Stoll CMS 933 User manual

Instruction manual for a
safe operation of the
knitting machine
Type Computer type Component type
CMS 933 769 OKC 000 - 004
CMS 922 770 OKC 000 - 004
CMS 830 C k&w 573 OKC 000 - 004
CMS 822 574 OKC 000 - 005
CMS 740 572 OKC 000 - 004
CMS 730 T k&w 586 OKC 000 - 004
CMS 730 S k&w 554 OKC 000 - 004
CMS 530 T 585 OKC 000 - 004
CMS 530 566 OKC 000 - 004
CMS 520 C 570 OKC 000 - 004
CMS 520 567 OKC 000 - 004
CMS 420 E 579 OKC 000 - 002
CMS 420 E multi gauge 577 OKC 000 - 001
CMS 420 E 575 OKC 000 - 001
Id no.: 244 428 US

Date: 2008-06-24
Version number: 1.7
H. Stoll GmbH & Co. KG, Stollweg 1, D-72760 Reutlingen, Germany
Our products are being developed further continuously. They are therefore subject to technical modifications.

Contents
1Safety instructions 1-1
1.1 Proper use ............................................................................................................................ 1-1
1.2 Organizational measures...................................................................................................... 1-2
1.3 Personnel qualifications and selection ................................................................................. 1-3
1.3.1 Personnel qualification ........................................................................................... 1-3
1.3.2 Selection of personnel ............................................................................................ 1-4
1.4 Warning................................................................................................................................. 1-5
1.4.1 Warnings used........................................................................................................ 1-5
1.4.2 Explanation to the Pictograph (ANSI)..................................................................... 1-7
1.4.3 Warnings in the documentation .............................................................................. 1-8
1.5 General safety instructions ................................................................................................... 1-9
1.5.1 Danger by mechanical parts................................................................................... 1-9
1.5.2 Danger by electrical energy.................................................................................... 1-9
1.5.3 Danger by operating materials. ............................................................................ 1-10
1.5.4 Other dangers....................................................................................................... 1-10
1.6 Safety instructions for the individual Operation Phases ..................................................... 1-11
1.6.1 Safety instructions for the transport...................................................................... 1-11
1.6.2 Safety instructions for lubrication.......................................................................... 1-11
1.6.3 Safety instructions for the electrical connection ................................................... 1-12
1.6.4 Safety instructions for the exchange of data ........................................................ 1-12
1.6.5 Safety precautions for production......................................................................... 1-12
1.6.6 Additional Safety Instructions for the operation with open cover hoods............... 1-13
1.6.7 Safety Instructions for the lubrication, cleaning and maintenance ....................... 1-14
1.6.8 Safety instructions for dismantling work ............................................................... 1-14
2Electrical data of the machine 2-1
2.1 Dimensions and weights....................................................................................................... 2-1
2.2 Electrical data ....................................................................................................................... 2-2
2.3 Electrical data (component type 000 and 001)..................................................................... 2-3
2.4 Gauge ranges ....................................................................................................................... 2-4
2.5 Operating conditions............................................................................................................. 2-4
2.6 Storage conditions ................................................................................................................ 2-5

2.7 Noise emissions.................................................................................................................... 2-5
3Main components of the knitting machine 3-1
3.1 Front side .............................................................................................................................. 3-1
3.2 Lateral view (right) ................................................................................................................ 3-3
3.3 Rear side............................................................................................................................... 3-4
3.4 Optical and acoustic Signal elements................................................................................... 3-5
3.4.1 Signal lamp ............................................................................................................. 3-5
3.4.2 Touch screen .......................................................................................................... 3-6
3.4.3 Horn ........................................................................................................................ 3-7
3.4.4 Lamps on the yarn control device........................................................................... 3-7
4Assembly and setting up 4-1
4.1 Preparing assembly .............................................................................................................. 4-1
4.1.1 Preparing installation location................................................................................. 4-1
4.1.2 Having tools and aids ready ................................................................................... 4-1
4.1.3 Transporting machine to installation location ......................................................... 4-1
4.1.4 Unpacking knitting machine.................................................................................... 4-1
4.2 Assembling machine.............................................................................................................4-2
4.2.1 Putting up knitting machine..................................................................................... 4-2
4.2.2 Connect the knitting machine ................................................................................. 4-5
4.2.3 Connect the knitting machine (component types 000 and 001) ............................. 4-8
4.2.4 Aligning knitting machine ...................................................................................... 4-13
4.3 Mounting yarn feeding and control device .......................................................................... 4-15
4.3.1 Mount the yarn control device .............................................................................. 4-15
4.3.2 Mounting signal lamp............................................................................................ 4-17
4.4 Glue on measuring tape...................................................................................................... 4-18
4.5 Switching on machine ......................................................................................................... 4-18
4.6 How to bring the carriage to an immediate standstill.......................................................... 4-19
4.7 Checking safety equipment................................................................................................. 4-20

Safety instructions 1
Proper use 1.1
1-1
1 Safety instructions
These operating instructions are designed to familiarize the user with the
machine and its designated use.
The instruction manual contains 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 textual and graphic representations need not always correspond to
the scope of delivery of the machine.
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 .
Additional information is provided by:
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 Instruction manual for future use. In case of a subsequent
resale of the machine , the Operating instructions are to be sent alongwith.
1.1 Proper 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 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.
Foreword to the Instructions

1Safety instructions
1.2 Organizational measures
1-2
1.2 Organizational measures
The instruction manual is 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 instruction leaflet
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. e.g.. 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 See spare parts catalogue
No modifications, additions or conversions may be made on the
machine that might endanger the safety.
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.

Safety instructions 1
Personnel qualifications and selection 1.3
1-3
1.3 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.
1.3.1 Personnel qualification
In order that the knitting machine can be operated correctly and safely, it
must be set up and operated by reasonably qualified personnel.
Electrician
Mechanic
Knitting expert
Trained or semi-skilled Person
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 possessess the following characteristics:
technical qualification
theoretical knowledge
practical experience
Knowledge of the relevant (country specific) regulations
Knowledge of the operating instructions
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 possessess the following characteristics:
technical qualification
theoretical knowledge
practical experience
Knowledge of the relevant (country specific) regulations
Knowledge of the operating instructions
Electrician
Mechanic

1Safety instructions
1.3 Personnel qualifications and selection
1-4
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 possessess 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
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 theoretcal and practical orientation on the knitting machine
practical experience
Knowledge of possible dangers
1.3.2 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
Start-up Knitting expert
Programming Knitting expert
Designing 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,
Cleaning
Knitting expert, trained or semi-skilled Person
Maintenance Mechanic, electrician or knitting expert
repair Mechanic or Electrician
Dismantling work Mechanic or Electrician
Knitting expert
Trained or semi-skilled
Person

Safety instructions 1
Warning 1.4
1-5
1.4 Warning
In this chapter you will find explanations to the warnings on the machine
and in the documentation.
1.4.1 Warnings used
Warnings on the machines correspond to the standard ANSI Z 535.4.
Scope of validity: USA and Canada
A warning instruction as per ANSI Z 535.4 comprises of the following
elements:
Fig. 1-1 Elements of a warning
No. Explanation
1 one warning indication
2 one safety indication (displays the danger of injury)
3 Display of the warning step (Danger: red, Warning: orange, Caution:
yellow)
4 Text comprises of :
Type and source of danger
Possible outcomes
Measures for protection against danger and prohibitions
Fig. 1-2 Site for labelling the warning on the machine
Site of labelling of the
warning on the machine

1Safety instructions
1.4 Warning
1-6
Warnings have to be maintained in a complete and legible condition at all
times
The order numbers of the labels are found in the spare parts catalogue.
No. Warning Explanation
1
Warning on the rear panel
2
Warning on the friction feed wheel
3
Warning on the shrouding cover control
cabinet right and left
4
Warning Front cover main switch
5
Warning on the base plate control cabinet
right and rear panel control cabinet right
6 Warning on the fabric take-down
7
Warning under the cover hoods
8
Warning on the central lubrication of front
and rear needle beds.
For tandem machines, on right-hand side
of right carriage as well.
Tab. 1-1 List of warnings
List of warnings on the
machine

Safety instructions 1
Warning 1.4
1-7
1.4.2 Explanation to the Pictograph (ANSI)
Following Pictographs are used on the machine:
Pictograph Explanation
General Warning indication
Dangerous electrical voltage
Danger of crushing and cutting
Danger from flying-off mechanical parts
or lubricating materials
Danger of suction
Tab. 1-2 Pictographs used on the knitting machine
A warning step comprises of the following parts:
Safety indications
The safety inidications warns about the danger of injury and death.
In order to avoid death and injuries, all measures that are indicated
alongwith the safety indications are to be followed.
Signal word
DANGER, WARNING, CAUTION
Signal color
depending upon the Signal word: red, orange, yellow
Warning step Explanation
Imminent danger of death or serious injuries
(irreversible).
Death of serious injury (irreversible) possible.
Slight injury (reversible) possible.
Damage to property possible
(without Safety indication).
Tab. 1-3 Warning steps for warning instructions as per ANSI
Pictograms on the machine
Warning steps for warning
instructions as per ANSI

1Safety instructions
1.4 Warning
1-8
1.4.3 Warnings in the documentation
The warnings in the documentation have the following structure:
Safety indications (display the danger of injury)
Signal word (Danger, Warning, Caution)
Text comprises of :
- Type and source of danger
- Possible outcomes
- Measures for protection against danger and prohibitions
Example:
DANGER
High voltage!
Electrical shock may cause death or serious injuries.
ÎSet the main switch to "0".
ÎSecure the machine agaisnt being switched on again.
Signal word Explanation
Danger Imminent danger of death or serious injuries
(irreversible).
Warning Death of serious injury (irreversible) possible.
Caution Slight injury (reversible) possible.
Caution
(without safety indications)
Damage to property possible.
Tab. 1-4 Explanation to the Signal words

Safety instructions 1
General safety instructions 1.5
1-9
1.5 General safety instructions
1.5.1 Danger by mechanical parts
Reason Protective measures
Danger of injury by rotating or
moving parts
Do not reach into the running machine.
Always stop the machine during an
intervention
Switch off the machine during mounting
activities and secure it against being
switched on again.
Wear safety glasses.
Injuries may be caused by pieces
broken off from needles when the
carraige and needles collide at
damaged points.
Wear safety glasses.
Danger of burns by motors; the
needle bed and parts of electric
controls that can become hot.
Wear protective gloves.
Danger of injury
in the case of mounting activities by
pressure and tension springs
(for. e.g. in the main take-down and
in the engaging rod), which could
have stored potential energy.
Relieve the springs before removing.
Carry protective equipment.
1.5.2 Danger by electrical energy.
Reason Protective measures
Danger to life by electrical shock
during work on the electrical
assemblies of the machine.
Work is to be done only by an electrician.
Switch off machine
Remove building fuses.
Secure the machine against being
switched on again.
Danger to life by electric shock in
case of electric faults like loose or
defective connectors/plugs or
braised or damaged cables.
Deactivate the machine immediately.
Remove building fuses.
Secure the machine against being
switched on again.
Eliminate all faults that can be caused by
an electrician.

1Safety instructions
1.5 General safety instructions
1-10
1.5.3 Danger by operating materials.
Reason Protective measures
Danger of chemical burns during
contact with oil, grease and other
chemical substances.
Wear protective gear (for. e.g. safety
glasses, gloves).
Observe the country-specific laws and
regulations.
Pay attention to the Manufacturers'
instructions.
Injuries by oil pressure in case of
damaged lines of the central
lubrication that are under a high oil
pressure (30 bar).
Deactivate the machine immediately.
Secure the machine against being
switched on again.
Get the damaged lines replaced by a
mechanic.
Remove the outcoming oil immediately.
Injuries by compressed air in case of
damaged lines of the fluff absorption
that are under a high air pressure.
Deactivate the machine immediately.
Secure the machine against being
switched on again.
Get the damaged lines replaced by a
mechanic.
Danger of skidding if the oil, grease
or other substances are blocked or if
a leakage appears.
Immediately mop these substances.
Observe the country-specific laws and
regulations.
Environment pollution is caused if the
disposal of replaced parts and of
consumables is not done
professionally.
Ensure that all consumables and
replaced parts are disposed of safely
and with minimum environmental impact!
Observe the country-specific laws and
regulations.
Pay attention to the Manufacturers'
instructions.
1.5.4 Other dangers
Reason Protective measures
Increased fire and explosion hazard
by lint, dust and other impurities.
Increased danger of short circuit
during knitting of metallic or
conductive materials by building up
of metallic fluff and dust.
Lint, dust and other impurities to be
removed regularly from the entire machine
depending upon the degree of dirt atleast
once in every shift.
Take care of any additional exhaustion.
Wear Inhalation protection gear.
Danger of damage by usage of
unsuitable cleaning materials.
Only cleaning materials that have been
mentioned in the Operating Instructions
for e.g. Alcohol are to be used. Do not
use cleaning material that can cause
health hazards or is acidic/corrosive in
nature.

Safety instructions 1
Safety instructions for the individual Operation Phases 1.6
1-11
1.6 Safety instructions for the individual
Operation 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 Instruction leaflet 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!
1.6.1 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.
The relevant Country-specific laws and
regulations to be observed during
transport with ground conveyors.
1.6.2 Safety instructions for lubrication
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 Dipose off protective films in an
environmentally responsible manner.
Observe the country-specific laws and
regulations.

1Safety instructions
1.6 Safety instructions for the individual Operation Phases
1-12
1.6.3 Safety instructions for the electrical connection
Type of risks Measures
Danger to life during work on the
electrical assemblies of the machine.
Get the machine connected by an
electrician.
Note technical data.
1.6.4 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 company Fa. H. Stoll
GmbH & Co. KG will take no guarantee
or responsability for damages in this
conjunction. For further enquiries
please contact Stoll-Helpline.
1.6.5 Safety precautions for production
Type of risks Measures
Danger of injury Close the cover hoods.
Close the rear panels of the machine.
Close the cover hoods.
Keep eyes away from the lateral slack tensioner.
Objects such as tools, yarn 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.
Danger of winding and
suction and danger of
crushing.
Do not reach into the fabric take-down rollers.
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.

Safety instructions 1
Safety instructions for the individual Operation Phases 1.6
1-13
Type of risks Measures
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 fibres
Dyestuffs causing health hazards
Yarns made of glass fibres, metallic-annealed
fibres, asbestos, carbon, PU or similar materials
Employ suitable measures to avoid the damage
caused by fibre, dust and fumes.
Observe the country-specific laws and
regulations.
Pay attention to the Manufacturers' instructions.
For any further queries please contact STOLL.
Risk of damage (Short circuit)
during the knitting of metallic
or electric yarns by fibres and
dust.
Remove lint, dust and other impurities regularly
from the entire machine depending upon the
degree of dirt; however atleast once per shift.
Take care of the additional extraction.
1.6.6 Additional Safety Instructions for the operation with
open cover hoods
If the shrouding 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 programmed speed (dead
man’s switch).
Type of risks Measures
Danger of crushing and cutting by the
carriages, racking, the needle beds,
the clamping and cutting devices.
Do not reach into the running machine.
Move carriage step by step or very
slowly (see Operating Manual).
Danger of injury by broken pieces off
cam and needle.
Wear safety glasses.
Danger of crushing and suction by the
fabric take-down, the auxiliary take
down, the take-down comb and the
additional 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 take-
down comb.

1Safety instructions
1.6 Safety instructions for the individual Operation Phases
1-14
1.6.7 Safety Instructions for the 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.
Health hazard When working with oil and grease,
pay attention to the safety regulations
(safety data sheets) applicable to the
respective product!
Pay attention to the Manufacturers'
instructions.
Environment Pollution Ensure that oil and grease is correctly
disposed of in an environmentally
responsible manner!
Observe the country-specific laws and
regulations.
Pay attention to the Manufacturers'
instructions.
1.6.8 Safety instructions for dismantling work
Dismantling for a longer storage or for evacuation:
Type of risks Measures
Danger to life because of electrical
shock
during work on the electrical
assemblies of the machine.
Get the machine disconnected from the
mains supply by an electrician.
Danger of damage to the machine
during transport.
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.
Dismantling and scrapping:
Type of risks Measures
during work on the electrical
assemblies of the machine.
Get the machine disconnected from the
mains supply by an electrician.
Environment pollution during disposal Observe the country-specific laws and
regulations.

Electrical data of the machine 2
Dimensions and weights 2.1
2-1
2 Electrical data of the machine
2.1 Dimensions and weights
Fig. 2-1 Machine dimensions (in cm)
A Width B Depth C Height
D Spacing of set screws E Nominal working width
The back-and-forth movement of the carriage causes the dynamic loads
listed above to occur at the set screws.
A B C D E Weight (kg) Dynamic weight (kg)
CMS 933 510 106 205 270 244 2060 700
CMS 922 456 106 205 270 244 1960 660
CMS 830 C k&w 403 91 205 239 213 1690 740
CMS 822 403 91 205 239 213 1670 730
CMS 740 355 91 205 209 183 1530 620
CMS 730 T k&w 355 91 205 209 183 1510 630
CMS 730 S k&w 355 91 205 209 183 1520 630
CMS 530 T 270 91 205 153 127 1260 550
CMS 530 270 91 205 153 127 1240 540
CMS 520 C 270 91 205 153 127 1250 540
CMS 520 270 91 205 153 127 1220 510
CMS 420 E (type 579) 237 91 205 153 114 990 470
CMS 420 E (type 575, 577) 270 91 205 153 114 1170 500
Tab. 2-1 Dimensions, weight and dynamic weight

2Electrical data of the machine
2.2 Electrical data
2-2
2.2 Electrical data
Valid for:
≥Component type 003 CMS 822
CMS 933 CMS 830 C CMS 740 CMS 530 T CMS 520
CMS 922 CMS 822 CMS 730 S CMS 530
≥Component type 002
CMS 730 T CMS 520 C
≥Component type 000 CMS 420 E
(type 579)
Electrical data Values
Supply voltage 400 V ±10 %
50 or 60 Hz
No. of phases 3
Observe clock wise phase sequence
Rated current 7 A
Main fuse (of customer) 16 A slow-blow
each phase
Power consumption approx.. 2.6 kW
Tab. 2-2 Connection data of the knitting machine
Before connecting the machine, check the mains voltage available on site.
It is generally not admissible to connect electrical or electronical
components of other makes to the machine's internal wiring. If such
assemblies are used, we are unable to guarantee optimum functional
performance of the machine.
If the knitting machine is operated by means of a generator, make sure
that the voltage supplied by the generator meets the requirements of the
EN 60204-1, paragraph 4.3.1.
In case of queries, please call the STOLL Helpline.