ROJ SUPER ELF S3 User manual

SUPER ELF S3
Instruction Manual

SUPER ELF S3 –Dornier
2
WARNING!
- Condensation could form on the Weft Feeder when it is moved from the cold environment of
the warehouse to the warmer environment of the weaving room. Make sure that it is
completely dry before connecting to power.
- Provide proper information to the people operating the weft Feeders.
- The installation, connection, adjustment, and maintenance of the Weft Feeder has to be
performed by technically qualified personnel.
- The Loom's main power switch MUST be switched OFF before any replacing or connecting
operation.
- Caution must be taken on the close vicinity of the Feeder. In normal working condition, it can
start running without prior warning and the moving parts might cause injuries.
- Repairing any electrical part of the unit has to be carried out by Roj s.r.l.
authorized personnel.
-Always use proper spare parts and accessories supplied by Roj s.r.l.
- Roj s.r.l. disclaims all responsibility for the improper use of the Feeder different from what
described in the chapter 1. General Information.

SUPER ELF S3 –Dornier
3
INDEX page
1. GENERAL INFORMATION
Super Elf S3 description 4
Super Elf S3 Technical Data 4
Pulsar HP brake description 4
Technical data of Pulsar HP 4
Other information about Super Elf S3 4
Features and Characteristics 5
2. SETTING AND CONTROL ELEMENTS
Front control elements 6
Back panel control elements 7
3. INSTALLATION AND CONNECTION
Electric connections 8
Diagram connection of the Voltage Supply Box 9
4. SETTINGS AND OPERATION
How to set working parameters 10
Insertion length 11
Reserve sensor 11
Filling tensioner (Pulsar HP) 12
Sensors sensitivity settings 14
Maintenance 16
Photocells automatic calibration 16
Photocells information 16
Weft length adjustment 17
Winding direction and coils pitch adjustment 18
Reserve loading (Full air threading, only with funnel) 19
Reserve loading (Half air threading) 19
5. TROUBLESHOOTING 20
6. ACCESSORIES
Funnel 21
Eyelet holder 21
Pulsar HP 21
Voltage Supply Box 22
7. DECLARATION OF CE CONFORMITY 25

SUPER ELF S3 –Dornier
4
1. GENERAL INFORMATION
Super Elf S3 description
SUPER ELF S3 is a Weft Feeder with yarn separation and direct CAN-bus communication
with the Loom Control. The new Permanent Magnet motor and the Reserve sensor allow very
fast reaction and accurate yarn storage control on the spool body. The new Reflective type
optical sensors guarantee robustness and best performances in dust environments and with
very fine yarns.
Super Elf S3 - Technical Data
Power supply by means of the specific Roj Control Box: 100 V dc –24 V dc
Weft feeding speed (pattern in advance info): max 2400 m/min
Threading channel: 4.5 mm
Yarn count range: 6 Nm - 10 dTex
Noise level: < 70 dB A
Weight: 8 kg
Working temperature: from 10 ° to 40 °C
Storage temperature: from –25 ° to +65 °C
Relative humidity: max 95% (not condensed)
Pulsar HP brake description
The Pulsar HP device, performs the following two functions:
Breaking function: to reduce the tension pick to the weft when the same is stopped by the
Electromagnet pin. This is to avoid the following problems:
a. weft breakage at the end of the insertion
b. weft loops or slack picks in the fabric.
Pull back function: after the yarn cutting, yarn is pulled back into the nozzle.
This is to avoid that the weft gets tangled in the next weft to be inserted by the
contiguous nozzle.
Technical data of Pulsar HP
Cycles per minute: 1.200
Reaction time: 7 ms
Max torque: 11.5 Ncm
Weft pull back length: max 35 mm
Eyelet's diameter: 6 mm
Other information about Super Elf S3
The Part Number (P/N) and the Serial Number (S/N) are printed on the CE label.

SUPER ELF S3 –Dornier
5
Features and Characteristics
o The Weft Feeder can be set for rotation S or Z depending on the yarn twist.
o Yarn separation is adjustable from 0.7 mm to 2.2 mm.
o Coils detection by means of photocells (Reflective system).
o Storage detection with an integrated photocell (Reflective system).
o Robust and reliable new Reflective sensors system.
o Input Weft breakage control through a photocell integrated in the Super Elf S3, or through
external TFE8 weft Stop Motion device.
o Weft length adjustment, by setting the spool body diameter and the number of coils to be
released at each insertion.
o Range of weft lengths: from 64 to 672 cm.
Note: Weft lengths ranging from 87 to 96 cm CANNOT BE MEASURED.
o CAN BUS communication protocol with the loom Control.
o Pulsar HP brake control.
o Full and half weft threading by means of a pneumatic system.
o New Electromagnet design.
o Reserve Storage position Photocell reliable also in dust environments.
o Permanent Magnet motor for more accurate speed control, faster acceleration, full torque at
all speeds and lower energy consumption.
o Sealed motor, photocells housing and cable connections are IP63 Water Proof standard
o New anti-balloon design with reclining Funnel simplifies maintenance and
optimizes space requirements for multi-color applications.

SUPER ELF S3 –Dornier
6
2. SETTING AND CONTROL ELEMENTS
Front Control elements
1 FUNCTION BUTTON
It activates the Electromagnet and allows the following operations:
a- Weft reserve removal.
b- New weft reserve loading.
c- Release of only one coil when the weft reserve is already on the Spool Body.
d- Photocells calibration
e- Reset of the fatal errors without switching OFF the main power.
A SIGNALING LED
When the weft feeder is powered, the led turns on if no faults are detected. In case of
problems, the led blinks. Slow blinking in case of warnings, fast blinking in case of fatal errors.
B ADJUSTMENT SCREWS FOR THE ELECTROMAGNET
POSITION
C, D, E ADJUSTMENTS SCREWS OF SPOOL BODY DIAMETER
(Coil length)
F PUSH BUTTON FOR SETTING OF WINDING DISC ROTATION
DIRECTION AND COILS SEPARATION

SUPER ELF S3 –Dornier
7
Back panel control elements
1 CONNECTION OF AIR LINE INPUT
2 CONNECTION OF AIR LINE FOR FULL AIR THREADING
Full air threading is possible only in combination with Funnel. If the feeder is fitted with eyelet
holder, or without any balloon control, this connection must be closed with relevant plug that it
is supplied with the feeder.
3 HALF THREADING BUTTON
Insert the yarn into the eyelet and press the half threading button (3), whilst lightly holding the
yarn.
4 FULL THREADING BUTTON
Insert the yarn into the eyelet and press the full threading button (4), whilst lightly holding the
yarn.

SUPER ELF S3 –Dornier
8
3. INSTALLATION AND CONNECTION
Voltage Supply Box and Weft Feeder installation
1. Fix the Voltage Supply Box to the Stand by means of the proper brackets.
Note: Minimum distance from the Box to the floor must be 20 cm. (see fig.1)
2. Install the Weft Feeders on the Stand by means of the existing clamps.
Note: The feeders must be positioned on the stand according to the type of installation. It is
important that yarn path is as straight as possible between the Feeders and the loom nozzles.
3. Place the Feeders' cables and the air tubes inside the tunnel of the Stand.
Electrical connections
1. Connect the Feeder's cables to the Voltage Supply Box by following the numeric
correspondence to the loom nozzles (Feeder working with the weft threaded in nozzle 1 must
be connected to the position 1 of the Voltage Supply Box; etc.).
2. Connect the CAN BUS cable to the loom (see fig.2 page 8).
3. Feeder's Stand and Creel must be connected to the earth of the loom.
4. Connect the plug of the 3-phase power cord to the socket on the loom main control cabinet
(MCC). See fig.2 page 8.
Warning! The connection between the Voltage Supply Box and the 3-phase power supply
network must always be as stated on the following page. In this way, the loom main switch
performs also as main switch for the Weft Feeders (see fig. 2 page 8).
Note: The Voltage values supplied to the Weft Feeders can be checked on the Voltage
Supply Box connectors (see fig. 3 page 8).

SUPER ELF S3 –Dornier
9

SUPER ELF S3 –Dornier
10
4. SETTINGS AND OPERATION
How to set working parameters
1. Turn the loom main switch ON. The feeders are now supplied with power and receive the
setup data from the loom Control (wait for about one minute).
2. The pulsar calibration cycle is then automatically performed. If no faults occur, the signaling
led, on the front side of the feeder, remains ON. In case of faults, the led blinks and a fault
message is shown on the loom Dialog panel display.
3. According to the woven article, adjust the functioning parameters of Super Elf S3, which
can be set on DORNIER loom Dialog panel (see picture below).
4. Press the icon to enter the feeder pages.
Note: Before switching the loom power ON, always
verify that the pulsar fork (F) is free to move and
therefore avoid:
· Yarn tied to eyelet holder or any other machine part
· Yarn inserted into the fabric and not cut
The yarn can be kept firmly by loom controlled devices
as these are synchronized with the Pulsar calibration
function. To reset the error "Pulsar not calibrated",
switch the loom OFF, make sure that the Pulsar fork is
free to move, then switch the loom back ON.

SUPER ELF S3 –Dornier
11
Insertion length
Note: the setting “Insertion Length” is dependent on the “Reed width” parameter which is
under the “Weft Insertion” menu. It is recommended to make the Feeder operating with the
Drum set to the wider diameter and releasing the minimum number of coils possible (see
table below for reference).
Reserve Sensor
Automatic = ON Automatic = OFF
When this is set to Automatic = ON, the Reserve Sensor automatically regulates the
take-off point at a fixed position.
• Possible setting: Off, 0, 1, 2
To set the number of coils (windings) to be released by the
Feeder at each pick.
• Possible setting: 2 -> 16.
• Recommended setting: see note

SUPER ELF S3 –Dornier
12
Off - Automatic position control deactivated
0 - Automatic position control activated with lower reserve storage
1 - Automatic position control activated with standard reserve storage
2 - Automatic position control activated with maximum reserve storage (the take-off point is
nearby the stopper pin)
• Recommended setting: 1
Reserve windings (to be set when Automatic = OFF)
It sets the number of coils to be wound on Spool body when a new Reserve is loaded. Set the
highest number of coils possible, avoiding them to overlap each other nearby the stopper pin
(the reserve has to be over 3/4 of the spool body length).
• Possible setting: 12 -> 68.
• Recommended setting: according to the yarn count, set the coils pitch as low as possible.
Note: In case of different reserve position between Feeders, set with the same number of
coils and make them equal by adjusting the coils pitch.
Filling Tensioner (Pulsar HP)
Stroke
This parameter allows set the stroke angle value:
• Possible setting:
off brake disabled
1 minimum stroke angle
2 low stroke angle
3 middle stroke angle
4 high stroke angle
5 maximum stroke angle
Set here the Yarn type
Possible settings:
fiber
filament < 500dTex
wool
filament > 500dTex
The Pulsar HP will automatically use the factory
pre-settings according to the chosen yarn type

SUPER ELF S3 –Dornier
13
• Recommended setting:
2 it gives a low reduction of the end insertion tension peek. (The yarn speed reduction at the
arrival is very low).
3 it gives a good reduction of the end insertion tension peek. (The yarn speed reduction at the
arrival is low).
4 it gives a very good reduction of the end insertion tension peek. The yarn speed reduction is
very high and the arrival is very irregular).
Note: Use the "1" and "5" values only in extreme cases:
1 - when the important is to avoid to slow down the yarn at the arrival. (The reduction of the
end insertion tension peak will be very low).
5 - to reduce the end insertion tension peek as much as possible. (The yarn speed reduction
is very high and the arrival is very irregular).
Duration
This parameter set the duration of braking function.
• Possible setting:
0 the fork reach braking position at same time when the electromagnet pin stops the yarn at
end of insertion
1 minimum braking anticipation
2 low braking anticipation
3 middle braking anticipation
4 high braking anticipation
5 maximum braking anticipation
• Recommended setting:
0, 1, 2 for filament yarns
2, 3, 4, 5 for fiber yarns and wool
Force
This parameter allows the user to choose between 5 force values:
• Possible setting:
0 minimum braking force
1 low braking force
2 middle braking force
3 high braking force
4 maximum braking force
• Recommended setting: Increase the braking force according to yarn size (Yarn count). See
table on next page.

SUPER ELF S3 –Dornier
14
Filling Draw back
This parameter allows to enable or disable the yarn filling draw back after yarn cut. It is also
possible to choose how large angle to use to pull the yarn back.
• Possible setting:
off disabled filling draw back
1 minimum angle for draw back
2 middle angle for draw back
3 maximum angle for draw back
• Recommended setting: Use mostly "2" and "3" values .
Sensors sensitivity settings
Reaction time of the Feed Sensor
Set the sensitivity for the photocell with function as input yarn break sensor
• Possible setting: 2, 3, 4, 5 and OFF (OFF = Feed Sensor OFF)
• Recommended setting: 3
Note: increase the value in case of “false” yarn break stops

SUPER ELF S3 –Dornier
15
Winding sensor
Sets the sensitivity of the photocell which is controlling the outgoing coils.
• Possible setting: normal yarn / fine yarn
• Recommended setting: normal yarn
Reserve sensor
Sets the sensitivity of the photocell which is controlling Automatic Reserve Position.
• Possible setting: normal yarn / fine yarn
• Recommended setting: normal yarn
Length correction
Avoids wrong weft length measurement due to the eventual overlapping of the coils on
the Spool body.
• Possible setting: ON / OFF
• Recommended setting: ON
Note: Set OFF in case of short picks (one coil less) with irregular insertion times.
Double yarn sensor
Controls the yarn break by means of an external sensor (Roj PIEZO sensor TFE6). This is
normally used in case of multiple weft insertions, i.e. when there is more than one yarn used
with one feeder.
• Possible setting: ON / OFF
Rotation direction
To set the winding direction of the Feeder according to the yarn twist.
• Possible setting: Z / S
Note: When changing the winding direction, the coils pitch has to be changed too.

SUPER ELF S3 –Dornier
16
Maintenance
Photocells automatic calibration
The Super Elf S3 is fitted with an automatic photocells calibration system, which is needed
when replacing the feeder circuit board or one of the sensors groups.
Proceed as follows:
1. Remove all the yarn from the spool body, and verify that the photocells glass and mirrors
are clean (see below)
2. Press the Reserve push-button on the feeder side for about 30 seconds, till the LED makes
a short blinking than remains steady ON: at this point the calibration is automatically
performed by the feeder SW.
3. Wait a few seconds, than reset the feeder by switching the loom OFF, than back ON. Wait
again until the loom has completed the normal initialization at power ON, than the feeder is
ready to run.
Note: if the calibration procedure is made with yarn on the spool body, or with glass -mirrors
dirty, the feeder can go in alarm “SYSTEM ERROR 4” and it is completely blocked. To unlock
the feeder, remove the yarn from spool body, or the dust from glass –mirrors, and make the
automatic calibration again. If, after performing correctly the automatic calibration, the same
error is still displayed on the loom Dialog panel, proceed as here below described:
- Check the stopper pin position and distance from the spool body (see page 17)
- Check the correct connection of the photocell circuit inside the spool body
- Replace the top spool body sector (that includes the sensors)
- Replace the stopper magnet housing
- Replace the CPU board and make a new automatic calibration
Photocells information
The Super Elf S3 works with an automatic compensation system, to grant same level of
reading signals, even when the dust stats to accumulate on the window glass of the optical
sensors. The amount of dust accumulated it is indicated on relevant display page.
Stopper / Pulsar test
This test activates a test cycle on the pulsar that will
move the pulsar fork according to the settings in the
Filling tensioner menu. The Stopper electromagnet is
also activated.

SUPER ELF S3 –Dornier
17
Weft length adjustment
The diameter of the Weft Feeder Spool Body must be set according to the indication shown
on the loom Dialog panel display.
Proceed as follows:
1. Loosen the screw B and raise the Photocells/Electromagnet Group. Fix it.
2. Loosen the both C socket head screws (3 mm socket).
3. Turn the Winding Disc until the eyelet is in the upper position.
4. Loosen the D1 socket head screw (3 mm socket).
5. Turn the Winding Disc until the eyelet is in the lower position.
6. Loosen the D2 socket head screw (3 mm socket)
7. Adjust the diameter of the Spool Body by turning the E socket screw (5 mm socket screw
with the hole for D1 screw) in order to move the sectors of the Winding Group to the
requested reference according to weft length to be inserted (see page 10).
8. Turn the Winding Disc until the eyelet is in the lower position.
9. Tighten the D1 and D2 socket head screws (3 mm socket) to block the fixed sectors
(remember to center the hole on the screw head, points 3 and 5).
10. Check that the movable sectors are centrally positioned in respect with the fixed ones.
11. Tighten the two screws C to block the movable sectors.
12. Turn the Winding Disc and check that no movable sectors get in contact with the fixed
ones; this is in order to avoid possible damages when the feeders is in operation. If the
sectors get in contact, use the C screws to adjust the movable sectors.
13. Loosen the screw B and position the Photocells/Electromagnet group so that the distance
between the Electromagnet and the Spool Body is about 1-1.2 mm (see picture below on the
right - use the special gauge supplied with the feeder).
14. Load the reserve as described on page 18.
15. Start up the loom and check if the length weft is as required. If it is too long, decrease a bit
the spool body diameter. If it is too short, increase a bit the diameter.
Note: Fixing torque recommended for the screws D1, D2 and C = 2.3 Nm ± 10%

SUPER ELF S3 –Dornier
18
Winding direction and coils pitch adjustment
The winding direction (S or Z) must be adjusted according to the yarn twist. Correspondence
is needed between the motor electric setting and the mechanical one of the Spool Body.
Proceed as follows:
1. Press the yellow Separation push-button F placed in front of the Spool Body and
simultaneously turn the Winding Disc until you hear a “click” (the yellow pushbutton is entered
in a slot).
2. While keeping pressed this push-button, turn the Winding Disc up to the chosen
position (the ceramic eyelet indicates the position). Release the push-button.
Note: The coils pitch must be adjusted according to the yarn count. In case of working with
Automatic Reserve set to OFF, set the Reserve Windings value on the loom Dialog panel by
avoiding excessive accumulation of coils in front of the Spool Body.
3. Select the winding direction rotation on the loom Dialog panel: the magnet pin goes up
allowing removal of the reserve from the Spool Body. In the meanwhile, the eyelet of the
Winding Disc moves to the threading position.
4. Press the start push button 1, the Electromagnet pin goes down and the weft reserve is
loaded.

SUPER ELF S3 –Dornier
19
Reserve loading (Full threading, only with funnel)
1. Press the start push-button 1 on the side of the feeder for more than 3 seconds: the
Electromagnet pin goes up and the Winding Disc automatically moves to the threading
position.
2. Release a few coils from the package and keep the yarn end near the input threading
eyelet, than press the full threading button 4 to thread the weft through the feeder body out to
the pulsar (if the old reserve is still on the spool body it will be automatically blown out).
3. Press the key in the front of the feeder a second time: the Electromagnet goes down and
the Feeder loads the reserve.
Weft reserve repair (Half threading)
If during the Feeder operation, a weft breakage occurs at Feeder's entry, proceed as
follows:
1. Release a few coils from the package and keep the yarn end near the input threading
eyelet, than press the half threading button 3, so that the weft is blown to the output of the
winding disk without affecting the existing reserve on the Spool Body. This operation allows
the weft to be knotted to the existing reserve.
2. Press the start push-button 1 on the front of the feeder in order to reset the weft breakage
error. The feeder will restore the complete weft reserve.

SUPER ELF S3 –Dornier
20
5. TROUBLESHOOTING
Description
All error messages from Super Elf S3 are shown on the display of Loom Dialog panel.
Note: Details to fault analysis and fault repair are possible to find in the Dornier
Documentation "Dialog Panel Ergo Weave" in chapter 4 "Messages"
The Feeder will also give an alarm by means of the signaling LED (see page 4). The LED is
steady ON during the normal operation of the Feeder. It is fast flashing in case of Heavy
Alarms (i.e. the feeder cannot continue to work), or it is slow flashing in case of Warning
Alarms (i.e. the feeder can continue to work, but some maintenance or checking is required)
In case the loom Control panel will display “ Feeder n. … SYSTEM ERROR 4” please
refer to the Automatic photocells calibration described on page 15.