Electrical / electronic equipment

Control cabinet
from WM no. 5044 onwards

General

The electrical control system of the weaving machine

is built into the control cabinet. The cabinet is sub-
divided into the power supply unit on the left and the
control unit on the right.

- Power supply unit: Contains all power components

(servo drives, frequency converter, power supply,
contactors etc.)
- Control unit: Contains all control components (vari-
ous PCBs); it is separated from the power supply
unit by a metal panel (EMV).

Contact with live components can be

dangerous for personnel, even if voltag-
es are low.

Caution! Always turn off the main switch

before replacing plug-in modules,
fuses, peripheral equipment etc.
as well as connecting and discon-
necting plug connections.

The Safety Rules filed in Index i are applicable and

Contents Page must be complied with.

General 1
Note: Th following illustrations are not binding in de-
Components in the power supply unit 2 tail. Minor changes can occur depending
on the version.
Overview of components in the control unit 3
Terminal 3
RGG module with electronics rack RKR-2 4
Description of printed circuit boards 10

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 Q500

G534
G536
Z500

Q502 Q503
400V TH
G531/533

K514 K513 K515

KS GEB FM
PCB

K510 K511 K512

HM KG-R KG-V
G530

G532

T520

T521

Components in the power supply unit PCB Power pack, brakes and clutches

T521 Sealing device transformer

Q500 Main switch
Q502 Motor protection switch, 400 VAC distribution
Z500 Line filter
Q503 Motor protection switch, mains voltage
G536 Main motor frequency converter distribution

G534 Servo drive, dynamic pile control K510 Main motor contactor

G530 Servo drive, ground warp let-off K511 Reverse creep speed contactor

G531 Servo drive, raised warp let-off (fancy) K512 Forward creep speed contactor

G533 Servo drive, terry warp let-off K513 Suction fan

G532 Servo drive, cloth take-up K514 Electric selvedge cutter

T520 Power supply K515 Dynamic pile control motor contactor

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 Overview of components in the control
unit

The PCBs indicated with dotted lines are options and

are mounted depending on machine configuration.

BDE Coupling elements to plant data logging

STA Coupling elements to status reports

The control PCB sequence is fixed

Caution!
and may not be altered.

Terminal

TER board (terminal) 820 401 XXX

The TER board is located directly below the front

plate of the terminal. It is powered with 24V DC. This
PCB accommodates the system EPROM D8 and the
X2 language EPROM D7.

Connector X2: Serial interface to WSK board and

power supply +24V DC.

D8
D7

TER board

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 Module RGG 880 075 xxx with electronics
rack RKR-2

Rack RKR-2 JAS RKA WAS CPU The RGG module assumes all the functions of the
previous boards RWP, NTL, WSK and SSM on the
G6200 weaving machine.

In addition, the RGG module acts as the motherboard

of the G6200 SK98 control system and contains slots
for the CPU, WAS, RKA and JAS (option) boards.

JAS JAS board (serial jacquard)

RKA RKA board (warp let-off control)
WAS WAS board (monitoring system)
1 2 3 4 5
CPU CPU board (central processing unit)
1xx
0xx
LEDs 1…5 permit an optical check of the power in-
put. If they are not lit, check the relevant fuses (LED
3xx 1…4) or wait until the multi-fuses have cooled down
(LED 5).
2xx
LED 1 Power supply path 24Vu_L (fuse 35)
LED 2 Power supply path 24Vu_D (fuse 37)
LED 3 Power supply path 24Vu_C (fuse 38)
LED 4 Power supply path 24Vu_E (fuse 39)
RGG module
LED 5 Logic power supply Vcc

0xx Plug connectors to internal destinations in

control cabinet
1xx Plug connectors to destinations outside the
control cabinet
2xx Plug connectors to variable destinations
3xx to boards in rack RKR-2

When replacing the RGG module,

Caution!
the following procedure must al-
ways be observed: Before tighten-
ing the four fastening screws of
the rack above the base board
RGG, carefully plug the CPU, WAS
and RKA boards into the appropri-
ate slots and lock with the knurled
thumb screws (centering the bus
connector). All four fastening
screws on the rack can now be
tightened.

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Page 6 G 6200 e 09.09.99

Functions of module RGG 880 075 xxx Modules used for the relevant
Internal plug connectors X 0xx functions

Connec- Circuit Functions of module RGG 880 075 xxx and

tor code diagram actuators / sensors / other modules controlled by RKA WAS CPU RGG Others
page it

X 000 113 +24VDC, power supply x Fuses

X 001 122 Fan for motherboard x
X 002 135 Quick warp pull-through SKD x x
X 003 135 Stroboscope x x
X 004 152 Plant data logging BDE x x BDE module
X 005 640 Waste saver (left) WS x x WS
X 006 Various. Contactor control / feedbacks OPTIONS x x x

X 010 551 Supply package direct (interface) x x FWA

X 011 710 Electronic cloth take-up EWA (interface) x x x EWA
X 012 251 Contactor feedbacks BASE x x
X 013 136 Four-colour signal column x x x
X 014 Div. Contactor controls BASE x x x

X 020 540 Electronic weft brake EFB (interface) x x EFB

X 021 460 Serial dobby SMS (interface) x x SMS
X 022 150 COM 1 x x
X 023 125 Main switch sub-contact HS-NK x x
X 024 612 Glass cutters x
X 025 153 Status outputs x Status module

X 030 821 Pile control DFR x x x DFR

X 031 252 Control LBK x x x LBK
X 032 252 Control PCB x x x PCB

X 040 620 Sealing device SVR (interface) x x SVR

X 041 124 Reserve serial 1 x x
X 042 151 Production management system, serial LS (interface) x x LS
X 043 265 / 266 Controlled main drive internal / external x x GHI / GHA

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Functions of module RGG 880 075 xxx Modules used for the relevant
Internal plug connectors X 0xx functions

Connec- Circuit Functions of module RGG 880 075 xxx and

tor code digram actuators / sensors / other modules controlled by it RKA WAS CPU RGG Others
page

X 100 812 Warp beam cylinder disengaging valve KBV x x

X 101 810 Valve for quick style change SSV x x
X 102 640 Waste saver: lubricating magnet x x
X 103 640 Waste saver: support magnet x x
X 104 560 Rapier cleaning valve VRG x x
X 105 550 Thread lifting magnet FAU x x
X 106 neu Controlled electric brake cleaning valve GEB x x
X 107 343 Leno end monitoring, left DFU / L x x
X 108 343 Leno end monitoring, centre DFU / M x x
X 109 343 Leno end monitoring, right DFU / R x x
X 110 520 Automat. weft feed backup ASS (conventional) x x
X 111 272 Pick finder sensor SS x x
X 112 821 Pile control sensor SFG (pile gear sensor) x x DFR
X 113 510 Weft detector SFW 1 x x
X 114 730 Batch winder connection x x
X 115 344 Warp stop motion, high, left KFW-H/L x x
X 116 344 Warp stop motion, high, right KFW-H/R x x
X 117 340 Warp stop motion, ground, left KFW-G/L x x
X 118 340 Warp stop motion, ground, right KFW-G/R x x
X 119 280 Bypass valve BPV x x
X 120 280 Lubricating pressure, left SDL x x
X 121 410 Connection positive tappet motion EM Staubli 1602 x x
X 122 125 Emergency stop button, left x x x
X 123 812 Warp beam cylinder disengaged sensor KBA x x
X 124 812 Warp beam cylinder engaged sensor KBE x x
X 125 126 Light barrier transmitter 1 LSS 1 x x x
X 126 126 Light barrier transmitter 2 LSS 2 x x x
X 127 126 Light barrier receiver 1 LSE 1 x x x
X 128 126 Light barrier receiver 2 LSE 2 x x x
X 129 510 Weft detector SFW 2 x x
X 130 821 Pile control sensor USW (monitoring spiked roller) x x
X 131 272 Synchronisation sensor SYS x x
X 132 130 VFD terminal 881 240 xxx x x
X 133 352 Position/ force sensor ground WKP1 / WKK1 x x x
X 134 535 Tape sensor, left BS/L x x
X 135 535 Tape sensor, right BS/R x x
X 136 810 Quick shaft change: shaft lock sensor, left SSA/L x x
X 137 810 Quick shaft change: claw coupling sensor, left ESA/L x x
X 138 810 Quick shaft change: shaft lock sensor, right SSA/R x x
X 139 810 Quick shaft change: claw coupling sensor, right ESA/R x x
X 140 146 Angle transmitter x x
X 141 311 Warp let-off limit switch WKE-G (ground) x x x
X 142 310 Warp let-off limit switch WKE-H (high) x x x
X 143 353 Position/force sensor, high WKP2 / WKK2 x x x
X 144 133 Second keypad, front (TAV/R) x x
X 150 420 Jacquard / name jacquard machine (interface) JM /NJM x x
X 151 132 Keypad terry WM rear left TFH/L x x
X 152 131 Keypad, front (auxiliary cross beam) TAV (TAV/L) x x x

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Functions of module RGG 880 075 xxx Modules used for the
Internal plug connectors X 0xx relevant functions

Connec- Circuit Functions of module RGG 880 075 xxx and

tor code digram actuators / sensors / other modules controlled by RKA WAS CPU RGG Others
Page it

X 200 Reserve input/output 04 x x Fuses

X 201 Reserve input/output 03 x x
X 202 Reserve input/output 02 x x
X 203 Reserve input/output 01 x x
X 204 910 Test connector x x BDE module
X 205 132 Keypad, warp (in SKR) TKE / TFH/R x x WS

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 Descriptions of printed circuit boards

JAS board (serial jacquard) 820 423 XXX

H1
The JAS board is an interface between the weaving
H2 machine and the jacquard machine.
Data transfer between interface and jacquard machine is
D19 effected via a serial interface RS 422.
Digital inputs and outputs are located on this board.
They permit direct signalling between jacquard ma-
chine and weaving machine.

Connector C: Digital inputs and outputs

Connector D: Interface RS 422 to jacquard machine
C
D19: EPROM
H1 + H2: Displays communication between WM
and JM

JAS board

RKA board (warp let-off control) 881 218 XXX

The RKA board monitors the position sensors and is

the interface to power unit KA.

Connector A: Connection to position sensors

A Connector C: Interface to BRU 105 (KA ground)
Connector D: Interface to BRU 105 (KA fancy)
Connector E: Warp safeguard limit switch
T
Test points T: For set and actual speed values as
well as sensor value

RKA board

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 WAS board (monitoring system) 880 080 XXX

The number of light barriers entered in

generic term 12 F41 must correspond
to the number of light barriers actually
fitted.
A
The WAS board is responsible for system monitoring
of the weaving machine and for controlling the vari-
B ous clutches and brakes.

Connector A: Light barrier emitter and

left-hand EMERGENCY STOP switch
C Connector B: Light barrier receiver and right-hand
EMERGENCY STOP switch
Connector C: Signal column control
Connector D: Connection to PCB board

All these connections are distributed by the RGG

D board to the appropriate destination.

WAS board

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 D17 D2 CPU board (central processing unit) 820 400 XXX

The number of light barriers entered in

generic term 12 F41 must correspond
to the number of light barriers actually
fitted.
D16
The CPU board is the central control unit for the
weaving machine. This PCB accommodates:
– Microprocessor D2 for the control system
– EPROMs D16 / D17 (program memories for the
B
general machine functions). The program version
D12 stored in the EPROM can be called up at the ter-
minal in generic term 12 D01. The EPROM is la-
C belled with the corresponding number of the pro-
G1 gram version.
– Parameter memory D12 (RAM), on which the D
functions are also stored. In the event of data loss
D
in the RAM, check the battery and replace it if
necessary.
– Battery G1 (approx. 3.6V DC) for supporting the
RAM memory when the main switch is off.

Connector B: Clock bus

Connector C: Clock bus
CPU board
Connector D: Angle transmitter

Activation and change of the battery G1

on CPU
G1
Activation of battery (Jumper X6)
X6
Prior to inserting the CPU into the weaving machine,
jumper X6 should be plugged from "0FF" onto "ON".

Batteries may be changed only

Caution!
with the machine switched off.

Each battery change results in data loss. Make back-

up with DC/1.

– Remove battery securing clamp by means of a

fine screwdriver.
– Replace battery G1 (pay attention to correct pola-
rity!).
– Remount battery securing clamp.

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 EWA board (electronic cloth take-up)
820 421 XXX

The EWA board is the interface between the weaving

machine and the cloth take-up drive unit (DDM).
A
Connector A: Interface RS 422 to RGG board,
clock bus and power supply
B Connectors B/C/D: Connections to DDM board

C D2
EPROMs
D3

D D2

D3

EWA board

EFB board (electronic weft brake) 820 410 XXX

This board controls the braking and release magnets

of each weft brake in accordance with the settings al-
ready loaded or entered at the WM terminal for colour
allocation, braking time and also the braking force
depending on the weft brake.

A
Connector A: Weft brake magnets
Connector D: Serial connection of RGG board,
clock bus and power supply

D6: EPROM

D6 EFB board

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 FWA board (colour selection unit) 820 411 XXX

The FWA board acts as the interface to the colour se-

lection unit.

Connector A: Magnets of the colour selection unit

Connector D: Interface RS 422 to RGG board, clock
bus and power supply.
A
D7: EPROM

D7

FWA board

SMS board (serial dobby) 820 417 XXX

The SMS is an interface board between weaving ma-

chine and electronic dobby.
V1 It controls the magnet assembly on the dobby with
24V DC. The pattern data of max. 16000 picks are
V2 managed on the CPU board.
Connector A: serial connection of WSK, clock bus
A and power supply
Connector B: magnet assembly or SML1 board
Connector C: SML2 board
B
V1 left: Error display
V1 right: Flashes = communication between SMS
and CPU
V2left: Control display +5V DC
V2 right: Error display

C A8: EPROM

A8 SMS board

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 SML board (dobby power pack) 880 069 XXX

The SML board is the driver assembly of the SMS

board for the "Fimtextile RD 3030/36" dobby connect-
ed on the outlet side.
A
Connector A: 24V DC, oil level and shed closure sig-
nal
Connector B: Connections to SMS board
B Connector C: Magnets SM RD 830
Connector D: Power supply 40V DC

SML board

SVR board (sealing unit) 820 424 XXX

D5
This PCB is used to control the operation of the sel-
vedge sealing unit. With the sealing unit, synthetic fi-
bres are severed during the weavng process and at
the same time re-sealed.

D5: EPROM
H1 H1: Control display +5V DC
H3 H2: Control display 48V AC (F3)
H3: Control display 48V AC (F2)
H2 F1: Fuse 0.63AT (5V DC)
F2: Fuse 5.0AT (48V AC)
F3: Fuse 5.0AT (48V AC)

F3 F2 F1 SVR board

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 DFR board (dynamic pile control) 820 422 XXX

The DFR board has two main functions: it controls the

H1, 3 "Pile warp let-off" (RKF) and the "Dynamic pile control"
(DFS) for the loose pick distance.
H2, 4 Communication with the WM control system is via a
serial interface.

A Connector A: Serial interface RS 422, clock bus,

power supply 24V DC, sensors
Connector B: connection to PCBs BRU 105 and
BRU 200.

H1 + H2: Flashing = processing

B H3: +24V DC check
H4: Error display
D5, D6: EPROMs

D6
D5

DFR board

PCB board (power clutch and brake) 820 429 xxx

Error
The PCB board is a processor-controlled power
X1 Ok pack. It controls the clutch and brakes as well as the
creep speed and pick finder clutches.

Connector X1: Connection to RGG board (check

connector)
X2
Connector X2: Power supply for logic and holding
brake
PCB Diagnosis/ software download

X5
Connector X5: Holding brake
Connector X6: Creep speed and pick finder clutch
X6
Connector X7: Main clutch / main brake
Connector X8: Power supply (up to 320 V DC)

After "MAIN SWITCH OFF", always

Caution!
X7 wait at least 3 minutes before dis-
connecting the AMP connector
X8
and removing the PCB board, as
the condensors are still live.

PCB board

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 DDM 019 board (brushless servo drive)
881 236 XXX

The DDM 019 is an industrial high-performance drive

orf modular design. It drives brushless permanent
Electro-Craft Status magnet synchronous motors with sinus waves.
It is used as power stage for driving the cloth take-up
motor and the warp let-offs, ground and high.
J5
BRU

Stecker J1: Connection to EWA / RKA boards

Stecker J2: Connection to encoder
Stecker J5: Serial connection

Connection TB1: Connection to power supply and

J2
motor

LED status : green = normal operation

blinking green/orange = drive fault
orange = hardware malfunction
J1 blank = power not supplied or
hardware malfunction

TB1

DDM 019 board

DDM 030 board (brushless servo drive)

881 237 XXX
Electro
BRU -Craft
Status
The DDM 030 is an industrial high- performance drive
of modular design. It drives brushless permanent
magnet synchronous motors with sinus waves.
TB2 It is used as power stage for driving the DFS (dynam-
ic pile control) motor.
J5
Connector J1: Connection to DFR board
Connector J2: Connection to encoder
DC Bus
Connector J5: Serial connection
J4

Connection TB1: Connection to power supply and

motor.
J3

Seven-segment display «Status»: Error display

J2

J1

TB1

DDM 030 board

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