Stoll CMS 530 User manual

Instruction manual for a safe operation of the
knitting machine
ID 267 886 GB
Type Computer type Component type
CMS 530 642
643
OKC5.0 000
000
CMS 520 C 647 OKC5.0 000
CMS 520 C+ 652 OKC5.0 000
CMS 502 645
646
OKC5.0 000

Date: 2014-07-08
Translation of the original operating instructions
Operating system of the machine: V_OKC_005.000.000_STOLL (or higher)
H. STOLL GmbH & Co. KG, Stollweg 1, D-72760 Reutlingen, Germany
Our products are being developed further continuously. They are therefore subject to technical modifica-
tions..

3
Table of Contents
1Documentation DVD 5
2Safety instructions 6
2.1 Intended use ........................................................................................................................ 6
2.2 Organizational measures..................................................................................................... 7
2.3 Personnel qualifications and selection................................................................................. 8
2.3.1 Personnel qualification ............................................................................................... 8
2.3.2 Selection of personnel ................................................................................................ 9
2.4 Symbols in this document.................................................................................................. 10
2.5 Warning ............................................................................................................................. 11
2.5.1 Warnings used.......................................................................................................... 11
2.5.2 Explanation to the pictogram (ISO) .......................................................................... 13
2.5.3 Warnings in the documentation ................................................................................ 15
2.6 Safety precautions regarding the machine's life phases.................................................... 16
2.6.1 Safety instructions for the transport.......................................................................... 16
2.6.2 Safety instructions for installing ................................................................................ 17
2.6.3 Safety instructions for the electrical connection ....................................................... 17
2.6.4 Safety Instructions for the Exchange of Data ........................................................... 17
2.6.5 Safety Precautions for Production ............................................................................ 18
2.6.6 Additional Safety Instructions for the Operation with Open Covers.......................... 19
2.6.7 Safety Instructions for Lubrication, Cleaning and Maintenance ............................... 20
2.6.8 Safety instructions for the repair............................................................................... 21
2.6.9 Safety instructions for dismantling work (dismantling).............................................. 25
3Electrical data of the machine........................................................................... 26
3.1 Dimensions and weights.................................................................................................... 26
3.2 Electrical data .................................................................................................................... 28
3.3 Gauge ranges .................................................................................................................... 29
3.4 Operating conditions.......................................................................................................... 30
3.5 Storage conditions .............................................................................................................30
3.6 Noise emissions................................................................................................................. 31
4Main components of the knitting machine ........................................................ 32
4.1 Front side........................................................................................................................... 32
4.2 Lateral view (right) ............................................................................................................. 34
4.3 Rear side ........................................................................................................................... 35
5Security relevant operating elements ............................................................... 36
5.1 Main switch ........................................................................................................................ 36
5.2 Engaging rod ..................................................................................................................... 37

6Optical and acoustic signal elements ............................................................... 38
6.1 Signal light ......................................................................................................................... 38
6.2 Touch screen ..................................................................................................................... 39
6.3 Horn ................................................................................................................................... 40
6.4 Lamps on the yarn control device...................................................................................... 41
7Assembly and setting up .................................................................................. 42
7.1 Preparing assembly ........................................................................................................... 42
7.1.1 Preparing installation location................................................................................... 42
7.1.2 Having tools and aids ready ..................................................................................... 42
7.1.3 Transporting machine to installation location ........................................................... 43
7.1.4 Unpacking knitting machine...................................................................................... 43
7.2 Assembling machine.......................................................................................................... 44
7.2.1 Putting up knitting machine ...................................................................................... 44
7.2.2 Connecting the knitting machine (mains voltage 230 V) .......................................... 48
7.2.3 Connecting the knitting machine (mains voltage 400 V) .......................................... 53
7.2.4 Connecting the knitting machine (mains voltage 230 V / 120 V, "Phase-Phase").... 58
7.2.5 Plug in battery pack .................................................................................................. 63
7.2.6 Mounting the yarn guide device................................................................................ 64
7.2.7 Mounting signal light................................................................................................. 66
7.2.8 Mounting friction feed wheel..................................................................................... 67
7.2.9 Set date and time ..................................................................................................... 68
7.2.10 Aligning knitting machine.......................................................................................... 69
7.3 Carry out the reference run................................................................................................ 72
7.4 Glue on measuring tape .................................................................................................... 73
7.5 How to bring the carriage to an immediate standstill ......................................................... 74
7.6 Checking protective devices .............................................................................................. 75
4

5
Documentation DVD 1
Documentation DVD
1Documentation DVD
Included in the accessories you will find a DVD with documents about your
machine.
◆Operating instructions
◆Safety instructions
◆Spare Parts Catalog
◆Circuit diagram
◆Brochure "Cleaning, maintenance, care"
◆Pocket Card
◆Training documents...
The documents are available in different
languages.
For browsing the documentation DVD:
1. Insert the DVD in the computer.
2. Open the "1_Start.htm" file double clicking on it.
➜Keep the DVD where it is accessible to all personnel
who are responsible for working on the knitting
machine.
➜In case of resale deliver the machine with the DVD.

6
2Safety instructions
Intended use
Safety instructio ns
2Safety instructions
Foreword to the instructions These operating instructions are designed to familiarize the user with the
knitting machine and its designated use.
The operating instructions contain important information on how to operate the
machine safely, properly and most efficiently. Observing these instructions
helps to avoid danger, to reduce repair costs and downtimes and to increase
the reliability and life of the machine.
The additional equipment of your machine can deviate from this description
depending on the machine type (type of machine, scope of supply, special
equipment).
The translations are carried out very carefully. Should you have any doubts
about the accuracy of the translation, please compare this with the
accompanying original document. In case of queries, please call the Stoll
Helpline.
Additional information is available via:
the Stoll branch office or Stoll dealer in your country
the Stoll Helpline:
– Tel: [phone]
– Fax: [phone]
– E-mail: [email protected]
Internet: http: //www.stoll.com
Training courses at the Stoll training centers
Preserve this operating instructions for future use. In
case of reselling the machine, the operating instructions
are to be included.
Intended use
2.1 Intended use
The machine is an industrial knitting machine of the A class according to EN
55011. Observe the country-specific laws and regulations.
The sole purpose of this knitting machine is the production of stitched items.
Only standard yarns are to be processed with the machine that are suitable for
usage in industrial knitting machines.
The yarn guide elements are not designed for the safe conductance of high
strength yarns or materials like for e.g. metals.
In case you have some specific requirements from the machine, kindly get in
touch with any of the Stoll outlets.

7
Safety instructions 2
Organizational measures
Organiza tional mea sures
2.2 Organizational measures
The operating instructions are to be made accessible to all personnel who
are responsible for working on the knitting machine.
The operator must ensure that the contents of the operating instructions
are clearly understood and can be applied by the personnel who are
responsible for working on the machine.
Apart from this the operator must ensure that the national/domestic
regulations are observed and followed. They are for example regulations
– for prevention of accidents,
– for protection of health,
– for environmental protection,
– for technical rules and
– for a safe and proper working.
The knitting machine is to be used only in a technically sound condition
and as per the stipulated conditions, awareness about the safety and
dangers should be there and the operating instructions must be followed.
The warnings on the machine are to be maintained in a complete and
legible condition.
Procurement of spare parts: [11]
No modifications, additions or conversions may be made on the machine
that are not authorized by Stoll.
Use only the original Stoll spare parts during repairs and maintenance.
No arbitrary changes are to be made in the program in the operating
system of the computer, the machine software and the controlling system/
controls.
No foreign software is to be installed in the machine.
Personnel qualifications and selection

8
2Safety instructions
Personnel qualifications and selection
2.3 Personnel qualifications and selection
Any work on and with the machine must be executed by reliable personnel
only.
Observe the country-specific laws and regulations.
Personnel qualification
2.3.1 Personnel qualification
In order that the knitting machine can be operated correctly and safely, it must
be set up and operated by reasonably skilled (qualified) personnel:
Electrician
Mechanic
Knitting expert
Trained or semi-skilled person
Electrician An electrician will be considered a person(expert in electrical area), who can
assess and execute the electrical jobs assigned to him and can identify
possible dangers.
The expert possesses the following characteristics:
technical qualification
theoretical knowledge
practical experience
Knowledge of the relevant (country specific) regulations
Knowledge of the operating instructions
Mechanic A mechanic will be considered a person (expert in mechanical area), who can
assess and execute the mechanical jobs assigned to him and can identify
possible dangers.
The expert possesses the following characteristics:
technical qualification
theoretical knowledge
practical experience
Knowledge of the relevant (country specific) regulations
Knowledge of the operating instructions

9
Safety instructions 2
Personnel qualifications and selection
Knitting expert A knitting expert will be considered a person who can assess and execute the
jobs assigned to him and can identify possible dangers.
The expert possesses the following characteristics:
technical qualification on the knitting machine and the pattern design
system
theoretical knowledge
practical experience
Knowledge of the relevant (country specific) regulations
Knowledge of the operating instructions
Trained or semi-skilled
person
A trained or semi-skilled person is considered as someone who, based on the
following characteristics can carry out definite, accurate tasks on the knitting
machine.
detailed theoretical and practical orientation on the knitting machine
practical experience
Knowledge of possible dangers
Selection of perso nnel
2.3.2 Selection of personnel
The operator must ensure that only personnel authorized for the same can
work on the machine.
The responsibilities of the personnel are to be laid out very clearly for the
following activities.
The table shows the minimum requirements for each personnel.
Activity Personnel
Assembly Mechanic
Electrical connection Electrician
Setting up Knitting expert
Programming Knitting expert
Patterning Knitting expert, trained or semi-skilled person
Setting up Knitting expert, trained or semi-skilled person
Operation Knitting expert, trained or semi-skilled person
Production Trained or semi-skilled person
Maintenance, care and cleaning Knitting expert, trained or semi-skilled person
Maintenance Mechanic, electrician or knitting expert
repair Mechanic or Electrician
Dismantling work Mechanic or Electrician

10
2Safety instructions
Symbols in this document
Symbols in th is document
2.4 Symbols in this document
Some information in this document are marked with special symbols to make
it easier to access this information quickly.
The additional equipment of your machine can deviate from this
description depending on the machine type (type of machine, scope of
supply, special equipment).
Background information is provided here.
Tips for optimal procedure are provided here.
DANGER
A warning is given here!
A warning protects you from death or injuries and the
knitting machine from serious damage.
➜Always read warnings carefully and observe them
exactly.
One-step action Carry out an one-step action:
Condition for the following action.
➜ Carry out one-step action.
Multi-step action Carry out a multi-step action:
Condition for the following actions.
1. Carry out first action.
2. Carry out second action.
3. Carry out third action.
- or -
➜Carry out the alternative action for point 3.
Result of the action sequence.
If something fails to function properly:
Information on the possible causes is provided here.
➜To solve the problem, carry out the action described
here.
Warning

11
Safety instructions 2
Warning
2.5 Warning
In this chapter you will find explanations to the warnings on the machine and
in the documentation.
Warnings used
2.5.1 Warnings used
Warnings on the machines correspond to the standard ISO 3864-2.
Scope of validity: all countries except USA and Canada
A warning as per ISO 3864-2 can comprise of the following elements:
Elements of a warning
Pictograph Explanation
one or more warning indications
one or more prohibitive indications (optional)
one or more commands (optional)
Elements of a warning
Site for labeling the warning
on the machine
Site for labeling the warning on the machine
Site for labeling the warning on the machine

12
2Safety instructions
Warning
List of warnings on the
machine
Warnings have to be maintained in a complete and
legible condition at all times.
The order numbers of the labels are found in the following
table.
List of warnings
No. Warning Explanation
1
ID 244 266
Warning on the rear panel
2
ID 244 274
Warning on the friction feed wheel
3
ID 244 265
Warning on the panelling of the
control cabinet right and left
4
ID 244 267
Warning front cover main switch
5
ID 244 275
Warning on the base plate control
cabinet right and rear panel control
cabinet right
6
ID 244 268
Warning on the comb take-down
7
ID 244 264
Warning under the covers
8
ID 244 273
Warning on the central lubrication of
front and rear needle beds.
For tandem machines, on right-hand
side of right carriage as well.
List of warnings

13
Safety instructions 2
Warning
Explanat ion to the pi ctogram (ISO)
2.5.2 Explanation to the pictogram (ISO)
Pictograms on the machine
Pictographs used on the knitting machine
Type Pictograph Explanation
Warning
indication
General warning indication
Dangerous electrical voltage
Danger of crushing and cutting
Danger from flying-off mechanical parts
or lubricating materials
Danger of suction
Prohibitive
indication
Prohibit rear panel removal
Prohibit panelling removal
Prohibit intervention

14
2Safety instructions
Warning
Pictographs used on the knitting machine
Warnings in the do cumentatio n
Command Wear safety glasses
Disconnect mains supply
Wear hair protection gear
Wait till all LEDs on the control cabinet are
off
Type Pictograph Explanation

15
Safety instructions 2
Safety precautions regarding the machine's life phases
2.5.3 Warnings in the documentation
The warnings in the documentation have the following structure:
Safety sign
The safety sign warns about the danger of injury and death.
In order to avoid death and injuries, all measures that are indicated along
with the safety sign are to be followed.
Signal word
DANGER, WARNING, CAUTION, IMPORTANT
Signal color
depending upon the signal word: red, orange, yellow, blue
Text comprises of:
–Type and source of danger
– Possible outcomes
– Measures for protection against danger and prohibitions
Example:
DANGER
Life-threatening high voltage!
Electrical shock may cause death or serious injuries.
➜Set machine main switch to "0".
➜Secure the machine against being switched on
again.
Explanation to the signal words
Signal word Explanation
Imminent danger of death or serious injuries
(irreversible).
Death of serious injury (irreversible) possible.
Slight injury (reversible) possible.
Damage to property possible.
Explanation to the signal words
Safety precau tions regarding th e machine's li fe phases

16
2Safety instructions
Safety precautions regarding the machine's life phases
2.6 Safety precautions regarding the
machine's life phases
Avoid any operational mode that might be prejudicial to safety.
Take the necessary precautions to ensure that the machine is used only
when in a safe and reliable state.
Operate the machine only when all the protective and security equipment
is available and functional.
In particular, malfunctions which could limit the safety of the machine are
to be remedied (or repair is to be commissioned) immediately!
Observe the warnings on the machine and in the operating instructions by
all means. By doing so you will protect yourself and the others from
dangers and will help to avoid damages to the machine and other tangible
assets.
No one may remain inside the machine. Risk of death!
Observe the start-up and shut-down procedures and the indicators.
Before starting up or setting the machine in motion, make sure that nobody
is at risk!
Safety instructio ns for the transport
2.6.1 Safety instructions for the transport
Type of risks Measures
Danger of injury by heavy loads. Country-specific regulations for the
prevention of industrial accidents for the
transport of heavy loads are to be
observed.
Use only appropriate means of transport
with sufficient load capacity for
transporting and installing the knitting
machine (e.g. fork lift).
The relevant country-specific laws and
regulations are to be observed when
transporting with a ground conveyor
(e.g. fork lift).
Ground conveyor: observe the safety
instructions of the manufacturer.
Transport the machine always with the
utmost caution and care.
Danger of damage to the machine. Attach all the transport locks.

17
Safety instructions 2
Safety precautions regarding the machine's life phases
Safety instruc tions for insta lling
2.6.2 Safety instructions for installing
Type of risks Measures
Danger of injury by heavy loads. Observe all technical data of the
machine.
Country-specific regulations for the
prevention of industrial accidents for
the transport of heavy loads are to be
observed.
Danger of damage to the machine. Remove all transport locks.
Connect side protective shrouding (on
left and right-hand sides of machine).
Environment pollution Dispose of protective films in an
environmentally responsible manner.
Observe the country-specific laws and
regulations.
Safety instruc tions for the ele ctrical con nection
2.6.3 Safety instructions for the electrical connection
Type of risks Measures
Danger to life during work on the
electrical assembly of the machine.
Get the machine connected by an
electrician.
Note technical data.
Safety Instructio ns for the Ex change of Data
2.6.4 Safety Instructions for the Exchange of Data
Type of risks Measures
Computer viruses!
Loss of data or production.
Computer viruses can creep into the
machine through unscanned data via
USB port or network.
Bring in only virus free data on to the
knitting machine.
The dangers associated with
computer viruses have been
increasing for years. Look into the
subject and ensure that the network
computer connected with the knitting
machine and the data carrier used on
the knitting machine are free from
computer viruses!
We advise you with emphasis to the
fact that the Co. H. Stoll GmbH & Co.
KG will take no guarantee or
responsibility for damages in this
conjunction. For further enquiries
please contact Stoll-Helpline.

18
2Safety instructions
Safety precautions regarding the machine's life phases
Safety Precauti ons for Production
2.6.5 Safety Precautions for Production
Type of risks Measures
Danger of injury Close the covers.
Close the rear panels of the machine.
Close the lateral covers.
Keep eyes away from the lateral yarn
tensioner.
Objects such as tools, bobbins etc. to be
removed from the inside of the machine.
If the machine is in operation, under no
circumstances should you reach into it.
Stop the machine if an intervention is
necessary.
Do not tear off the yarn by hand but use
scissors.
Danger of winding and
suction and danger of
crushing.
Do not reach into the fabric take-down rollers
nor into the belt take-down.
Do not touch the friction feed wheel while the
machine is in operation and keep away loose
garments and hair strands.
Wait for the feed wheel to stop moving after
stopping the machine.
Health hazard by fibers, dust
and fumes.
Special caution is to be observed while knitting
of yarns that cause health hazards or a
damage to the machine:
◆Yarns with heavy fiber fly
◆dyestuffs causing health hazards
◆Yarns made of glass fibers, metallic-
annealed fibers, asbestos, carbon, PU or
similar materials
Employ suitable measures to avoid the hazard
caused by fibre, dust and fumes.
Observe the country-specific laws and
regulations.
Observe the manufacturer's specifications
(safety data sheet).
For any further queries please contact Stoll.
Fire hazard by fluff, dust and
other impurities.
Increased danger of short
circuit during knitting of
metallic or conductive
materials by building up of
conductive fluff and dust.
Fluff, dust and other impurities to be removed
regularly from the entire machine depending
upon the degree of dirt at least once in every
shift.
Take care of any additional suction.
Wear Inhalation protection gear.

19
Safety instructions 2
Safety precautions regarding the machine's life phases
Additiona l Safety Instructi ons for the Ope ration with Open Covers
2.6.6 Additional Safety Instructions for the Operation with
Open Covers
If the covers are open the engaging rod cannot be locked into it's highest
position (production). The user must hold the engaging rod in this position so
that the machine works at the set speed "MSECCO" (dead man's switch).
The maximum carriage speed with open cover can be set in the "Machine
parameter" window. (Value range in input field "MSECCO": 0.00 to 0.20 m/s,
standard: 0.05)
DANGER
The carriage moves at production speed!
Danger of crushing and cutting by the carriage.
If the "MSECCO" check box is deactivated, the
carriage moves at production speed.
After the reversal point, the carriage can move at
higher speed, if it is set up that way in the knitting
program.
➜Close the covers.
➜Do not deactivate the "MSECCO" check box.
Operation with open covers (EP net, belt take-down)
Type of risks Measures
Danger of crushing and cutting by
the carriages, racking, the needle
beds, the clamping and cutting
devices and the additional needle
beds.
Do not reach into the running machine.
Move carriage step by step or at creep
speed (see operating instructions).
Danger of injury by broken cam box
and needle pieces.
Wear safety glasses.
Danger of crushing and suction:
◆by the fabric take-down (main
take-down, auxiliary take-down,
comb take-down, belt take-
down)
◆by the additional needle beds
Do not reach in the gap between the
needle beds.
Keep hands, face, loose clothing and
other loose objects away: danger of
crushing.
Do not reach into the area between the
fabric take-down roller and the comb
take-down.

20
2Safety instructions
Safety precautions regarding the machine's life phases
Safety Instructions for Lubrication, Cleaning and Maintenance
2.6.7 Safety Instructions for Lubrication, Cleaning and
Maintenance
Type of risks Measures
Danger of crushing and cutting by the
carriages, racking, the needle beds,
the clamping and cutting devices.
Switch off machine at main switch.
Secure the machine against being
switched on again.
After working on the rear of the
machine, re-fix the rear panels
again.
Cleaning with compressed air Observe the country-specific laws
and regulations.
Risk of soiling - do not blow directly
into the motor.
Recommendation:
In order to avoid any dust being
deposited on the inaccessible points
of the machine, we recommend that
the dust should be vacuum cleaned
and the machine not to be cleaned
by compressed air.
Caution:
Damage of needles!
The spring-mounted needle latches
will be damaged if the needles are
blown out with compressed air.
Always vacuum fluff and dust off the
needles, never blow them out.
Health hazard When working with oil and grease,
pay attention to the safety
regulations (safety data sheets)
applicable to the respective product!
Observe the manufacturer's
specifications (safety data sheet).
Environment pollution Ensure that oil and grease is
correctly disposed of in an
environmentally responsible
manner!
Observe the country-specific laws
and regulations.
Observe the manufacturer's
specifications (safety data sheet).