to follow the instructions in this manual.
Disposal
You should dispose of MRA 2 components in compliance with the regulations for the disposal of electrical and elec-
tronic components.
Symbols used in this manual
CAUTION!
This symbol marks important instructions where failure to follow the instructions can cause personal
injury or damage to the equipment.
INFORMATION!
This symbol marks useful information which will help you to get the best from the equipment.
!
i

3
Description
Function
The hollow shaft encoder detects and measures machine
movements and rotation, translates this measurement
into a signal and then sends the signal to the control unit
where it is used to control the MRA 2 motor. The GT3
console is used to precision set the yarn feed rate for
each individual belt. The yarn feed rate for fabric press-off
rectication can be reduced by programming. The MRA
2 motors can run in both directions. This means that the
feeder for S and Z yarns can be run with left-handed or
right-handed direction of rotation.
In the event of a mains power failure, capacitor batteries
will continue to power the system until the machine has
come to a complete standstill. If a fault occurs during an
operating cycle, the machine will be powered down; it will
not be possible to restart the machine.
MRA 2 motors can be exchanged when required without
the need for any reprogramming.
Components
MRA 2 motor: The MRA 2 motors receive control signals
from the control unit and drive the toothed belts at the
speed for the set yarn feed rate. In order to handle speed
changes, manual operation and starting and stopping,
the motor incorporates advanced control technology. The
MRA 2 motor incorporates a frequency converter which
converts line current into three-phase alternating current
with variable frequency. No additional electrical cabinet is
required because the converter is already incorporated
in the motor.
GT3 console: The GT3 console is used to enter all the
parameters needed to install and operate the system.
Control unit: The control unit is powered from the mains
power supply at 3 x 400 V AC. It can power up to six MRA
2 motors. It stores operating parameters and distributes
information from the GT3 console and the hollow shaft
encoder. The GT3 console is used to enter the yarn
feed rate and displays the information about machine
movements received from the hollow shaft encoder. This
information is processed by the control unit and then
transmitted to the MRA 2 motors.
Hollow shaft encoder: The hollow shaft encoder is
installed on the drive shaft and is connected via a gear
box to the machine cylinder. The hollow shaft encoder
detects cylinder movements, translates these into pulses
and transmits the pulses to the control unit.
Capacitor batteries: Inthe eventof a mainspowerfailure,
the batteries ensure that the system continues running
until the machine has come to a complete standstill; this
prevents yarn breakage.
Unit components
1 - MRA 2 motors
2 - GT3 console
3 - Control unit
4 - Hollow shaft encoder
5 - Capacitor batteries
4
3
2
5
1

4
Installation options
Single motors on two different diameter rings with two toothed belts
Single motor on one diameter ring with one toothed belt
Single motors on two same diameter rings with two toothed belts

5
Installation options
Twin motors on two different diameter rings with four toothed belts
Twin motor on one diameter ring with two toothed belts
Single motor and twin motors on three different diameter rings with ve
toothed belts

6
Preparing for installation
Setting the hollow shaft encoder ratio
Before you t the MRA 2 system you must set the ratio
between the one machine revolution and the revolutions
of the knitting machine drive shaft.
Rotate the machine through one revolution and count
the number of revolutions of the quality adjustment
pulley.
The last revolution of the quality adjustment pulley
must coincide with the end of the single machine
revolution and should be counted at this point (e.g. 1
machine revolution = 10.8 quality adjustment pulley
revolutions)
Measure the yarn feed rate per machine revolution.
You will need to know the yarn feed rate in order to
ne adjust the hollow shaft encoder ratio (see the
section Setting the hollow shaft encoder for the set
yarn feed rate).
Example:
10.8
1
Setting the toothed belt length
MPF unit on the feeder ring:
Toothed belt length = (ring outer diameter + 200 mm) x
3.14 + 500 mm
MER unit on the feeder ring:
Toothed belt length = (ring outer diameter + 150 mm) x
3.14 + 500 mm
Continuous toothed belts are available in sizes from 2 to
16 metres in steps of 200 mm. Measure the belt length
required (for example 7100 mm) and then use the next
belt length up (7200 mm in this example).
Removing the toothed belts, the
tensioning devices and the quality
adjustment pulleys.
Before you t the MRA 2 you must rst remove the toothed
belts, the tensioning devices and the quality adjustment
pulleys.
You can also remove any unnecessary drive shafts and
housings.

7
Assembly
2
5
4
6
3
1
Fitting the hollow shaft encoder
Fix the adapter (2) and the torque bracket (5) to the
hollow shaft encoder (4).
Fit the encoder support (6) to the torque bracket
(5).
Slide the hollow shaft encoder (4) onto the drive shaft
(8).
Screw the screw (1) of the adapter (2) into the keyway
on the drive shaft (8).
Attach theencodersupport(6)to thedrivebar/column
(9) of the knitting machine.
CAUTION!
Only the rotor (3) of the hollow shaft encoder
(4) should rotate with the drive shaft (8).
The torque support (5) should not be bent or
kinked.
!
Fit the hollow shaft encoder (4) to the drive shaft (8) and
then the quality adjustment pulley (7).
7
1
8
9

8
Assembly
Fitting the control unit
Fit the control unit to the drive bar or column or to the
machine foot (see the section Device Components).
Connect the MRA 2 motors to the control unit using the
motor cables (1.8 or 3.0 metre lengths).
CAUTION!
The MRA 2 must only be installed and
serviced by qualied electricians working
in accordance with current electrical engineering
practices and regulations.
Before you connect or disconnect a motor cable,
you must power down the knitting machine. Wait two
minutes before unplugging the motor cable.
!
Power supply
3 x 400 V AC
PE L1 L2 L3
PE: yellow/green
L1: black
L2: black
L3: black
Connecting up the step-down trans-
former (optional)
The MRA 2 system operates a rated voltage of 400 VAC.
At input voltages greater than 400 V AC and up to 585
V AC, you must t a step-down transformer between the
knitting machine and the control unit.
Fit the step-down transformer in the electrical cabinet
or on the machine foot.
585 V
530 V
485 V
440 V
585 V
530 V
485 V
440 V
585 V
530 V
485 V
440 V
Power supply from knitting machine
3 x 440 - 585 V, 50/60 Hz
Power supply for the control unit
3 x 400 V, 50/60 Hz
Fitting the capacitor batteries (optional)
In the event of a mains power failure, knitting machines
continue to run on for some time. In the event of a power
failure, a MRA 2 system without capacitor batteries will
stop the yarn feed immediately and this could cause yarn
breakage.
OnanMRA2systemwithcapacitorbatteries,thecapacitor
batteries will continue to power the MRA 2 system until
the knitting machine has come to a complete standstill.
The number of capacitor batteries required depends
on a variety of factors and can only be decided on site.
The factors inuencing the number of batteries required
includes: machine speeds; rotating mass (open wide knit-
ting machines); general condition of the knitting machine;
number of MRA 2 motors tted; motor power required;
yarn sensitivity.
Fit the capacitor batteries to the machine foot and
connect them to the control unit (see the control unit
terminal connection diagram).

9
Assembly
2
1
3
5
7
4
8
INFORMATION!
To loosen the cone clamp, unscrew the screws
by a few turns.
Unscrew and remove two of the screws and then
screw them into the two bores by the same amount.
This will force the outer cone shell out of the inner
shell and thus release the connection.
i
Fitting the MRA 2 motors
Attach the MRA 2 motors (7) to the motor ange (3) with
the cheese head screws (5). Adjust the toothed pulley (2)
with the cone clamping element (1) to the same height as
the tension roller (4) on the drive shaft (6) of the MRA 2
motor (7).
Fix the MRA 2 motors (7) with the motor ange (3) to the
feed ring (8) of the machine.
INFORMATION!
In order to prevent vibrations on the feeder ring,
the MRA 2 motors should be mounted close to
a ring support bracket wherever possible.
i
3
6
7

10
Assembly
Fitting the toothed belts
The motor ange tension roller (1), the MRA 2 motor
toothed pulley (2) and the feeder toothed pulley must
all be adjusted to the same height. This is ensure that
the toothed belts do not run up against the anks of
the tension rollers; belts will be damaged if they run
up against the anks.
Do not kink or twist the toothed belts.
Fitting the GT 3 console
Fit the GT 3 console to the motor ange of the MRA 2
motor.
The GT 3 console can also be tted to a bar.
Fitting the tensioning device
Fit the tensioning device to the feeder ring.
CAUTION!
The MRA 2 should only be used with an
unsprung tensioning device.
!
1
2

11
!
Terminal connection diagram
Control unit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
2
3
4
5
6
GT3 console Hollow shaft
encoder
Switching off
Power supply
3 x 400 V AC
PE L1 L2 L3
+24V CAN H CAN L GND +24V A B GND C NO NC
white green yellow brown
yellow/ green
black black black
MRA 2
Motor
MRA 2
Motor
MRA 2
Motor
MRA 2
Motor or
capacitor
batteries
MRA 2
Motor
MRA 2
Motor
Motor cable
Electrical connections
Connect up the MRA 2 system as shown on the
terminal connection diagram.
CAUTION!
The MRA 2 must only be installed and
serviced by qualied electricians working
in accordance with current electrical engineering
practices and regulations.
CAUTION!
Before you connect or disconnect a motor
cable, you must power down the knitting
machine. Wait two minutes before unplugging the
motor cable.
!
CAUTION!
At input voltages greater than 400 V AC and
up to 585 V AC, you must t a step-down
transformer (optional) between the knitting machine
and the control unit.
!
250 kbit/s
Standard
500 kbit/s
CAN BUS
brown green grey white

12
Access level menu
No access permitted.
Access level 1 for knitting machine operators with
password “2810”. Users at this level can modify the
yarn feed rate per machine revolution, modify the
reduction factor in the fabric press-off rectication
mode and modify the number of machine revolu-
tions.
Access level 2 for machine setters with password
“72280”. Users at this level can congure the encoder,
the number of teeth on the MRA 2 motor toothed
pulley, the feeder direction of rotation and the unit
of measurement (metres or inches) used.
Operation
Layout of GT3 console display
Device information about the control unit and the
MRA 2 motors
Congure MRA 2 system
Fabric press-off rectication
Access level menu
Fault or status message
Console
Exit menu
Next page
The elds with a yellow background can be set accord-
ingly.
INFORMATION!
Before you can make any changes You must
enter a valid password.
i
Enter a valid password.

13
Access level 1 or 2 will be granted.
To leave the menu, use the button.
Operation
INFORMATION!
If the touch pad is not touched for two minutes,
the access level rights will be automatically
withdrawn.
i
Conguration menu
Number of teeth on the toothed belt pulley of the
MRA 2 motor (1), the default value is 30.
Number of hollow shaft encoder revolutions per
machinerevolution,i.e.theratiobetweenthemachine
cylinder and the hollow shaft encoder (2).
INFORMATION!
Enter the ratio on the system before you install
the unit (see the section Setting the hollow shaft
encoder ratio).
Number of pulses per hollow shaft encoder revolution
(3). Take the value from the hollow shaft encoder;
the default value is 2000.
Enter the values using the touchpad (4).
CAUTION!
In the interests of your own safety, please
enter all the necessary data on the GT3
console.
1
2
3
!
i
4

14
Operation
Feeder type selection list (1).
Yarn feed rate per feeder revolution (2).
Number of teeth on feeder toothed pulley (3).
If a feeder is not on the feeder list (1) you must enter the
yarn feed rate per feeder revolution (2) and the number
of teeth on the toothed pulley (3) using the touchpad.
1 32
YoucannotmodifythedefaultsettingsfortheMPF, MER B,
MER C and MCF feeders.
Set the direction of rotation of the toothed belts during
conguration.
INFORMATION!
The direction of rotation should be the same as
that of the knitting machine toothed belts.
i

15
Operation
Product-specic default control parameter settings for
service personnel.
Setting the hollow shaft encoder for
the set yarn feed rate
Enter the yarn feed rate per machine revolution set
before assembly (see the section Setting the hollow
shaft encoder ratio).
Start the knitting machine.
Measure the actual yarn feed rate per machine
revolution.
If the actual yarn feed rate does not match the origi-
nal yarn feed rate, you must adjust the hollow shaft
encoder ratio.
Start the knitting machine and measure the actual
yarn feed rate per machine revolution again.
Repeat this procedure until the actual yarn feed
rate per machine revolution matches the yarn feed
rate measured before installation on the knitting
machine.

16
Device information menu
This provides information about the devices installed and
their software (Sw) and hardware (Hw) versions.
MIF_***
MRA_***
MRA_***
A****
A****
A****
Operation
Fabric press-off rectication
Start fabric press-off rectication
Stop fabric press-off rectication
Yarn feed rate reduction factor (1). To modify the
reduction factor, enter the password “2810”.
Number of machine revolutions for which fabric
press-off rectication is valid (2).
Number of machine revolutions remaining until fabric
press-off rectication is automatically nished (3).
Fabric press-off rectication mode is active (4).
INFORMATION!
At the end of the fabric press-off rectication
cycle the machine will stop. The knitting proc-
ess can continue.
1
23
4
i

17
Fault and status message menu
When a MRA 2 system fault occurs this is indicated
immediately on the GT 3 console display.
Operation
Console menu
Software version of GT3 console (1).
Modify the unit of measurement (2) (metres or
inches).
Change the user language.
Setup.
Set the display contrast (3).
Display adjustment.
1
2
3

18
Technical data / Troubleshooting
Technical data
Line voltage: 3 x 400 V AC ± 10%
Line frequency: 45 – 66 Hz
Power: 250 VA per MRA2 motor
Max. number of driven feeders: 60 MPF units per belt per MRA 2 motor
24 MER units per belt per MRA 2 motor
Max. belt speed: 360 m/min (with 30-tooth drive pulley)
500 m/min (with 40-tooth drive pulley)
576 m/min (with 48-tooth drive pulley)
Ambient temperature (operation and storage): 0° to 50° C
Weight, GT3 console: 1.1 kg
Weight, hollow shaft encoder: 0.9 kg
Weight, control unit: 2.3 kg
Weight, MRA2 motor with motor flange: 6.2 kg
Troubleshooting
Fault after installation Possible cause Solution
The MRA 2 motor does not run. Does the motor shaft vibrate for approx. two seconds
when you switch on? No. Change the MRA 2 motor or the control unit. Before you connect or disconnect a motor cable,
you must power down the knitting machine. Wait two
minutes before unplugging the motor cable.
Yes. Set the parameters correctly.
The MRA 2 motor does not run. Check if the MRA 2 motor has any torque. Turn the
motor shaft by hand.
!
CAUTION!
Exercise extreme caution.
No. Change the MRA 2 motor or the control unit.
Before you connect or disconnect a motor cable,
you must power down the knitting machine. Wait two
minutes before unplugging the motor cable.
Yes. Set the parameters correctly.
The yarn feed rate is too high. The motor speed is too high. Fit a toothed pulley with 48 teeth to the MRA 2 motor.
Fault / message during oper-
ating cycle Possible cause Solution
Fault message -
Insufficient Permission Level You have entered an invalid password. You have not entered a password.
Access rights are withdrawn automatically after two
minutes of inactivity.
Enter a valid password.
Fault message -
Device Status menu Internal electronic fault Switch the MRA 2 system off and then on again.