Stoll CMS ADF-3 User manual

Instruction manual for a safe operation of the
knitting machine
Type Computer type Component type
CMS ADF-3 681 OKC3.0 000 - 002
ID 264 847 US

Date: 2016-04-01
Translation of the original operating instructions
Operating system of the machine: V_OKC_006.000.000_STOLL (or higher)
H. STOLL AG & Co. KG, Stollweg 1, D-72760 Reutlingen, Germany
Our products are being developed further continuously. They are therefore subject to technical 
modifications.

3
Table of Contents
1 Documentation DVD 5
2 Safety instructions 7
2.1 Intended use ............................................................................................................................ 7
2.2 Organizational measures ......................................................................................................... 8
2.3 Personnel qualifications and selection .................................................................................... 9
2.3.1 Personnel qualification ................................................................................................. 9
2.3.2 Selection of personnel................................................................................................ 10
2.4 Warning ................................................................................................................................. 11
2.4.1 Warnings used ........................................................................................................... 11
2.4.2 Explanation to the pictogram (ANSI).......................................................................... 14
2.4.3 Warnings in the documentation.................................................................................. 16
2.5 Safety precautions regarding the machine's life phases ....................................................... 17
2.5.1 Safety instructions for the transport............................................................................ 17
2.5.2 Safety instructions for installing.................................................................................. 18
2.5.3 Safety instructions for the electrical connection......................................................... 18
2.5.4 Safety Instructions for the Exchange of Data............................................................. 18
2.5.5 Safety Precautions for Production.............................................................................. 19
2.5.6 Additional Safety Instructions for the Operation with Open Covers ........................... 20
2.5.7 Safety Instructions for Lubrication, Cleaning and Maintenance ................................. 21
2.5.8 Safety instructions for the repair................................................................................. 22
2.5.9 Safety instructions for dismantling work (dismantling) ............................................... 26
3 Electrical data of the machine 27
3.1 Dimensions and weights ........................................................................................................ 27
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
4 Main components of the knitting machine 33
4.1 Front side ............................................................................................................................... 33
4.2 Rear side ............................................................................................................................... 35

4
5 Security relevant operating elements 37
5.1 Main switch ............................................................................................................................ 37
5.2 Engaging rod ......................................................................................................................... 38
6 Optical and acoustic signal elements 39
6.1 Signal light ............................................................................................................................. 39
6.2 Touch screen ......................................................................................................................... 40
6.3 Horn ....................................................................................................................................... 41
6.4 Lamps on the yarn control device .......................................................................................... 42
7 Assembly and setting up 43
7.1 Preparing assembly ............................................................................................................... 43
7.1.1 Preparing installation location..................................................................................... 43
7.1.2 Having tools and aids ready....................................................................................... 43
7.1.3 Transporting machine to installation location ............................................................. 44
7.1.4 Unpacking knitting machine........................................................................................ 44
7.2 Assembling machine .............................................................................................................. 45
7.2.1 Putting up knitting machine ........................................................................................ 45
7.2.2 Connecting the knitting machine if the mains voltage is not 400 V ............................ 49
7.2.3 Plug in battery pack.................................................................................................... 53
7.2.4 Mounting the yarn guide device.................................................................................. 54
7.2.5 Mounting signal light................................................................................................... 56
7.2.6 Set date and time ....................................................................................................... 57
7.2.7 Aligning knitting machine............................................................................................ 58
7.3 Carry out reference runs ........................................................................................................ 60
7.4 Glue on measuring tape ........................................................................................................ 63
7.5 Have the test rod ready ......................................................................................................... 63
7.6 How to bring the carriage to an immediate standstill ............................................................. 64
7.7 Checking protective devices .................................................................................................. 65

5
1 Documentation DVD
1 Documentation DVD
Included in the accessories you will find a DVD with documents about your
machine.
For browsing the documentation DVD:
1. Insert the DVD in the computer.
2. Open the "1_Start.htm" file double clicking on it.
Operating instructions
Safety instructions
Spare Parts Catalog
Circuit diagram
Brochure "Cleaning, maintenance, care"
Pocket Card
Training documents...
The documents are available in different languages.
➜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.

Documentation DVD 1
6

7
2 Safety instructions
2.1 Intended use
2 Safety 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 haveany 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
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.
Preserve this operating instructions for future use. In case of
reselling the machine, the operating instructions are to be
included.

Safety instructions 2
Organizational measures 2.2
8
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.

9
2 Safety instructions
2.3 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.
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

Safety instructions 2
Personnel qualifications and selection 2.3
10
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
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

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2 Safety instructions
2.4 Warning
2.4 Warning
Inthischapter youwillfind explanations to thewarningsonthemachineand
in the documentation.
2.4.1 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:

Elements of a warning
Site for labeling the warning
on the machine

Site for labeling the warning on the machine
No. Explanation
1 one warning indication
2 one safety sign (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

Safety instructions 2
Warning 2.4
12
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.
No. Warning Explanation
1

ID 265 267
Warning on the rear panel
(sliding board)
2

ID 244 270
Warning on the friction feed
wheel
3

ID 244 261
Warning on the panelling of the
control cabinet right and left
4

ID 244 263
Warning front cover main switch
5

ID 244 271
Warning on the base plate
control cabinet right and rear
panel control cabinet right
List of warnings

13
2 Safety instructions
2.4 Warning
6

ID 244 272
Warningonthe combtake-down
and on the sliding board on the
right and on the left
7

ID 244 276
Warning under the covers

ID 244 269
8

ID 265 384
Warning on the panelling of the
light curtain
No. Warning Explanation
List of warnings

Safety instructions 2
Warning 2.4
14
2.4.2 Explanation to the pictogram (ANSI)
Pictograms on the machine Following pictograms 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
Pictographs used on the knitting machine

15
2 Safety instructions
2.4 Warning
Warning steps for warning
instructions as per ANSI A warning step comprises of the following parts:
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
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.
Warning steps for warning instructions as per ANSI

Safety instructions 2
Warning 2.4
16
2.4.3 Warnings in the documentation
The warnings in the documentation have the following structure:
Safety sign (display the danger of injury)
Signal word (DANGER, WARNING, CAUTION, IMPORTANT)
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.
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

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2 Safety instructions
2.5 Safety precautions regarding the machine's life phases
2.5 Safety precautions regarding the
machine's life phases
Avoid any operational mode that might be prejudicial to safety.
Takethenecessaryprecautionstoensurethatthemachine is usedonly
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!
2.5.1 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
withsufficientloadcapacity for transporting
andinstalling theknittingmachine(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.

Safety instructions 2
Safety precautions regarding the machine's life phases 2.5
18
2.5.2 Safety instructions for installing
2.5.3 Safety instructions for the electrical connection
2.5.4 Safety Instructions for the Exchange of Data
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.
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.
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.
Lookintothe subject andensurethatthe
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.

19
2 Safety instructions
2.5 Safety precautions regarding the machine's life phases
2.5.5 Safety Precautions for Production
Type of risks Measures
Danger of injury Close the covers.
Close the rear panels (sliding boards) of the
machine.
Close the lateral covers.
Keep eyes away from the lateral yarn tensioner.
Objectssuch as tools,bobbinsetc. to beremoved
from the inside of the machine.
If the machine is in operation, under no
circumstances should you reach into it.
If the machine is in operation, do not reach into
the area of the yarn carrier rails under any
circumstances.
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.
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.
Observethe 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 fromthe entiremachinedependingupon
the degree of dirt at least once in every shift.
Take care of any additional suction.
Wear Inhalation protection gear.

Safety instructions 2
Safety precautions regarding the machine's life phases 2.5
20
2.5.6 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.
Type of risks Measures
Danger of crushing and cutting by the
carriage, the autarkic yarn carriers, the
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.