mr 15plct frevtfeb12

MR-15 PLC-TMR-15 PLCT-F

BraidmaticInstruction Manual

andParts Catalog18, 24 AND 36 CARRIERS

LIGHTWEIGHT

MIIMAYER INDUSTRIES INC.CG-76

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.

Date of Issue for original and changes pages are:

Revision Pages Changed Date

Original April, 2006

Rev A Changes made to the following pages: 2-2, 2-13,2-16, 2-26, 2-33, 2-37, 2-39, 2-43, 2-47 4-26,thru 4-38, 5-3 thru 5-6, 7-1, 7-3, 7-11 thru 7-25, 7-30, 7-31, 7-35, 7-36, 7-71, 7-84 thru 7-97,7-133 thru 7-145, 9-1;Chapter 8: added safety information;Added Italian and Dutch Safety Information to this section

June, 2006

Rev B Changes made to the following pages: 7-117,7-142 thru 7-145

August, 2006

Rev C Changes made to the following pages: 2-14,2-15, 6-1, 7-31, 7-96, 7-97, 7-135, 7-146, 8-43

September, 2006

Rev D Changes made to the following pages: 7-55,7-73, 7-97, 7-108, 7-110, 9-1Added sections to Chapter 4

December, 2006

Rev E Changes made to the following pages: 4-40, 5-5,7-9, 7-90, 7-91, 7-102

August, 2007

Rev F Changes made to the following pages: 7-12 thru7-21, 7-55, 7-142 thru 7-145, 7-97, 9-1 thru9-6

December, 2007

Rev G Dutch translations added to Sections 4.6, 4.9, 4.10, and 4.11

January, 2008

Rev H Changes made to the following chapters for the Optional Braid Material Runout System:Chapters 4, 6, and 10

March, 2008

Rev J Added Dual Drive Information; Changes also made to the following pages: 1-6, 5-4, 5-5, 6-20, 7-12 thru 7-21, 7-77, 7-96, 7-114 thru 7-119,8-37 thru 8-42, 9-7

October, 2008February, 2012 MR-15 PLC-T Manual

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.

Date of Issue for original and changes pages are:

Revision Pages Changed Date

Rev K Changes made to the following pages: 6-24,6-25, 6-31 thru 6-41, 7-9, 7-12, 7-21, 7-40, 7-41, 7-84, 7-85, 7-91, 7-116 thru 7-119, 8-38

February, 2009

Rev L Added 18 Carrier information. Changes also made to the following pages: Table of Contents, 2-8, 3-3, 3A-3, 4-37, 4-39 thru 4-42, 5-5, 6-76-23, 6-34, 6-35, 7-5, 7-104, 7-105

November, 2009

Rev M Added Safety Cautions, 36 Carrier Parts, and new Jog Box

March/April, 2010

Rev N Replaced Inverter Parameter List in Chapter 4 to show Dual Drive

November, 2010

Rev P Changes made to the following pages: 6-24, 6-28, 6-29, 6-31, 6-33, 6-35, 6-40, 6-41, 7-15,7-21, 7-34, 7-35, 7-48 thru 7-51, 7-54, 7-55,7-103, 7-105, 9-7

December, 2010

Rev R Added Color Touchscreen information Chapter 4A; Changes made to the following pages: 3-3, 3A-2, 3A-3, 6-42 thru 6-58 (Stand Alone),7-112, 7-113, 7-116 thru 7-119, 7-143

May, 2011

Rev S Changes made to the following pages: 1-4, 6-19thru 6-21, 6-27 thru 6-31, 6-53, 7-3, 7-9, 7-38thru 7-43, 7-49, 7-142 thru 7-145, 9-7

October, 2011

Rev T Changes made to the following pages: 1-4, 1-5,1-32, 2-10, 5-2, 6-46 thru 6-57, 7-13, 7-17 thru 7-21, 7-36 thru 7-41, 7-71, 8-29, 8-47

February, 2012February, 2012 MR-15 PLC-T Manual

FOREWORD

This is the operating and parts manual for the Braidmatic MR-15 PLC-T and MR15 PLCT-F. Thefurnishing of this document does not constitute or imply a grant of any license under any patents,patent applications, trademarks, copyrights or any other rights of seller or any third party.Machines made prior or subsequent to the publication date of this manual may have parts,systems, or configurations that are not covered herein. Please contact Customer Service.

NOTE: The Figure numbers in this manual correspond with the Chapter and Paragraph numberswherein they are located.February, 2012 MR-15 PLC-T Manual

SAFETY FOR MR-15 PLC-T AND MR-15 PLCT-F BRAIDMATIC

Braiding machines are designed to produce quality braided structures by transferring shuttles viacam tracks. Producing the braided structures requires high speed, high horsepower, and movingelements. This in turn requires that operators and maintenance personnel of this equipment besafety conscious to avoid an accident which could be crippling or fatal to the operator ormaintenance personnel.

Setup of this equipment should be done by trained mechanics and/or riggers.

We cannot anticipate all possible factors that could cause an accident to occur with thisequipment, but are listing general safety considerations as an aid to the operator or maintenancepersonnel becoming safety oriented.

When this symbol is shown in the manual, the written instructions must be followed 100percent to prevent personal injury. If you dont understand the instructions, pleasecontact Mayer Industries Inc.

An operator or maintenance personnel should become completely familiar with all machinecontrols and corresponding moving elements before setting up, operating, or working on themachine.

We suggest snug fitting clothing and safety glasses be worn. No ties and no attempt made tooperate the machine while fatigued or ill. Do not operate the machine if it is malfunctioning in anyway.

The following safety equipment and precautions should be utilized by all personnel operating and/or working on this equipment.

Safety shoes with steel toes. Safety glasses with side shields. Hearing protection Leather gloves when handling steel reinforcement materials. Only trained personnel should set up, operate, or work on this equipment

Do not store wrenches or other items on machine surfaces.

Maintain a clean and safe work area. Keep oil from floor to prevent slipping.

Be sure that all guards and covers are properly in place and doors are closed and fastened whileoperating the machine.

CAUTIONFebruary, 2012 MR-15 PLC-T Manual

The movement of the deck, gear, and transfer areas can create pinch points and the operator mustavoid these points.

During maintenance work, the control must be turned OFF, as an accidental control actuation cancause an unexpected machine movement which could cause as accident. Utilize your plants lockout/tag out procedures.

High voltage is used to power this machine. Only authorized electricians should correct anelectrical component failure. Other maintenance must be performed by authorized personnel.

In conclusion, operators and maintenance personnel must be properly trained before beingallowed to operate or work on this equipment. Operators and Maintenance Personnel must treatthis equipment with the utmost respect and observe all safety precautions.

All rights are reserved for this instruction manual. It must not be copied nor made available toothers without Mayer Industries' previous consent nor its contents exploited in any other way bythe user or any third party. Reprints, whether complete or partial, require the express authorizationof Mayer Industries.

These operating instructions have been formulated to give you information on the construction,operation and maintenance of the machine. The enclosed diagrams and drawings illustrate theimportant features of the design. However, dimensional accuracy and design details are notguaranteed and we reserve the right to make any changes or amendments at any time.

The operating instructions also describe devices, spares or other parts which do not belong to thestandard version of the machine and which are only available to order as an extra. No right toequip the machine with such parts or devices may be derived from these operating instructions.

Please consult Chapter 7 when ordering spares. The machine warranty is valid only if usinggenuine MII or MII-approved components or replacement parts.

Before and while operating the machine, all general and special safety rules must be observed andnecessary safety protections taken. No protective or safety devices must be put out of action.February, 2012 MR-15 PLC-T Manual

TRANSLATIONS FOR LABELS AND CONTROL BUTTONS

SYMBOL TRANSLATIONS

English: CAUTION

English: NOTE

English: STOP

English: JOG / RUN

English: SAFETY OFF / ON

English: JOG / FORWARD

CAUTION

NOTEFebruary, 2012 MR-15 PLC-T Manual


SYMBOL TRANSLATIONS

English: STOP

English: DANGER / HIGH VOLTAGE

English: LASER LIGHT:Do not stare into beam

English: DANGER TOXIC FUMES

English: DANGER:Do Not Operate Without Guards In Place

STOPFebruary, 2012 MR-15 PLC-T Manual


SYMBOL TRANSLATIONS

English: HIGH VOLTAGE

English: PINCH POINT

English: DANGER PINCH POINT

English: DANGERDO NOT OPERATE UNLESS PROPERLY TRAINED

English: DANGERONLY TRAINED AND EXPERIENCED MAINTENANCE PERSONNEL OR RIGGERS SHOULD BE ALLOWED TO MOVE AND SETUP THIS EQUIPMENT.NOTE: MACHINE WEIGHT AND STABILITY ARE MAJOR CONCERNS IN LIFTING AND MOVING THE EQUIPMENT.February, 2012 MR-15 PLC-T Manual


SYMBOL TRANSLATIONS

English: DANGERDO NOT OPEN WHILE MACHINE IS IN OPERATION

English: WARNINGFebruary, 2012 MR-15 PLC-T Manual

SICHERHEITSREGELN FR MR-15 PLC-T/MR-15 PLCT-F BRAIDMATIC

Braiding Maschinen sind entwickeld um hohe Qualitts braided structur produkte zu produzierenbei transfer shuttles ber cam tracks. Beim Produktstionsvorgang wird mit hoher geschwindigkeitund mit viel Kraftaufwand gearbeitet. Um unflle zu vermeiden soll nur geschultes Personal zurBedienung der Maschine verwendet werden.

Wir Knnen nicht alle mglichkeiten aufzhlen die einen Unfall verursachen Knnen, aber wirfhren hier in generell einige Sicherheitsvorschriften auf.

Wenn dieses Zeichen im Buch erscheint, die instruktionen mssen 100% erfllt werdenum Unflle zu vermeiden. Wenn sie irgend etwas nicht verstehen, fragen sie uns bitte.

Bedienungspersonal und Betriebsmechaniker mssen sich vorhehr mit der Funktion der Maschinebestens vertraut machen. Elektrisch und mechanisch.

Wir schlagen vor eng anliegende kleidung. Keine Krawatte, aber eine Schutzbrille zu tragen.Bleiben sie weg von der Maschine wenn sie sich nicht wohl fhlen, oder krank sind. Niemals dieMaschine laufen lassen mit einem eventuellen defekt.

Lasse niemals Werkzeug irgendwo in der Maschine Liegen.

Mach sicher das alle Abdeckungen immer in richtiger position sind und fest angeschraubt wenndie Maschine Luft.

Die sich bewegenden elemente Transferposition und Ritzel Knnen Leicht zu einer Falle werden,so sei vorsichtig und trete zurck.

Bei Reperaturarbeiten mach sicher das die Maschine ausgeschaltet ist. AUS da wir mit hoherSpannung arbeiten.

Mach sicher das nur geschulte Elektriker an der Maschine arbeiten.

Am ende mchten wir daraufhinweisen das, das Personal die Maschine immer mit Respektbehandelt, und immer alle Sicherheitsvorschriften beachtet.

Mayer Industrie behlt sich alle rechte fr die Betriebsanleitung vor. Es drfen Keine copiengemacht werden, ohne das Wissen von Mayer Industrie.

Die Betriebsanleitung ist gemacht worden um zu helfen die Maschine in Produktion zu geben undzu halten. Die Zeichnungen in Buch sind gemacht um zu erklren und zu helfen wie alleszusammen geht. Die Zeichnungen sind aber nicht Masstab gerecht gezeichnet.

WARNUNGFebruary, 2012 MR-15 PLC-T Manual

TABLE OF CONTENTS

PAGECHAPTER 1 INSTALLATION

SECTION I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1SECTION II MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4SECTION III INSTALLATION AND SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11SECTION IV PRE-OPERATION ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31SECTION V DECK WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

CHAPTER 2 SYSTEMS, ADJUSTMENTS, SETTINGS, AND MAINTENANCESECTION I GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1SECTION II SHUTTLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1SECTION III SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6SECTION IV CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9SECTION V WIRE BRAIDING BOBBIN PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 2-15

YARN BRAIDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15SECTION VI BOBBIN RUN OUT DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19SECTION VII BROKEN BRAID DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22SECTION VIII DRIVE CARTRIDGE AND CHANGE GEAR DRIVE . . . . . . . . . . . . . . . . . . 2-23

SPEED LEAD CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27SECTION IX DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33SECTION X ROTOR AXLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34SECTION XI ROTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

CHAPTER 3 CONTROLSSECTION I INTRODUCTION (EINFHRUNG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1SECTION II OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

CHAPTER 3A PLCT-F CONTROLSSECTION I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1SECTION II OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2

CHAPTER 4A ELECTRICAL SYSTEM - COLOR TOUCHSCREENSECTION I GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1SECTION II SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1SECTION III INVERTER PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13SECTION IV ELECTRICAL CABLE INSTALLATION LOCATIONS . . . . . . . . . . . . . . . . . 4A-14

CHAPTER 4 ELECTRICAL SYSTEMSECTION I GENERAL DESCRIPTION (GENERELLE BESCHREIBUNG) . . . . . . . . . . . . 4-1SECTION II SYSTEM DESCRIPTION (SYSTEM BESCHREIBUNG) . . . . . . . . . . . . . . . . 4-2SECTION III INVERTER PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33SECTION IV ELECTRICAL CABLE INSTALLATION LOCATIONS . . . . . . . . . . . . . . . . . 4-34February, 2012 MR-15 PLC-T Manual

CHAPTER 5 LUBRICATION SYSTEMSECTION I GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1SECTION II SERVICE INSTRUCTIONS FOR BIJUR CENTRAL LUBRICATION SYSTEM . 5-4

CHAPTER 6 OPTIONSSECTION I SUPER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1SECTION II TRUMPET AND BRAIDRING (SLO OPTION) . . . . . . . . . . . . . . . . . . . . . . 6-3SECTION III BROKEN BRAID DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4SECTION IV BRAIDER STEEL MOUNTING PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6SECTION V BRAIDING NOSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11SECTION VI BRAID MATERIAL RUNOUT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18SECTION VII DUAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

CHAPTER 7 PARTSBREAKDOWN AND ORDERING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . 7-5SEE PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

CHAPTER 8 MAINTENANCE AND OVERHAULSECTION I MR-15+ BRAIDMATIC OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12SECTION II ROTOR INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20SECTION III SHUTTLE INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23SECTION IV PRELIMINARY SHUTTLE ADJUSTMENT AND INSTALLATION . . . . . . . . . 8-26SECTION V INSTALLATION OF ROTOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 8-26SECTION VI ROTOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29SECTION VII SHUTTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29SECTION VIII OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33SECTION IX INSTRUCTIONS FOR THE USE OF THE 240-1078 GAUGE . . . . . . . . . . . . 8-35SECTION X INSTRUCTIONS FOR THE USE OF THE 240-1075

ROTOR GEAR TIMING GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39SECTION XI INSTRUCTIONS FOR THE USE OF THE 240-1076

CAM SET GAUGE WITH MASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40SECTION XII DISASSEMBLING, REASSEMBLING, ADJUSTING, AND

MAINTENANCE OF CARRIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

CHAPTER 9 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

CHAPTER 10 ELECTRICAL SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1February, 2012 MR-15 PLC-T Manual

MR-15 PLC-T Manual February, 2012

1-INSTALLATIONCHAPTER 1INSTALLATION

SECTION I. INTRODUCTION

UNLESS NOTED IN THE TEXT, THE INFORMATION GIVEN FOR THE PLC-T ISSTANDARD FOR THE PLCT-F ELECTRONIC VERSION.

1.1. SCOPE.

1.2. FEATURES. The MR-15 PLC-TBraidmatic is todays most advanced meansfor producing quality braidmatic structures.

The revolutionary concept of the braiderfeatures:

Increased package capacity Improved braid quality through patented

strand control One carrier for both yarn and wire High speed Low operating cost Sound level-85 dBA (with complete

enclosure and in an environment with a maximum 75 dBA ambient noise level)

Automatic lubrication

This manual is intended to provide the userwith the necessary information to obtain themaximum benefits from the MR-15 PLC-TBraidmatic.

A thorough understanding of this manual willassure that the braider will be productive formany years.

1.3. BENEFITS. The braider provides the userthe expected benefits of modern-day braiders.

Modular construction Compatibility with existing equipment Safety of operation Change gear lead control (PLC-T) Recirculating automatic lubrication Modern electrical controls Optional Inverter Drive (PLCT-F)

1.4. TRANSFER PRINCIPLE. The MR-15 PLC-T Braider is a special variation of MaypoleBraiders. As with all Maypole decks, therotors are arranged in an endless circle. Therotors consist of six pairs of pockets at 60 toone another, and the rotors are in timedrelation to one another in that each drives theother by a rotor gear: thus, when one turnsclockwise, its neighbor turns counter-clockwise.

The rotors are intended to simultaneouslypropel one-half the number of shuttles in onedirection, and the others in the oppositedirection. Their respective paths beingsinusoidal causes the shuttles to pass oneanother. Each shuttle is equipped with acarrier to provide strand storage and let-offmeans. The strands from each are braidedtogether to form a structure by the fact that theshuttles were "passed by" in 3 over 3 underplait formation.

The braider does all of these, yet does themdifferently, efficiently, and with a goal ofproductivity and quality.

The MR-15 PLC-T Braidmatic transfer will bedescribed in such a manner that the sections ofthis manual explaining instructional andmaintenance information are more readilyunderstood.

On the braider, the function of the planetarygear system is to provide a programmedpositive, independent rotation of the axis ofany shuttle from that of the rotors direction ofrotation.February, 2012 MR-15 PLC-T Manual 1-1

1-INSTALLATION

1-2The rotor and axle assemblies of the MR-15PLC-T Braidmatic are identical to one another.One peculiarity is that each of the identicalrotors is assembled with alternate rotorspositioned 60 (1/6 turn) from that of itsadjacent or neighboring rotor.

With this assembly pattern, and knowing thatevery rotor has six pairs of shuttle pockets ason a clock dial at 12 o'clock and 6 o'clock, and8 oclock and mate in rotation with pockets at2 o'clock and 6 o'clock and 10 oclock pocketson adjacent rotors, the transfer principle of theMR-15 PLC-T braider should begin toemerge.

Every pair of opposite rotor pockets (12o'clock, 4 oclock and 8 o'clock) includes threefront cam follower assemblies on the outerflange of the rotor while the rotor pockets (2o'clock, 6 oclock and 10 o'clock) on the samerotor have rear cam follower units affixed tothe inner rotor frame. In like manner, pocketsat 12 o'clock, 4 oclock and 8 o'clock have apair of planetary gears which mesh with one oftwo gears on each rotor axle.

Pockets at 2 o'clock, 6 oclock, and 10 o'clockof the same rotor have different planetarygears which mesh with the other gear teeth ofthe same rotor axle.

All shuttle assemblies are of identical designand manufacture and are equipped with a camtrack having two semi-circular segments.These segments are passed behind theappropriate cam follower assembly (front orrear) and retain the shuttle in the given rotorduring its travel. Each shuttle assembly has agear to keep the timed relation to the semi-circular cam track. These shuttle assembliesare also loaded into rotor assemblies in aspecific timed relationship.

Now it can be seen that a shuttle traveling in itsprogrammed path "outside" the rotor (seeFigure. 1.4.1, step 1) is retained by a front camfollower having positive rolling engagementwith the cam track. The meshing of the shuttlegear, rotor planetary gear and the rotor axleassembly control the orientation of the shuttleaxis.

At a point in time the shuttle assemblyadvances by rotation of the rotor to mate withthe next rotor (seen earlier to be at 60). Nowcontrol of the shuttle is smoothly shifted fromone rotor to the next by the rear segment of thecam track picking up the rear cam follower: atthe same time, the front segment of the camtrack disengages from the front cam trackfollower. This is done at a constant velocity.The shuttle has now moved from one rotorframe to the next.

It should be noted that the transfer in no waycauses the shuttle axis to rotate as planetarygearing cancels out the reversed directionalinfluence of the rotors. The planetary geartrain results in the shuttle completing a 360rotation for every revolution of the shuttleabout the complete deck.

Successive transfers are made in the same way.The entire sequence takes place between therotor and shuttles without any need for guidesor tracks.

Figure 1.4.1 illustrates a step by step operationtogether with the unique control of rotationbetween the rotor and shuttle axis. Theadvantages of the patented MR-15 PLC-Tprinciple are:

Constant velocity of shuttle Eliminated all "deck plates" Anti-friction bearings at every friction

source Constant angular rotation of shuttle axisMR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.4.1: THE MR-15 PLC-T BRAIDMATIC DIFFERENCE

STEP 3TRANSFER

STEP 2AT TRANSFER

STEP 1APPROACHING

TRANSFER

COMPLETED

REAR CAMTRACK

FRONT CAMTRACK ROTOR

SHUTTLE GEARPLANETARYGEAR

FIXED GEARS

CAMFOLLOWER

CAMFOLLOWERFebruary, 2012 MR-15 PLC-T Manual 1-3

1-INSTALLATION

1-4SECTION II. MACHINE SPECIFICATIONS

1.5. MACHINE SPECIFICATIONS.

TABLE 1.5.1: MACHINE SPECIFICATIONS

DECKNumber of carriers 18 24 36RPM of rotors

a. Wire 225 225 225b. Yarn 235 235 235c. Super Pak 225 225 225

RPM of carriersa. Wire 75 56.25 37.5b. Yarn 78.3 58.75 39c. Super Pak 75 56.25 37.5

Approx. weight per model (includes bobbins, carriers, and 20 lbs of wire per bobbin)

6500 lbs 7585 lbs 15034 lbs2954.5 Kg 3447.7 Kg 6834 Kg

Floor space requirements See Figures 1.10.1 through 1.10.14Braider principle MaypoleBraid pattern 3 over 3Product orientation HorizontalConstruction ModularSpeed and braid angle control (PLC-T) Change gears (24 & 36 Car. Only)Speed and braid angle control (PLCT-F) Inverter DriveRotor diameter 15 inch (381 mm)Sound level (with complete machine enclosure and in an environment with a maximum 75 dBA ambient noise level)

85 dBA

Lubrication Automatic-meteredProduct height 51-1/8 inches above floor (24 carrier)

62 inches above floor (36 carrier(includes 1 inch mounting plate)

Power Usage (PLC-T) 1 Deck 2 Deck 3 Deckfor 24 carrier decks (including haul-off) 15Hp/

11.5Kw15Hp/11.5Kw

20Hp/15Kw

for 36 carrier (including MC-3 haul-off) 20Hp/15Kw 20Hp/15Kw Free Braiding (no braidring required)

Power Usage (PLCT-F)

18 and 24 Carrier Decks7.5Hp (5.6Kw) Inverter Drive/Dk7.5Hp (5.6Kw) Inverter Drive/HO

36 Carrier Decks15Hp (11Kw) Inverter Drive/Dk7.5Hp (5.6Kw) Inverter Drive/HO

POWER (PLCT-F)Machine Type:

Max Power Voltage Current Main Fuse

PLCT-F MR-11 & MR-15, all types except 36 CarrierSingle Deck 2 x 7.5 Hp Motors 6 Kw 380-480V 12-15A 25A

6 Kw 200-220V 27-30A 50AMR-15 PLC-T Manual February, 2012

1-INSTALLATIONPOWER (PLCT-F) (CONTINUED)Machine Type:

Max Power Voltage Current Main Fuse

Double Deck 3 x 7.5 Hp Motors 10 Kw 380-480V 16-25A 25A10 Kw 200-220V 35-50A 50A

PLCT-F MR-11 & MR-15, 36 CarrierSingle Deck 1 x 7.5 Hp Motor 8 Kw 380-480V 16-21A 50ASingle Deck 1 x 15 Hp Motor 8 Kw 380-480V 16-21A 50ADouble Deck 1 x 7.5 Hp Motor 12 Kw 380-480V 25-32A 50ADouble Deck 2 x 15 Hp Motors 12 Kw 380-480V 25-32A 50A

CARRIERS (the same for wire and yarn)Type of carrier Torsion springRelease tension variable (by changing springs)*See Chapter 2, Section 2.16 for the spring ranges.

6 - 25 lbs2.7 - 11.3 Kg26.5 N - 110.8 N

Compensation Patented rotaryLet-off Wrapped spring

BOBBINSSingle let-off wire

Weight of wire-approximate 20 lbs (9.1 Kg)Weight of bobbin-approximate 3.5 lbs (1.6 Kg)Total package Not to exceed 23.5 lbs (10.66 Kg)Volume of flange bobbins 98 cubic inches (1600 cu cm)

Single let-off yarn-cardboard tubeVolume of yarn 229 cubic inches (3747 cu cm)Total package weight Not to exceed 7 lbs (3.18 Kg)

Single let-off yarn bobbinsWeight of yarn-approximate 4.75 lbs (2.15 Kg)Weight of bobbin-approximate 2.25 lbs (1.02 Kg)Total package weight (one bobbin) Not to exceed 7.0 lbs (3.2 Kg)Volume of flange bobbins 223 cubic inches (3800 cu cm)

Super pack yarnVolume of cardboard tube 302 cubic inches (4947 cu cm)Total package weight/tube and yarn Not to exceed 10 lbs (4.5 Kg)Volume of flange bobbins 300 cubic inches (4900 cu cm)Weight of yarn on flange bobbin 7.39 lbs (3.35 Kg)Weight of bobbin-approximate 2.61 lbs (1.2 Kg)Total package weight/bobbin and yarn Not to exceed 10 lbs (4.5 Kg)

TABLE 1.5.1: MACHINE SPECIFICATIONSFebruary, 2012 MR-15 PLC-T Manual 1-5

1-INSTALLATION

1-6FIGURE 1.5.1: MR-15 PLC-T BRAIDMATIC24 CARRIER

28.35 IN720 mm

13.78 IN350 mm

63 IN1600 mm

27.56 IN700 mm

40.7 IN1035 mm

19.

69 IN

500

mm

49.7

6 IN

1264

mm

11.0

2 IN

280

mm

1.34

IN34

mm

64.17 IN1630 mm

86.4

6 IN

2196

mm

51.1

IN12

98 m

m

1

2

3

45

6

7

8

81.8

9 IN

2080

mm

81.1

IN20

60 m

m

5.35

IN13

6 m

m

** TOTAL HEIGHT DIMENSIONS CAN VARY 10MMMR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.5.2: MR-15 PLC-T BRAIDMATIC36 CARRIER

1

2

3

4

5

67

8

9

10

11

12

28.3 IN720 mm

12.6 IN320 mm

12.6 IN320 mm

25.2 IN640 mm

25.2 IN640 mm

84.3 IN2140 mm

33.5 IN850 mm

112.

5 IN

2857

.8 m

m

85.3 IN2166.1 mm

62 IN

1574

.8 m

m1.

4 IN

34.8

mm 11

.02

IN28

0 m

mFebruary, 2012 MR-15 PLC-T Manual 1-7

1-INSTALLATION

1-8FIGURE 1.5.3: MR-15 PLC-T BRAIDMATIC18 CARRIER

28.35 IN720 mm

13.78 IN350 mm

63 IN1600 mm

27.56 IN700 mm

40.7 IN1035 mm

7.8

7 IN

200

mm

49.7

6 IN

1264

mm

11.0

2 IN

280

mm

1.34

IN34

mm

58.85 IN1495 mm

82.3

IN20

90 m

m

51.1

IN12

98 m

m

1

2

34

5

6MR-15 PLC-T Manual February, 2012

1-INSTALLATION1.6. FLOOR CONSTRUCTION. The MR-15PLC-T Braidmatic is like other generallyheavy, high speed machinery in that properinstallation will enhance and extend the usefullife.

The nature of the braider floor loadings(weight) and expected motion (vibration) willinvolve concern for the proper specificationsof the floor in the vicinity of the braiders site.

CAUTION

Overload and vibration hazard.Only ground floor locations maybe used. Personal injury orproduct or property damage couldresult.

Only mounting hardware of MI approvalshould be used; see Figure 1.6.1. Thefoundation pockets to accommodate thisshould be sized as shown by the forms onFigure 1.10.15. Form 1 is preferred.

GROUT. MI has two types of grout that canbe used on the MR-15 PLC-T, MC-2 and MC-3. The standard grout is Unisorb.

The requirements for use with the MR-15PLC-T, MC-2 and MC-3 are as follows:

The part number for the Unisorb is S-3708(ONE KIT).

The part number for the Chock Fast Gray is S-4984 (ONE KIT).

UNISORB

Kits Required

18 Carrier

24 Carrier

36 Carrier

1 deck+1 Haul-Off 4 4 52 deck+1 Haul-Off 7 7 93 deck+1 Haul-Off 10 10 13

CHOCK FAST GRAY

Kits Required

18 Carrier

24 Carrier

36 Carrier

1 deck+1 Haul-Off 4 4 52 deck+1 Haul-Off 6 6 73 deck+1 Haul-Off 8 8 10February, 2012 MR-15 PLC-T Manual 1-9

1-INSTALLATION

1-10The floor is to be of steel rod reinforcedconcrete of first quality and minimum 3,500psi compression strength. Two types offoundation pads are recommended as shown inFigures 1.10.1, 1.10.6, and 1.10.11. Thesemay be used individually or in combination toaccommodate various machine arrangements.For 24 carrier braiders, no more than six decks

should be mounted on a pad: this may be twothree-deck machines abreast as shown inFigures 1.10.3 and 1.10.8, or three two-deckmachines abreast as shown in Figures 1.10.4and 1.10.9. Single-deck machines should belimited to four abreast as shown in Figures1.10.2 and 1.10.7. See Figures 1.10.11 thru1.10.13 for 36 carrier braiders.

FIGURE 1.6.1: MOUNTING HARDWARE(See Figure 7.5.3 for part numbers)

MACHINE BASE FRAME

SPACER SLEEVE INCLUDED INPACKING. DO NOT THROW AWAY.

PERMATEX FLOOR LINE

FOUNDATION

HEX HEAD BOLT (TORQUE VALUE

2647 Nm)

LOCK WASHER

FLAT WASHER

THREADEDNUT

PLATE

FOOT

COVER THIS END OF FOOTTO KEEP GROUT OFF OFBOLT THREADS

BUSHINGTHREADS

1955 FT-LB

6 IN

(152

mm

)FLOOR 330 MM13 IN MIN.PAD THICKNESSMR-15 PLC-T Manual February, 2012

1-INSTALLATIONSECTION III. INSTALLATION AND SET-UP

1.7. MACHINE ERECTION AND MOUNTING. Every MR-15 PLC-T Braider Deck has beencompletely assembled and operated at thefactory, prior to package and shipment.

1.8. MOVING AND LOCATING THE MACHINE.

CAUTION

Only trained MaintenancePersonnel or Riggers should beallowed to move and set up thisequipment.

Each braider deck is fitted with a lifting eyeinstalled at the factory. This eye is intendedfor up-righting the deck from its shippingposition, and can be used for in-planttransporting of the deck to its intended locationwithin the plant. General handling of the deckshould be by forklift truck. The deck shouldbe carried by forklift in its shipping position,i.e. laying over on its side or upright.

CAUTION

When carrying in the uprightposition, it must be noted that thedeck bottom is hollow. It isimportant, therefore, to use forksthat extend the complete lengthand somewhat past the base ofthe machine. It is also importantthat caution must be used insecuring the deck to prevent itfrom tipping.

The Hauloff should be transported as far aspractical on its shipping skid by forklift truck.It can be lifted by overhead means, by using 12

mm eye bolts in the angle brackets on each endof the machine. A sling or lifting bar can thenbe used. Generally the hauloff is moved andlocated by fork lift truck.

1. Position the Braider(s) and haul-offunit according to Figure 1.10.10 or1.10.14. Mounting hardware is shownin Figure 1.6.1 and Figure 7.5.3.

2. Level module(s), using the outer faceof the rotor within 0.010 in, per foot(0.8 mm/m), "B" on Figure 7.5.2. (Analternate leveling surface is theprotruding shuttle spindle shaft, "C" onFigure 7.5.2.) The base of the lowerdeck frame should be leveled within0.015 per foot (1.2 mm/m). Amachined surface has been providedfor this adjustment, "A" on Figure7.5.2.

3. (Not required for dual drive.)Assemble the connecting drive shaft,part number 240-2084, (for the 24carrier) or number 536-2084 (36carrier) between haul-off and MR-15PLC-T deck module and 240-2083,(for the 24 carrier) or 536-2085 (36carrier) between other decks (it isimportant that a total lengthwise gap of1/8 in.-3/16 in. (3.2 mm - 4.76 mm)exists between the shafts to beconnected; see Figures 7.5.26 and7.5.27) using set screws and keys ateach end of line shafts to be connected.

4. (Not required for dual drive.) Adjustthe center line height of the deckmodule drive shaft to the identicalheight of the drive shaft of the haul-offunit. Align the shaft of the deck modulewith the haul-off shaft within .005 in.per foot (0.4 mm/m). This alignment ismade with the use of a precision leveland by attaching a dial indicator to thedeck end of the connecting drive shaftand with the indicator probe contactingFebruary, 2012 MR-15 PLC-T Manual 1-11

1-INSTALLATION

1-12the face of the MR-15 PLC-T driveshaft flange. The shaft is turned byhand to read the accuracy of alignment.Recheck step 2. Note, Figures 7.5.26and 7.5.27.

5. After all the units are in properlocation, check again for spacing, driveshaft alignment (standard drive), andthat the floor mounting hardware isimbedded in the floor per Figure 1.6.1.Check each foot (Figure 1.6.1) ondeck(s) and hauloff. Make sure that thefoot is not touching the sides of thefoundation pocket at any place. Turnthe hex head bolt (Figure 1.6.1) untilthe spacer sleeve is flat against theplate. Do not over tighten as this maydistort the spacer sleeve, allowinggrout to get onto the hex head threads.Only first quality, high head threadsand first quality, high strength, non-shrinking grouting should be used. Thegrouting must be of a type formulatedto withstand vibration and impact fromdynamic and repetitive loading.

6. Following "set-up" of floor (step 5), afinal check is made for alignment of allcomponents, and mounting hardware islocked down. Apply permatex tothreads of all floor bolts. See torquevalue for hold down bolts, Figure1.6.1. Re-torque bolts after the first 500hours of operation. Check and re-torque as required thereafter.

7. Assemble line shaft covers (standarddrive) and deck drain pans according toFigure 7.5.33 (24 carrier) or Figure7.5.36 (36 carrier) and connectlubrication lines. Level line shaftcovers. Position remote oil settlingtank and connect flexible lines, asshown, to Bijur pump filters, and lowerdeck frame.

8. Install sensor stand assembly to fronttunnel cover, as shown in Figure7.5.30, for standard drive and to the

floor for dual drive, as shown in Figure6.12.1.1.

9. Construct acoustical enclosure accord-ing to separate instructions providedwith each enclosure. Locate enclosureper Figure 1.10.10 or 1.10.14.

10. Install electrical panels, door switches,blower fan and related electricals. SeeChapter 10, Schematics.

1.9. MACHINE STORAGE PRIOR TO INSTALLATION. If the braider is to be storedfor up to 30 days before installation, certainprecautions must be taken.

1. Check the shipping crates for damage.If there is damage, report it to theproper personnel. Contact MI if indoubt.

2. The braider and all of its sealedcomponents must remain sealed whilein storage.

3. The shipping crates must be stored in adry location.

4. Wind must not be able to force rain ormoisture into the crates.

5. Keep all the crates together.

If the braiders must be stored for longer than30 days, contact the MI SERVICEDEPARTMENT for instructions.

1.10. FINAL ASSEMBLY. The following com-ponents must be installed prior to operating themachine: Shuttles - See Chapter 2, Section II Sensors - See Chapter 2, Section III Carriers - See Chapter 2, Section IV Bobbins - See Chapter 2, Section V Broken Braid Detector - See Chapter 2,

Section VII Options - See option sections for those

options provided on your machine.MR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.1: TYPE 1 FOUNDATION18 & 24 CARRIER

10 IN

254

mm

12 IN O.C. @ 90305 mm

FLOOR LINE INSULATION SEALANTCONTINUOUS BEAD

ADJACENTPLANTFLOOR

WELD (TYP).75 IN20 mmREINFORCING ROD (TYP)

1 IN25 mmSTYROFOAM

17 FT - 2 IN5232 mm

SINGLE DECK

4 FT - 2 IN1270 mm

2 FT - 2 IN673 mm

13 F

T - 3

IN40

38 m

m

4 FT

- 0

IN12

20 m

m4

FT -

0 IN

1220

mmFebruary, 2012 MR-15 PLC-T Manual 1-13

1-INSTALLATION

1-14FIGURE 1.10.2: TYPE 1 FOUNDATION - SINGLE DECK MACHINE ARRANGEMENT18 & 24 CARRIER

2 FT - 2 IN673 mm

41 F

T - 6

IN12

649

mm

9 FT

- 4

IN (M

IN)

2845

mm

9 FT

- 4

IN (M

IN)

2845

mm

9 FT

- 4

IN (M

IN)

2845

mm

4 FT

- 0

IN12

20 m

m

3 FT

- 0

IN91

5 m

m(M

IN)

3 FT

- 0

IN91

5 m

m(M

IN)

3 FT

- 0

IN91

5 m

m(M

IN)

4 FT

- 0

IN12

20 m

m 4 FT - 2 IN1270 mm

17 FT - 2 IN5232 mmMR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.3: TYPE 1 FOUNDATION - THREE DECK MACHINE ARRANGEMENT18 & 24 CARRIER

9 FT - 4 IN2845 mm

22 FT - 7 IN6884 mm

2 FT

- 2

IN67

3 m

m

30 F

T - 4

IN92

49 m

m4

FT -

2 IN

1270

mm

4 FT - 0 IN1220 mm

3 FT - 0 IN915 mm

4 FT - 0 IN1220 mmFebruary, 2012 MR-15 PLC-T Manual 1-15

1-INSTALLATION

1-1FIGURE 1.10.4: TYPE 1 FOUNDATION - TWO DECK MACHINE ARRANGEMENT18 & 24 CARRIER

23 FT - 9 IN7239 mm

4 FT - 2 IN1270 mm

9 FT

- 4

IN28

45 m

m

31 F

T - 1

1 IN

9734

mm

4 FT

- 0

IN12

20 m

m3

FT -

0 IN

915

mm

3 FT

0 IN

915

mm

9 FT

- 4

IN28

45 m

m

2 FT - 2 IN673 mm

4 FT

- 0

IN12

20 m

m6 MR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.5: TYPE 1 FOUNDATION18 & 24 CARRIER

4 FT

- 8

IN

4 FT-0 IN1220 mm

4 FT-3.57 IN1310 mm

5 FT-5 IN1650 mm

2 FT-10 3/8 IN874 mm

2 FT-3 IN700 mm

2 FT-3 IN700 mm

4 FT

-3 IN

1309

mm

1420

mm

2 FT

-4 IN

720

mm

2 FT

-8 3

/4 IN

832

mm

13 F

T - 3

IN40

39 m

m

23 FT - 9 IN7239 mm

12 IN O.C.@90305 mm

10 IN

254

mm

STYROFOAM1 IN25 mm

REINFORCING ROD.75 IN20 mm (TYP)

WELD (TYP)


ADJACENTPLANTFLOORFebruary, 2012 MR-15 PLC-T Manual 1-17

1-INSTALLATION

1-18FIGURE 1.10.6: TYPE 2 FOUNDATION18 & 24 CARRIER

VIEW A-AFLOOR ONLY

.75 IN (20 mm)12 IN

305 mm

ADJACENTFLOOR

INSULATIONSEALANT

FLOORLINE

12 IN O.C. @ 90 305 mm

STYROFOAM1 IN (25 mm)

WELD(TYP)

15 FT-2 IN4622 mm

8 FT-6.8 IN2610 mm

2 FT-1.5 IN648 mm

A

A

12 IN

305

mm

12 IN

305

mm

12 IN305 mm

2 FT-2 IN673 mm

9 FT

-3 IN

2819

mm

2 FT

-3.5

IN69

9 m

m

10 IN

254

mm

REINFORCING ROD (TYP)MR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.7: TYPE 2 FOUNDATION - SINGLE DECK MACHINE ARRANGEMENT18 & 24 CARRIER

2 FT - 2 IN673 mm

2 FT 1.5 IN648 mm

2 FT

3.5

IN69

9 m

m

12 IN

305

mm

3 FT

- 0

IN91

5 m

m(M

IN)

12 IN

305

mm

3 FT

- 0

IN91

5 m

m(M

IN)

3 FT

- 0

IN91

5 m

m(M

IN)

2 FT

3.5

IN69

9 m

m 12 IN305 mm

8 FT - 6.8 IN2610 mm

15 FT - 2 IN4622 mm

9 FT

- 4

IN28

45 m

m(M

IN)

9 FT

- 4

IN28

45 m

m(M

IN)

9 FT

- 4

IN28

45 m

m(M

IN)

37 F

T - 3

IN11

355

mm

(MIN

)February, 2012 MR-15 PLC-T Manual 1-19

1-INSTALLATION

1-20FIGURE 1.10.8: TYPE 2 FOUNDATION - THREE DECK MACHINE ARRANGEMENT18 & 24 CARRIER

9 FT - 4 IN2845 mm

12 IN305 mm

12 IN305 mm

18 FT - 7 IN5664 mm

2 FT

- 2

IN67

3 m

m21

FT

- 9 IN

6630

mm

28 F

T - 1

IN85

60 m

m

12 IN

305

mm

2 FT - 3.5 IN699 mm

3 FT - 0 IN915 mm

2 FT - 3.5 IN699 mm

2 FT

- 1.

5 IN

648

mmMR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.9: TYPE 2 FOUNDATION - TWO DECK MACHINE ARRANGEMENT18 & 24 CARRIER

21 FT - 8 IN6605 mm

15 FT - 1.8 IN4620 mm

2 FT - 2 IN673 mm

12 IN

305

mm

12 IN305 mm

2 FT

- 3.

5 IN

699

mm

3 FT

- 0

IN91

5 m

m

9 FT

- 4

IN28

45 m

m9

FT -

4 IN

2845

mm

27 F

T - 1

1 IN

8510

mm

3 FT

- 0

IN91

5 m

m2

FT -

3.5

IN69

9 m

m

2 FT - 1.5 IN648 mm

12 IN

305


1-INSTALLATION

1-2FIGURE 1.10.10: FLOOR SPACE REQUIREMENTS18 & 24 CARRIER (SEE FIGURE 1.10.16 FOR DOOR LOCATIONS)

2 FT - 8.8 IN832 mm

1 FT - 4.4 IN416 mm

2 FT

10.

4 IN

874

mm 1 FT - 4 IN

314 mm

1 FT

-6 IN

457.

8 m

m

4 IN

102

mm

2 FT

-9 IN

838.

6 m

m7 FT

- 0

IN"L

" S I

NG

LE21

35 m

m

13 F

T - 5

.5 IN

"L"

DO

UB

LE41

03 m

m

20 F

T - 5

.5 IN

"L" T

RIP

LE62

36 m

m

2FT-

3.6

IN70

0 m

m

M=6

FT-

7 IN

2010

mm

M=6

FT-

7 IN

2010

mm

7 FT

-8.5

IN23

50 m

m

2FT-

3.6

IN70

0 m

m2F

T-3.

6 IN

700

mm2 FT - 4.4 IN

720 mm

4 FT - 7.9 IN1420 mm

4 FT - 3.1 IN1298 mm

8 FT - 4 IN2540 mm

6 FT

- 4

IN19

29 m

m

FLO

OR

LIN

E

FAN

5 FT

5.6

IN16

66 m

m2 MR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.11: TYPE 2 FOUNDATION36 CARRIER

MC-3 HAUL-OFF

2 FT - 5 IN749 mm

18 FT - 11 IN5755 mm

4 FT

- 4.

5 IN

1336

.5 m

m

11 F

T - 6

IN35

05 m

m

14 IN355.6 mm

12 IN O.C. @ 90305 mm

13 IN

330.

2 m

mSTYROFOAM1 IN25 mm

REINFORCING ROD.75 IN20 mm (TYP)


ADJACENTMACHINEFOUNDATION

A

A

(MIN

)

WELD (TYP)VIEW A-A

FLOOR ONLY

11 FT3353 mmFebruary, 2012 MR-15 PLC-T Manual 1-23

1-INSTALLATION

1-2FIGURE 1.10.12: DOUBLE DECK ARRANGEMENT36 CARRIER

MC-3 HAUL-OFF

11 FT - 6 IN3505 mm

6.1

IN15

7 m

m20

FT

- 10

IN63

43 m

m

27 F

T - 5

IN83

55 m

m1 FT - 2 IN355.6 mm

2 FT

- 5

IN74

9 m

m2 FT - 8 IN813 mm

1 FT - 5 IN444 mm

2 FT

- 10

IN87

3 m

m7

FT -

2 IN

2181

mm

8FT

- 6 IN

2280

mm4 MR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.13: TRIPLE DECK ARRANGEMENT36 CARRIER

MC-3 HAUL-OFF

2 FT

- 10

IN

11 FT - 6 IN3505 mm

1 FT - 5.5 IN444 mm

6.2

IN15

7 m

m

23 F

T - 1

1 IN

7290

mm

7 FT

- 6

IN22

80 m

m7

FT -

6 IN

2280

mm

7 FT

- 2

IN21

81 m

m

26 F

T - 5

IN80

43 m

m

33 F

T - 0

IN10

055

mm

873

mm

2 FT - 8 IN813 mm

1 FT - 2 IN357 mm

2 FT

- 5.

5 IN

749


1-INSTALLATION

1-2FIGURE 1.10.14: FLOOR SPACE REQUIREMENTS36 CARRIER (SEE FIGURE 1.10.17 FOR DOOR LOCATIONS)

8 FT

- 7

IN26

16 m

m

12.25 IN311 mm

10 FT - 0 IN3048 mm

4 IN

101.

6 m

m

5 FT - 2 IN1571 mm

11 FT - 9 IN3581 mm

23 F

T - 1

1 IN

7290

mm

TRIP

LE16

FT

- 4 IN

4978

mm

DO

UB

LE8

FT -

10 IN

2692

mm

SIN

GLE

6 FT

- 1

IN18

55 m

m

1 FT

- 3.

75 IN

400

mm6 MR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.15: ANCHOR POCKET FORMS(EUROPEAN PROJECTION)

FORM 3

FORM 2

6 IN152 mm

FORM 1

8.6 IN218 mm

8.6

IN21

8 m

m

5.7

IN14

5 m

m

6 IN152 mm

5 IN127 mm

5 IN

127

mm

6 IN

152

mm

6 IN152 mmFebruary, 2012 MR-15 PLC-T Manual 1-27

1-INSTALLATION

1-28FIGURE 1.10.16: ENCLOSURE DOOR LOCATIONS18 & 24 CARRIER

TO H

AU

LOFF

24 IN

610

mm

(TY

P.)

10 IN

87.5

IN

171.

5 IN

4356

.1 m

m

2222

.5 m

m

253.

8 m

m MR-15 PLC-T Manual February, 2012

1-INSTALLATIONFIGURE 1.10.17: ENCLOSURE DOOR LOCATIONS36 CARRIER

TO H

AU

LOFF

31.2

IN79

2 m

m24

IN

121.

4 IN

610

mm

(Typ

.)

3083

mm

16 F

T - 4

IN49

76 M

M

10 FT 7 IN3226 mm

15.7

5 IN

400


1-INSTALLATION

1-30 MR-15 PLC-T Manual February, 2012

1-INSTALLATIONSECTION IV. PRE-OPERATION ADJUSTMENTS

EINSTELLUNGEN VOR INBETRIEBNAHME

1.11. MECHANICAL. The following items mustbe checked, properly adjusted, installed or setbefore operating the braider.

CAUTION

Be aware moving elements/pinchpoints. Personal injury couldresult.Personnel performing this workmust be familiar with thisequipment and properly trained insafety procedures. Always lockout/tag out braider when possible.

a. Braiders and Haul-Off leveled and alignedb. Drive shafts aligned properly and

tightened. (Not for dual drive.)c. Bolts into floor torqued properly.d. Pay-off position and tension correct on

carriers.e. Lube spindles before installing bobbins.f. Shuttle to rotor frame key in transfer.g. Cam follower to cam track clearance.h. Shuttle sensor clearance.i. All safety stops operating.j. Insure that all carriers are securely locked

to shuttle spindle.k. Insure 1 mm play in axial direction on all

bobbins.l. All installed options adjusted.m. Broken braid detector.n. Silent Chain tensioned for standard drive.

Gear bolts for dual drive.o. Rotor frame axial play.p. Bobbin runout detector adjusted

1.11 MECHANISCH: Folgende Teile mssengeprft und richtig eingestellt werden bevordie Maschine in Produktion genommenwerden Kann

a. Maschine und Abzugsraupe in die Waagestellen und ausrichten.

b. Antriebswelle ausrichten und festschrauben.

c. Befestiegungsschrauben im Fussboden gutanziehen.

d. Spannung an den Klppeln Kontrollierenund einstellen.

e. Alle Spindel schmieren bevor die Bobineninstalliert werden.

f. Klppelachse zur Rotoranlage Keil imTransfer.

g. Spiel zwischen Transferlager undTransferschiene.

h. Spiel zwischen Klppelachse undAbsteller sensor.

i. Kontrollieren das alle Sicherheitsabstellerfunktionieren.

j. Versichern das alle Klppel auf derKlppelachse gut eingerastet sind.

k. Versichern 1mm Spiel in axialer Richtungan allen Bobinen.

l. Alle installierten mglichkeiten eingestellt.m. Draht-Fadenbruch absteller.n. Ketten spannung.o. Axial Spiel der Rotoranlage.p. Auslaufende Bobinen Absteller eingestellt.

1.12. LUBRICATION. The following itemsmust be checked, properly adjusted, or setbefore operating the braider.

a. Oil pump pressure.b. Settling tank filled.c. Rear deck sump filled. (Not on dual drive.)d. All rotor axles filled with oil.e. All clamps and fittings are tight.f. No leaks.February, 2012 MR-15 PLC-T Manual 1-31

1-INSTALLATION

1-321.12 SCHMIERUNG: Folgende Teile mssenKontrolliert oder eingestellt werden bevor dieMaschine in Produktion genommen werdenKann.

a. lpumpen druck.b. ltank gefllt.c. Hintere Deck tank gefllt.d. Alle Rotorenachsen gefllt mit l.e. Alle Klemmen und Verbindungsteile fest.f. Keine Lecks.

1.13. ELECTRICAL. See Chapter 3 or 3A foruse of the controls, and for set-up procedures.

1.13 ELEKTRISCH: Siehe Chapter 3/3A frdas Elektrische System, und ber dieverschiedenen Einstellungsfunktionen.

1.14. SETTING THE MOTOR SPEED. Forstandard (PLC-T) drive only.

CAUTION

All electrical circuits areenergized. Electrical shock mayoccur if these directions are notfollowed.

Personnel required: two (2).

Before turning on the motor:

1. Drive line is to be fitted with a tachometerand drive gears are to be removed from thedecks to create minimum load condition.

2. Unplug the user panel on the inverter, plugin the extension cable that comes with theinverter and run the other end out of thehauloff through the slit above the mainmotor doors. Plug the user panel into theother end of the extension cable. This willallow one to close all of the safetyinterlocks (gearbox doors) while still

having access to the inverter controls/parameter unit.

See the Mitsubishi manual for exactdescriptions on how to change the parame-ters; the parameters that are used for speedcontrol are described below.

Parameter 4 Multi-speed setting, highspeed this frequency should be set to thestandard run speed of the machine. Checkthe drive-shaft speed and increase/decreasethe hertz setting to get the correct speed.

Parameter 5 Multi-speed setting,medium speed this frequency should beset to approximately 2/3 of the driveshaftspeed set in Parameter 4. Pressing theslowstart button on the main cabinet willengage this speed for one hour before auto-matically changing the machine speed tothat which is set in Parameter 4. This isuseful for running in carriers slowly afterthe braider has been sitting for a while.

Parameter 6 Multi-speed setting, slowspeed This frequency should be set forthe Jog speed of the machine.

Two other parameters that a user mightwant to change are:

Parameter 7 Acceleration time

Parameter 8 Deceleration time.

1.14 MOTOR GESCHWINDIGKEIT EINSTEL-LUNG.

WARNUNG

Folgende Regeln mssenbeachtet werden um elektrischenSchock zu verhindern.

2 Personen werden gebraucht.MR-15 PLC-T Manual February, 2012

1-INSTALLATIONBevor der Motor gestarted werden Kann:

1. Antriebswelle verbinden mit einemtachometer, die Antriebsritzel entfernen sodas die Decks nur eine minimaleKraftaufwand brauchen.

2. Entferne den Deckel am Inverter, steck dasVelngerungskabel vom Inverter durch dieAbzugsraupe und verbinde es mit deinerInverter controls parameter einheit.

Schlag nach im Mitsubishi.

Betriebsanleitungsbuch, die genaue param-eter Einstellung fr die unten genanntenPunkte.

Parameter 4 Mehrfache geschwindig-keitseinstellung. Hohe geschwindigkeit,diese Frequenz sollte fr die Standardgeschwindigkeit der Maschine eingestelltwerden. Kontrollier geschwindigkeit derAntriebswelle bei zu hoher, oder zu niedri-ger geschwindigkeit. Einstellung mit derhertzzahl.

Parameter 5 Mehrfache geschwindig-keitseinstellung. Mittlere geschwindigkeit,diese Frequenz sollte ungefhr 2/3 derStandard geschwindigkeit von Parameter 4eingestellt werden. Drcken den KnopfLangsam slowstart am SchaltschrankLsst die Maschine eine Stunde LangsamLaufen, und schaltet dann automatisch umauf die normale Produktionsgeschwindig-keit. Der Grund ist um die Klppel KpfeLangsam einlaufen zu Lassen.

Parameter 6 Mehrfache geschwindig-keitseinstellung. Langsame geschwindig-keit, diese Frequenz ist fr die Tipgeschwindigkeit der Maschine.

Zwei weitere Parameter die mangebrauchen Knnte:

Parameter 7 Geschwindigkeitsbeschle-unigung.

Parameter 8 Geschwindigkeitsreduz-ierung.

SECTION V. DECK WIRING

1.15. CONNECTING THE DECK TO THE ELEC-TRICAL SYSTEM. The following table showsall of the wiring that leads from a deck to theBraider electrical system. Twenty-four carrierdecks are wired identically with one cablecontaining all of the main connections fromthe deck. Thirty-six carrier decks have an extracable containing the extra twelve shuttlesensors. Facing the back of the deck, the cablecontaining shuttle sensors 1-24 is on the leftand the cable containing shuttle sensors 25-36is on the right.

The wiring is always connected into theterminal strip inside the primary operator boxlocated on the side of the enclosure. Terminalnumbers refer to terminals on the terminalstrips inside that operator box.

All decks have three sets of wires that arewired in separately, in addition to the maincable. One is the proximity sensor for the hourmeter, which consists of three wires; the otheris the bobbin run-out sensor, which consists ofone wire. These connections are also shown onthe table below.

On the 36-carrier, there is a terminal stripmounted on the back of the deck, these wirescan optionally be wired into this strip instead.

The last is the green-yellow ground wirecoming from the deck. Note that this must beconnected for proper operation since most ofthe sensors on the deck itself are tripped by aconnection to ground. February, 2012 MR-15 PLC-T Manual 1-33

1-INSTALLATION

1-34TABLE 1.15.1: DECK WIRING MR-15 PLC-T CONTROLLERCONNECTION BETWEEN DECK AND PRIMARY OPERATOR BOX

WIRE COLORFROM DECK CABLE TO PRIMARY OPERATOR BOX (3000412)

Blk X1/3Brn X1/3Red X1/4Org X1/4Yel X1/5Grn X1/5Blu X1/6Vio X1/6Gry X1/7Wht X1/7Tan X1/8Pnk X1/8Blk/Wht X1/9Brn/Wht X1/9Red/Wht X1/10Org/Wht X1/10Yel/Wht X1/11Grn/Wht X1/11Blu/Wht X1/12Vio/Wht X1/12Gry/Wht X1/13Brn/Blk/Wht X1/13Red/Blk/Wht X1/14Org/Blk/Wht X1/14Red/Yel X1/23Yel/Blk/Wht X1/27Red/Blk X1/30Blu/Blk/Wht X1/31Red/Grn X1/1Grn/Blk/Wht X1/1MR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCECHAPTER 2ADJUSTMENTS AND MAINTENANCE

SECTION I. GENERAL

UNLESS NOTED IN THE TEXT, THE INFORMATION GIVEN FOR THE PLC-T ISSTANDARD FOR THE PLCT-F ELECTRONIC VERSION.

2.1. GENERAL. This section delineates thevarious systems utilized and all normaladjustments, settings and maintenancerequired to maintain and operate the MR-15PLC-T Braidmatic. Special requirements maybe discussed with the Mayer Industries ServiceDepartment.

All components, sub-assemblies andassemblies have been thoroughly checked,adjusted and set for average normal operatingconditions. Re-adjustments may be required tosuit particular conditions and requirements.

When a malfunction of the machine causesundue strain, wear, or damage to any part orassembly, the machine should be checked

immediately to see that the affected part andassociated parts are operable, are not broken,or moved out of proper adjustment or setting.

NOTE

Do not operate the braider fasterthan 100 RPM, and for a time notto exceed 5 minutes, withoutcarriers and bobbins installed onall shuttles. Failure to follow theseinstructions can result in smashingthe braider.

SECTION II. SHUTTLE ASSEMBLY (FIGURE 7.5.17)

2.2. SHUTTLE ASSEMBLY. The shuttleassembly serves two major functions. First, itis the element which contributes to the transferfrom one rotor to the adjacent rotor andsecondly, it is the structure onto which thecarrier is affixed, together with the strandmaterial to be braided.

Every shuttle assembly is interchangeable withthat of another of the same design for the samequantity of rotors per deck.

The MR-15 PLC-T and MR-15 PLCT-Fbraider concept produces "three over three"braid structures only, and this pattern is

dependent upon the shuttle assemblies beingloaded into rotors in six transfer pockets.

The basic shuttle assembly may be convertedfrom wire braiding, using MR-15 PLC-Tbobbins, to yarn wound on paper tubes orbobbins. The conversion is accomplished bythe addition of a shuttle spindle adapter withshuttles loaded into the deck. (see Figure2.2.1)

The correct MR-15 PLC-T transfer requiresaccurate axial and radial control of the shuttleassembly, rotor cam followers, and the rotorpockets.February, 2012 MR-15 PLC-T Manual 2-1

2-ADJUSTMENTS AND MAINTENANCE

2-2FIGURE 2.2.1: SHUTTLE SPINDLE ADAPTER, YARN

STRAND SHOWNOVER CENTERROLLERSMR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCE2.3. REMOVAL AND RELOADING OF SHUTTLE ASSEMBLIES. Theoretically, all shuttles maybe removed and loaded into the deck byremoval of front cam follower assemblies oftwo rotors. The manufacturer has provided apreferred pair of adjacent rotors as below (seeFigures 1.5.1, 1.5.2 and 1.5.3 for rotornumbers):

Rotor numbers 5 and 6 of 12 rotor decks Rotor numbers 3 and 4 of 8 rotor decks Rotor numbers 2 and 3 of 6 rotor decks

The designated rotors include a prepinnedlocation for the front cam followersassemblies. This feature eliminates the needfor adjustment of cam followers in the samesix pockets of the same rotor assemblies.

2.4. REMOVAL OF SHUTTLE ASSEMBLIES FROM BRAIDER.

CAUTION

Moving elements/pinch points inthe shuttle assembly area.Personal injury to hands and armscould occur.

Only trained personnel/mechanicsare allowed to install and removeshuttles and/or work in this area.Personal safety equipment is tobe worn.

Work area to be clean and free ofoil to prevent slipping.

Cut power off at the maindisconnect and remove the upper

change gear on PLC-T models.Follow plant lock out/tag outprocedure

Cut power off at main disconnectand remove the drive belt onPLCT-F models. Follow plant lockout/tag out procedure.

Read and follow manualinstructions.

1. Remove all carriers and strand packages orbobbins from shuttles.

2. Remove outer shields, Figure 7.5.2.

NOTE

Removal of shuttles requires twotrained mechanics using specialtool #2000302, which mounts tothe face of the rotor frame usingthe (4) M6 holes that are used tomount the rotor cap. Mount thistool to the rotor frame closest tothe 8:00/9:00 deck position.The two mechanics must be ableto communicate.The mechanic turning the deckmust be strong enough to controlthe movement of the rotors.Installing the shuttles will causeuneven loading until they have allbeen installed. This unevenloading will result in unwantedmovement of the rotors that mustbe controlled by the mechanicusing the special tool.Note: Tool #2000302 is availablefrom MI (Figure 9.1.8).February, 2012 MR-15 PLC-T Manual 2-3


2-4CAUTION

Moving elements.

Personal injury could result.

Use only special tool #2000302which gives the second personcontrol of the rotor/shuttlemovement.

3. Position rotors as shown in Figure 2.4.1.

4. Removal of one front cartridge numberedtransfer #1 will permit one sixth of thedeck shuttles to be removed. Remove fourM6 screws from face of rotor cam followercap, Figure 7.5.19. The removal of thecartridge is made without removing thecartridge cap. Care must be exercised toreach behind rotor front face to pushcartridge and not on extended shaft toremove entire cartridge assembly as oneunit. Place removed cam followerassembly on clean surface with cap down.

5. Rotate rotor with removed cartridge inclockwise direction and reach into rotor tolift the first shuttle from the rotor pocketwithout the cartridge.

6. Repeat step 5 to lift one sixth of shuttlesfrom the same rotor pocket. Do not dropshuttles. Keep these shuttles together. SeeChapter 8, Section I, paragraph 8.2.

7. Replace cam follower cartridge andassembly with one or two M6 screws.

8. Repeat steps 1-7 by removing camfollower assembly #2 and continue torotate rotor clockwise to remove secondtransfer shuttles. Replace the cartridge. Donot mix any shuttles from one transfer withshuttles from another transfer.

9. Repeat steps 1-7 to complete the removalof all shuttles from adjacent rotor.

CAUTION

Release of shuttle assemblies.

Do not attempt to remove camfollower assemblies when ashuttle is engaged with thecartridge.


10. The removal of all shuttles from rotors willgive opportunity to check the rotors for:

a. Axial thrust bearing clearance.

b. Check all rotor cam follower cartridgesby rotating by hand to insure properfunction.

c. General operating condition.

With all the shuttles removed, clean theinside of the deck of any foreign matter.

FIGURE 2.4.1: SHUTTLE UNLOADING

FRONT CAMFOLLOWERREMOVEDMR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCE2.5. RELOADING OF SHUTTLES INTO DECK. Loading of the shuttles, as with unloading,requires two people in the same positions asfor unloading.

CAUTION

Follow all Safety Precautionsdocumented in Paragraph 2.4.

All shuttles are alike for a given deck. Be surethat all the shuttles go back into the transferthey came out of.

1. Remove #4 transfer cam follower cartridgefrom rotor as before.

2. Hold shuttle in two hands and direct personin rear using a special tool on upper changegear shaft to turn the lower of the tworotors in a counterclockwise direction tothe approximate position shown in Figure2.5.1.

3. Rotate rotor counterclockwise until theshuttle is in transfer position at which timethe shuttle gear and cam track should be inthe correct timed engagement with theupper rotor rear cam follower. Continue torotate in the same direction slowly until theshuttle engages the upper rotor in transfer.If the shuttle gear teeth were orientedcorrectly in mesh with the rotor planetarygears, the two transfers should be smoothand positive.

4. Repeat steps 2-4 for the remaining shuttlesin transfer #4. Replace timed cartridge intransfer #4. Repeat identical procedure forthe other five transfers until the deck isfull.

5. Rotate upper change gear shaft by hand

slowly, using special adapter tool 240-3040, to insure correct loading. Person infront should inspect each transfer by feelfor proper shuttle cam track to rotor camfollower radial clearance. Check also foraxial play in transfer. See paragraph 2.69.

NOTE

The braider includes an electricalsensor device to monitor the pathof a shuttle cam track under loadat high speed. Frequently, thesensor probe may becomedislocated during unloading orloading of shuttles into rotors. Theposition of the sensor probes willrequire checking prior to operationof the deck. See instructions inChapter 4, Electrical System.

FIGURE 2.5.1: SHUTTLE LOADING INTO ROTORS

SHUTTLE

FRONT CAMFOLLOWER REMOVEDFebruary, 2012 MR-15 PLC-T Manual 2-5


2-62.6. SHUTTLE DISASSEMBLY AND ASSEMBLY. Every part of a shuttle assembly isinterchangeable with another within deckshaving the same number of shuttles. SeeChapter 8, Section III and Section IV, fordisassembly and assembly instructions.

CAUTION

Be aware of possible sharp edgeson parts.

2.7. NOT APPLICABLE.

2.8. NOT APPLICABLE.

SECTION III. SENSORS

2.9. SENSOR STAND ASSEMBLY. (Figure7.5.30) The sensor stand assembly providesthe braider system with a combination offunctions, including:

Mounting and adjustment of braid detectorshown in detail in Figure 7.5.31.

Means for "tying in" plaits from carriersduring threading, Figure 7.5.29.

Mounting provision for the operator "JOG"button to jog the deck from within theenclosure, Figure 7.5.29.

CAUTION

Moving elements in deck.Inside safety switch should alwaysbe in the "ON" position whenworking on deck. When the safetyswitch inside the enclosure is"ON" the braider cannot be runfrom any location and can bejogged only from the safety switchthat is "ON".Personal injury could result.

CAUTION

Only one trained operator to beallowed inside the enclosure toperform this task. Reason: toprevent the braider from beingstarted by a second operator.

Moving elements causing pinchpoints that could result in injury tohands and arms.

"Always" switch the inside safetyswitch to the "ON" positionimmediately upon entering thesafety enclosure. This preventsthe braider from being run fromany other position and allows thebraider to be jogged from thislocation.

The following safety equipment isrecommended:

Safety glasses

Safety shoes

Noise protection

Leather glovesMR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCE2.10. TYING IN OF BRAIDING STRANDS. Thebraider provides a means to reduce the timeand effort required to attach plaits of yarn orwire to a mandrel, hose or other object towhich strand materials are attached. The objectis to reduce operator reaching and lifting ofcarriers and strand packages during the loadingand threading operation.

The braider carriers are most convenientlyloaded at rotors number 4 and 5 on one side orrotors 8 and 9 on the opposite side. Thesepositions require less reaching and for thisreason, provide faster reloading, threading andtying-in. Place the eye bolt assembly (3,Figure 7.5.29) in the position shown. Be surethe sensor pin (5, Figure 7.5.29) goes thru bothsides of the swinging arm assembly (4).

After loading 3 to 6 bobbins at these locationsand locking the carriers on, the operatorthreads the plaits from the bobbins, through thecarriers and ties them onto the hook (3, Figure7.5.29). Now with the pole, mandrel, etc. inplace, and carrier latches locked, the operatormay "JOG" the deck to bring other carriersrequiring service to within operator'sconvenient reach. These next 3-6 carriers maybe loaded, threaded and plaits once again tiedin to the hook.

NOTE

Be Aware: Uneven loading ofbobbins can result in gravitycausing an unintended movementof the carriers.

The sequence is continued until all carriers areprepared for production.

The additional benefits of this approach are:

Cutting of wires or yarns is performed at alocation where stray ends are preventedfrom getting inside the deck.

NOTE

Use eye protection and leathergloves.

The tension on the plaits when tying to thehook eliminates reaching to "back-wind"threaded carriers to keep strands tight.

The sequential threading and tying-in canavoid lumps in hose which would other-wise necessitate readjustment of the haul-off unit.

Once all threading and tying-in isaccomplished, the operator removes the pivothardware, and the hook is lowered intoposition for braider production.

Double check to insure all carriers are in thelatched position.

CAUTION

Moving elements in deck.

Always lock latches on carrierassembly.


Severe machine damage willoccur.February, 2012 MR-15 PLC-T Manual 2-7


2-82.11. JOG BUTTON.

NOTE

When the safety switch inside theenclosure is "ON" the braidercannot be run from any locationand can be jogged only from thesafety switch that is "ON".

2.12. BRAID SENSOR ASSEMBLY INSTRUCTIONS. (Figure 7.5.31). Each deck ofthe braider is equipped with a device whosepurpose is to detect a failure in the carrier plaitlet-off. The sensor operates on the principlethat when any one or all strands from anycarrier plait becomes tangled, or when thecarrier clutch fails to release, the additionaltension in that plait will dislocate the braidedstructure and jerk the braided member from itsusual position.

The dislocation of braided product will triggerthe broken briad detector and electrically shutoff the machine drive. The device has bothelectrical and mechanical adjustments forsensitivity.

While other "grounding" sensors can be usedin combination with the MR-15 PLC-T braidsensor to detect broken wires, etc., theobjective here is to continuously monitor thebraid at each deck and to detect abnormalstrand behavior before the wires or plaitsrupture which can cause damage to braidedproduct or the braider deck.

The MR-15 PLC-T braid sensor functions withyarn or wire braid strands.

A braid failure will shut off the machine andwill show a message on the touch screen forthe deck in question.

The operator may re-set the deck by clearingthe sensor and pushing the Reset button.

2.12.1. ADJUSTMENTS. (MECHANICAL).

1. The braid sensor is located in a directionparallel to the hose, but should be as closeto the braid point as possible.

2. See Section VII of this chapter (Figure7.5.31).

2.12.2. ELECTRICAL. The sensitivity of thesensor to respond to movement of the innerring, Figure 7.5.31, is made at each individualdeck. Experience with use for a particularapplication will be the basis for the correctsetting.

NOTE

The ring halves must have aclearance between the O.D. of thehose and the I.D. of the ringhalves. The clearance isrecommended to be 2 to 5 mm perside. Ring halves with differentI.D. are available from MayerIndustries. Please contact thesales department for anyadditional information.MR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCERing halves are available in the followingsizes: NOTE

Generally, the closer the sensor isto the braid point, the quicker thedefect will be detected.Experience with the sensor willdetermine the best location for theproducts being used.

SECTION IV. CARRIER ASSEMBLY

2.13. GENERAL DESCRIPTION. The MR-15PLC-T carrier is a compact assemblycontaining a torsion spring tensioning device,ball bearing compensator, and one way clutch.

MR-15 carriers are inter-changeable.

The braider carrier is readily adapted tosatisfy a wide range of applications includ-ing:

Strand Materials Need for preforming Strand release tensions

See Chapter 8, Section XII for additionaldetails.

2.14. CARRIER COMPENSATIONS. Thefunction of the compensator is to store theexcess plait length produced by the carrierbeing propelled from "outside" to "inside" of arotor during the usual Maypole cycle.

The MR-15 PLC-T carrier eliminates manyproblems experienced on earlier Maypolecarriers by the use of a rotary ball bearing inthe compensator.

The compensator, working together with thetorsion spring, is capable of producing aunique tension cycle suitable for a wide rangeof braiding applications.

2.14.1. CARRIER CYCLE. To obtain anadequate amount of strand compensation, theMR-15 PLC-T carrier requires eight (8) strandrollers - six (6) mounterd to the compensatorplate and two (2) mounted to the stationarycap. The strand threading path is shown inFigure 2.19.2.

2.14.2. COMPENSATION AND ADJUSTMENT.

CAUTION

Keep fingers clear of the pinchpoint between the carrier housingand compensator plate (relaxedposition) when checking or settingthe carrier tension and/or thepayout position. If the wire/yarnslips or breaks, damage can occurto the fingers.

RING I.D. MM

RECOMMENDED HOSE SIZES

MM

(DIA. OVER THE BRAID)

INCH15 5-11 .197-.43320 10-16 .394-.63025 15-21 .591-.82730 20-26 .787-1.02435 25-31 .984-1.22040 30-36 1.181-1.41745 35-41 1.378-1.61450 40-46 1.575-1.81155 45-51 1.772-2.008February, 2012 MR-15 PLC-T Manual 2-9


2-10(Reference Section 2.14.3).

.

To obtain an adequate amount of strand lengthcompensation, each carrier must "release" or"payout" at the same position of compensatorrotation as other carriers on the same deck. Thesetting for "A" (Figure 2.14.2.2) should be 0-8mm (0-5/16"). These settings may vary fromproduct to product. Experimenting withdifferent settings will determine the bestsetting for the product you are making.

2.14.3. COMPENSATION ADJUSTMENTS. It isimportant that each carrier "release" or"payout" at the same position of compensatorrotation as other carriers on the same deck.

Adjustment to this factory setting isaccomplished by first recognizing that thetorsion spring (20, 21, or 22, Figure 7.5.4), isattached to the actuator block which ismounted onto the compensator (Figure 7.5.5).The rotation of the compensator clockwisecontinues until the end of the actuator blockcontacts the clutch sleeve member. Furtherclockwise motion will rotate the sleeve andrelease the clutch for strand payout.

The adjustment to the payout position is madeby positioning the tang of clutch spring into adifferent slot within the plastic sleeve (Figure2.14.2.1).

You must understand that the release positionis independent of the release tension.

2.15. CARRIER CLUTCH. (Figure 7.5.4) TheMR-15 PLC-T carrier clutch operates on theone-directional wrapped spring principle. Ithas been developed for long, trouble-freeperformance.

The clutch function is to prevent the strandsupply wire bobbin or yarn package fromrotating until the plait has attained apredetermined tension, at which time thecompensators clockwise rotation will actuatethe plastic clutch sleeve (13) which will openthe wrapped spring (11) or (12), and allow themoveable hub (9) to rotate with the strandsupply package.

The stationary hub (6) of the clutch assemblyis timed to the carrier housing (1) with pin(25). This fixed relationship insures that everyMR-15 PLC-T carrier will relate to any shuttleassembly.

The movable hub (9) uses grease forlubrication. Manually apply grease. Seelubrication, Chapter 5.

FIGURE 2.14.2.1: PAYOUT POSITION ADJUSTMENT

FIGURE 2.14.2.2:

DECREASE

INCREASE

AMR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCE2.16. CARRIER PAY-OFF TENSIONS.

NOTE

Pay-off tensions indicated areapproximate. The actual releasetension will vary somewhat with:strand diameter, strand material,number of ends of strand/plait,and to what extent (if any) the pre-form pin is involved.

NOTE

When the desired pay-off tensioncan be satisfied with any twosprings, the practice shouldalways be to use the spring havingthe higher tension capability.

2.16.1. ADJUSTMENT OF PAY-OFF TENSION (SAME SPRING). Adjustment of the pay-offtension is accomplished by the rotationaladjustment to the carrier adjusting ring (3,Figure 7.5.4).

CAUTION


When viewed from the front of the carrier, acounter clockwise adjustment "increases" pay-out tension while a clockwise rotation"reduces" pay-out tension.

Radial holes have been provided in ring (3) tomake tension adjustment more convenient.When the desired tension has been attained,the socket head screw (32) is tightened in theadjusting clamp (7) to secure the adjusting ringto the carrier housing.

2.16.2. SUBSTITUTION OF ONE SPRING FOR ANOTHER (SAME CARRIER). (Figures 7.5.4and 7.5.5)

CAUTION


1. Remove carrier from deck.

2. Loosen M8 screw (32, Figure 7.5.4) toallow disassembly of adjusting ring (3).

PAY-OFF TENSION

LBS KILOGRAMS TORSION SPRING6 - 9 2.7 - 4.1 Light

12 - 18 5.4 - 8.2 Medium19 - 25 8.6 - 11.3 HeavyFebruary, 2012 MR-15 PLC-T Manual 2-11


2-123. Loosen spring clamp (14, Figure 7.5.4) byloosening screw assembly (29) and screws(28). Remove the spring from the actuatorblock (5) and spring clamp (14).

4. To install a spring place, the end of thespring that is bent radially outward againstthe spring clamp (14) and the portion of thecoil adjacent to the tang should lay on thesurface of actuator block (5). See Figures7.5.4 and 7.5.5, assembled outline ofspring. Tighten screw (28) which willdraw spring clamp (14) in toward actuatorblock (5). Note that screws (29) and (28)should be snug while this is being done.Tighten all three screws to 10.3 ft-lbs (14Nm). All parts should be tight and appearas in Figure 7.5.4, assembled view.

5. To install the tension ring on the spring,place the end of the spring that is bentradially inward against the raised lip, seeFigure 2.16.2.1. The curve of the spring issuch that it will not slip under the edge ofthe raised lip easily. On the bottom springcoil opposite the spring tang push radiallyoutward and twist the spring clockwise.This will allow the edge of the spring to

slip over the lip and be pulled under therest of the lip by the twisting motion. If thisdoes not seat the spring or the spring goesunder the lip opposite the spring tang butwon't rotate, use a wide blade screwdriverto force the inside edge of the spring up toand under the lip.

CAUTION

Do not let the screwdriver beingused to push the spring, gouge ornick the spring. This will cause astress riser and results in thepremature failure of the spring.

The thinner the spring the easier it will beto force it up to the lip. The spring tangmust be up against the edge of the lip onthe tension ring as shown in Figure2.16.2.1, section A-A. If it is not, the pay-off tension can be set with a gap at sectionA-A and then when the carrier goes intoproduction the working of the spring will

FIGURE 2.16.2.1: TENSION SPRING INSTALLATION

A A SECTION A-A

SPRING

ADJUSTING RING

TORSION SPRINGMR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCEpull the spring tang against the lip, but thiswill change the payoff tension. If thistension is critical, hose problems coulddevelop.

6. Replace the adjusting ring (3) intoadjusting clamp (7) and back into thecarrier housing (1) as shown in Figure7.5.4.

7. Adjust pay-off tension for plait material.Tighten the screw (32) to secure theadjusting ring in place. Use an allenwrench and hand tighten. The ring (3)should not move.

2.17. CARRIER LATCH. Every MR-15 PLC-Tcarrier incorporates a simple, yet positive,latch to secure the carrier assembly to theshuttle shaft, or the shuttle extension.

The latch involves a 90 rotation to engage andlatch to the spindle. See Figure 2.17.1. It alsoentails a slight pushing force to release thelatch for rotation.

MI's latch tool, part number S-5503, isrecommended for this purpose.

All carriers, when viewed from the front andmounted to the shuttle assemblies in safe,operating latched position, will be observed tohave the latch bars form a circle when they areall in the latched position.

Double check to insure all carriers are in thelatched position.

CAUTION

"Always" switch the inside safetyswitch to the "ON" positionimmediately upon entering thesafety enclosure.

Follow all instructions and safetyprecautions listed in Paragraph2.10 for tying in of braidingstrands.

2.18. CARRIER BOBBIN OR YARN PACKAGE CHANGE. Every MR-15 PLC-T carrier isinterchangeable with another carrier and anycarrier may be latched to any shuttle assemblyon the same deck.

With this in mind, and assuming all or themajority of all carriers will be changed at onetime, experience will indicate a preferredsequence of package change.

1. Remove any one carrier assembly from theshuttle using the latch tool. Place thiscarrier aside. (This will be the last carrierreplaced when all others are loaded.)

2. Remove the empty bobbin or yarn tubefrom the same shuttle spindle and replace itwith a full package or bobbin.

3. Remove an adjacent carrier from the

FIGURE 2.17.1: CARRIER LATCH

UNLATCHED POSITION

LATCHED POSITION

HOLE

LATCH BAR

LATCH BAR

HOLEFebruary, 2012 MR-15 PLC-T Manual 2-13


2-14shuttle spindle and place this carrier ontothe first shuttle having the full package.Lock the carrier.

4. Repeat sequence until the full deck isreloaded.

2.19. PREFORMING OF WIRE. Preforming isthe practice of producing a set or curl in anotherwise straight strand. The curl isaccomplished by drawing the strand over astationary or rolling surface under tension tointroduce compressive stress to one side of astrand.

Preforming serves a very useful purpose inproducing certain wire braided structures.

NOTE

Using the stationary preform pinon the L-support is the preferredmethod for the MR-15 braiders.See Figure 7.5.13.1.

For other braid applications, the ability of acarrier to provide "rolling contact" between thestrand and carrier surfaces is the primary goalfor minimizing friction. This then allows thestrand to retain its usefulness as areinforcement member without disturbance tothe strand surface.

The MR-15 PLC-T braider has one carrier forall conditions and materials, and offers pre-forming as an elective capability.

A minor change in threading path canintroduce a preform pin. See Figure 2.19.1.

The variables for pre-form will include:

Wire strand diameter

Carrier release tension

Preform pin diameter

Number of ends per bobbin

In the majority of hose applications, thestandard braider pre-form components willsuffice.

FIGURE 2.19.1: OVER CENTER ROLLERS AND PREFORM PIN

FIGURE 2.19.2: OVER CENTER ROLLERS

TOHOSE

TOHOSEMR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCESECTION V. WIRE BRAIDING BOBBIN PREPARATION

2.20. BOBBIN WINDING. See Figure 7.5.63.

NOTE

For superior high speed windingquality, MI recommends using theMayer MCW-LT series high speedwinder.

2.20.1. ADAPTING BOBBINS. The MayerCarrier works exclusively with Mayeraluminum bobbins. Bobbin winders of othermanufacturers may be readily converted toparallel wind the Mayer braider bobbin.Contact the MI SERVICE DEPARTMENT fordetails on winding adapters.

Since the length of the Mayer aluminumbobbin is different, the tailstock of the winderis readjusted to suit the shorter length.

Care should be taken to insure that adequateaxial force is maintained so that the bobbin issecurely held by the winder.

2.20.2. WINDING QUALITY. Winding qualityis important to all braiding results.

Proper let-off tension control, suitable traverse"stop" adjustments and guide beak conditionwill benefit the quality of braider performanceand resulting braid product quality. Catenarytests should be run as required.

2.20.3. BOBBIN CARE. Proper care of the MR-15 PLC-T bobbin will provide the user withlong trouble-free service. The user iscautioned against:

NOTE

1. Tensions in excess of 2.25 lbs./bobbinfrom winder supply spool let-off canexceed bobbin flange strength andshorten the bobbins useful life.

2. Improper traverse setting at winder.

3. Rough handling of aluminum bobbinswhen full or empty. Do not drop.

2.21. YARN BRAIDING. The MR-15 PLC-TBraidmatic features the capability to convert toa deck from braiding wire on 20 lbs. capacityaluminum bobbins to yarn braiding with largecapacity packages wound on a paper tube orfabricated bobbin.

The changeover from wire to yarn or yarn towire braiding utilizes the same basic carrierand shuttle assembly for both strand options.The conversion may be made with shuttleassemblies remaining in the deck.

2.21.1. YARN PACKAGE. The single let-offMR-15 PLC-T yarn package is preparedaccording to Figure 2.21.1.1, and is wound onyarn tube #240-4016, Figure 2.21.1.2. Namesand addresses of both tube and yarn suppliersare available by contacting MI.February, 2012 MR-15 PLC-T Manual 2-15


2-16FIGURE 2.21.1.1: S.L.O.Y. PACKAGE

MAX. BULGE IN6.4 mm

8 IN TRAVERSE203 mm 6 IN (MAX) 165 mm

7/16 IN11.1 mm

DIRECTION OF WINDMUST BE AS SHOWN NOTE:

YARN MUST BEBELOW ENDS OFTUBE.

TOTAL PACKAGE WEIGHTMUST NOT EXCEED 7 POUNDS(3.8Kg)

FIGURE 2.21.1.2: S.L.O.Y. TUBE (240-4016)

1.75 IN 44.5 mm

+.01-.00

+.25-.00

VIEW A-A

LAY OFPAPER

8.86 IN225 mm

+.00-.062+.00-1.5 .02

5.

01 .25

.44 IN11.2 mm

.25

IN6.

4 m

m

A

A

2.4 IN 61 mm

1. 2. CONSTRUCTION:

SONOCO PRODUCTS COS SPIRAL DUROLENEWITH SEAMLESS LOW MARK OUTSIDE PLY.

NOTCHES TO BE AT 180 2.MR-15 PLC-T Manual February, 2012

2-ADJUSTMENTS AND MAINTENANCE2.21.2. ADDITIONAL PARTS FOR CONVERSION TO YARN PACKAGES. Theconversion from an MR-15 PLC-T deckbraiding wire on an aluminum flanged bobbinto large capacity yarn on paper tube orreusable fabricated bobbins will require theaddition of shuttle spindle extensions. SeeChapter 7, Figure 7.5.11, and Figure 7.5.12.

All parts are interchangeable with any MR-15PLC-T lightweight shuttle assembly.

2.21.3. PROCEDURE FOR FIELD CONVERSION OF WIRE TO YARN.

CAUTION

Moving elements/pinch points inthe shuttle assembly area.Personal injury to hands and armscould occur.

Only trained personnel/mechanicsare allowed to install and removeshuttles and/or work in this area.Personal safety equipment is tobe worn.

Work area to be clean and free ofoil to prevent slipping.

Cut power off at the maindisconnect and remove

mr 15plct frevtfeb12

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