Model JAT810 - Toyota Textile Machinery...TEXTILE MACHINERY DIVISION 1, Toyodacho 2-chome, Kariya-shi, Aichi, 448-8671 JAPAN T E L : +81 566 27 5316 F A X: +81 566 27 5301 Thank you

Model

JAT810TOYOTA

AIR

JET

WEAVING

MACHINE

INSTALLATION

GUIDE

HEAD OFFICE: TOYOTA INDUSTRIES CORPORATION

TEXTILE MACHINERY DIVISION

1, Toyodacho 2-chome, Kariya-shi, Aichi, 448-8671 JAPAN T E L : +81 566 27 5316F A X: +81 566 27 5301

　

　

　

Thank you for purchasing the JAT810 Air Jet Weaving Machine.

　

This installation guide describes the work required for your weaving machines from their delivery

through installation, including necessary preparations before starting production.

　

Make preparations according to the time schedule as instructed in this guide so that you can have

everything ready when our service personnel arrive. This will eliminate wasted time and efforts. If

preparations are not completed, our service personnel will have to leave and come back again at a later

date.

　

If you have any questions concerning the installation, please contact us at the following locations:

　

Notice: Specifications, operating instructions, and dimensions in this manual are subject to change for

improvements without prior notice.

TOYOTA shall take no responsibility for loss, damage, expense or claims for bodily injury or property

damage arising from incorrect usage which is not in accordance with the instructions given in this

manual.

　

Please also understand that we will not be held responsible for the result of operating this machine.

This manual uses the following symbols: , , ATTENTION.

(1)

The symbol is used in this manual, alerting you to a situation that might cause serious

injury or death to the worker if he or she does not follow the instructions in this manual necessary to

avoid any dangers in the machinery.

(2)

The symbol is used in this manual, alerting you to a situation that might cause minor

injury to the worker if he or she does not follow the instructions in this manual necessary to avoid

any dangers in the machinery.

(3) ATTENTION

The ATTENTION mark is used here, alerting you to possible substantial property damage if the

worker fails to follow the instructions in this manual.

　　　

ContentsOUTLINE OF INSTALLATION WORK ……………………………………………………………………………1

S.　SAFETY …………………………………………………………………………………………………………2

[1]　Safe Work ……………………………………………………………………………………………………2

[1.1]　Rules for Installation Work …………………………………………………………………………3

1　Before Installation ……………………………………………………………………………………3

2　During Installation ……………………………………………………………………………………4

3　Before Trial Run ………………………………………………………………………………………7

4　During Trial Running …………………………………………………………………………………7

[1.2]　Rules for Safe Operation ……………………………………………………………………………8

1　General Rules …………………………………………………………………………………………8

2　Precautions for Weaving ……………………………………………………………………………9

[1.3]　Rules for Maintenance ……………………………………………………………………………11

1　Before Maintenance Work …………………………………………………………………………11

2　Precautions for Maintenance Personnel …………………………………………………………12

3　During Maintenance Work …………………………………………………………………………13

4　Lubrication ……………………………………………………………………………………………13

[1.4]　Rules for Operating or Checking the Electrical Devices ………………………………………14

1.　PREPARATIONS FOR INTRODUCING THE MACHINE …………………………………………………15

[1]　Building ……………………………………………………………………………………………………15

[2]　Foundation Work …………………………………………………………………………………………17

[2.1]　Structure of Foundation ……………………………………………………………………………17

[2.2]　Laying the Foundation for Wiring and Piping ……………………………………………………18

[2.3]　Floor Surface Conditions …………………………………………………………………………18

[2.4]　Preparing Glue or Quick-hardening Cement ……………………………………………………19

[2.5]　Marking on the Floor ………………………………………………………………………………22

[2.6]　Laying Anchor Bolts (Only for the bolting installation method) …………………………………22

[3]　Wiring (for looms other than towel weaving machine) …………………………………………………30

[3.1]　In-plant Electric Facilities …………………………………………………………………………30

1　Power Requirements ………………………………………………………………………………30

2　Earth leakage breaker ………………………………………………………………………………30

3　Class D grounding …………………………………………………………………………………30

4　Capacities of non-fuse circuit breakers on switch board ………………………………………30

5　Cable capacity selection ……………………………………………………………………………30

6　Position for installation of phase compensation capacitor for slow inching specification ……31

7　When wiring the loom power cable to the loom, it is recommended to lay them at least 200 mm

away from each other to prevent noise generation. ………………………………………………31

8　Line filter installation to counteract radio noise …………………………………………………31

9　Selection of wire type ………………………………………………………………………………31

[3.2]　Circuit Breakers ……………………………………………………………………………………32

1　Capacity of non-fuse circuit breaker (A) for group inverter ………………………………………32

2　Capacity of non-fuse breaker (B) for loom ………………………………………………………33

[3.3]　Cable Capacity ……………………………………………………………………………………34

1　Supply voltage fluctuation and line voltage drop …………………………………………………34

2　Current in each loom operation state ………………………………………………………………35

3　Motor rated current In ………………………………………………………………………………35

4　Cable selection ………………………………………………………………………………………36

[3.4]　Cable Capacity Calculation Examples (reference examples) …………………………………37

1

1　Selection of cable ① between circuit breaker on switchboard and group inverter ……………37

2　Selection of cable ② between inverter and loom …………………………………………………38

3　Selection of cable ③ between circuit breaker on switchboard and loom ………………………39

4　Selection of cable ③ between circuit breaker on switchboard and electronic shedding loom

…………………………………………………………………………………………………………40

[3.5]　Group Inverter ………………………………………………………………………………………41

1　Determination of installing location ………………………………………………………………41

2　Major specifications, dimensions and weight of inverter …………………………………………41

3　Wiring method between inverter and loom ………………………………………………………42

4　Cautions for wiring …………………………………………………………………………………42

[3T]　Wiring (for towel weaving machine) ……………………………………………………………………43

[3T.1]　In-plant Electric Facilities …………………………………………………………………………43

1　Power Requirements ………………………………………………………………………………43

2　Earth leakage breaker ………………………………………………………………………………43

3　Class grounding ……………………………………………………………………………………43

4　Capacities of non-fuse circuit breakers on switch board ………………………………………43

5　Cable size selection …………………………………………………………………………………44

6　Line filter installation to counteract radio noise …………………………………………………44

7　Selection of wire type ………………………………………………………………………………44

[3T.2]　Circuit Breakers ……………………………………………………………………………………44

1　Capacity of non-fuse breaker (A) for loom ………………………………………………………45

[3T.3]　Cable Capacity ……………………………………………………………………………………46

1　Current in the loom operation state (Excluding the jacguard) …………………………………46

2　Calculating current for cable selection ……………………………………………………………46

3　Current in the loom operating condition …………………………………………………………47

4　Calculation formula for selecting a cable type ……………………………………………………47

[3T.4]　Cable Capacity Calculation Examples (reference examples) ………………………………48

1　Cable size on cable ① between the switchboard breaker and the loom ………………………48

2　Cable size on cable ① between the switchboard breaker and the loom ………………………49

[4]　Air Compressor ……………………………………………………………………………………………50

[4.1]　Compressed-air Requirements for Air Jet Weaving Machines and Precautions for Piping …50

[4.2]　Choice of Air Compressor Type and the Number of Compressors ……………………………51

1　Calculating air volume required for weaving machines …………………………………………51

2　Calculating the capacity and the number of air compressors required …………………………52

3　Calculating the approximate power consumption of compressor ………………………………53

[4.3]　Layout Examples of Air Compressors and Related Equipment ………………………………55

1　Turbo type oil-free compressor ……………………………………………………………………55

2　Packaged oil-free screw (dry screw) compressor ………………………………………………55

3　Packaged oil injection screw compressor …………………………………………………………55

4　Oil-free reciprocating compressor …………………………………………………………………55

[4.4]　Piping ………………………………………………………………………………………………56

1　Compressor room ……………………………………………………………………………………56

2　Weaving room ………………………………………………………………………………………56

3　Mounting drain ports and valves ……………………………………………………………………57

4　Other precautions ……………………………………………………………………………………57

[5]　Other Equipment ……………………………………………………………………………………………58

[5.1]　Temperature Control and Air Conditioning ………………………………………………………58

[5.2]　Lighting ………………………………………………………………………………………………58

[5.3]　Prevention from Fly, Fleece, and Dust ……………………………………………………………58

2

[5.4]　Separate Take-up Motion …………………………………………………………………………59

1　Power supply to separate take-up motion …………………………………………………………59

2　Running/forward signal ……………………………………………………………………………59

3　Loom stop signal from separate take-up motion …………………………………………………60

2.　INSTALLATION WORK ………………………………………………………………………………………61

[1]　Preparations for Installation ………………………………………………………………………………61

[1.1]　Arrangement of Workers …………………………………………………………………………61

[1.2]　Setting-up of Unpacking and Carrying-in Tools …………………………………………………61

[1.3]　Preparation of Piping ………………………………………………………………………………61

[2]　Installation Work ……………………………………………………………………………………………62

[2.1]　Positioning of the Weaving Machine ……………………………………………………………62

[2.2]　Jobs to be Done before Securing the Legs of the Weaving Machine …………………………62

[2.3]　Installation …………………………………………………………………………………………63

1　Levelling the weaving machine ……………………………………………………………………63

2　Installing the cheese stand base …………………………………………………………………65

3　Installing the EDP stand ……………………………………………………………………………66

4　Control box support …………………………………………………………………………………68

[2.4]　Wiring and Piping to Weaving Machines …………………………………………………………70

1　Wiring …………………………………………………………………………………………………70

2　Piping …………………………………………………………………………………………………70

3.　PREPARATIONS FOR WEAVING START-UP ……………………………………………………………72

[1]　Warp-related Preparations ………………………………………………………………………………72

[1.1]　Mounting the Warp Beam(s) and Procuring Warp Yarn ………………………………………72

1　Mounting a single beam ……………………………………………………………………………72

2　Mounting twin beams ………………………………………………………………………………74

3　Mounting a grand beam of towel loom ……………………………………………………………75

4　Mounting a pile beam of towel loom ………………………………………………………………77

5　Winding warp onto a warp beam …………………………………………………………………79

6　Preparing warp yarn …………………………………………………………………………………79

[1.2]　Preparing the Droppers ……………………………………………………………………………80

[1.3]　Preparing the Healds ………………………………………………………………………………81

[1.4]　Preparing the Reed and Drawing in Warp ………………………………………………………84

1　Drawing-in width ……………………………………………………………………………………84

2　Drawing-in procedure ………………………………………………………………………………85

[1.5]　Preparations for Selvage Construction …………………………………………………………86

1　For Full-leno Selvage Device ………………………………………………………………………86

2　For Half-leno Selvage Device (Klöcker) …………………………………………………………88

3　For warp-addition device ……………………………………………………………………………90

[1.6]　Preparations for Waste Selvage Device …………………………………………………………92

1　For stand-equipped type (which has a waste-selvage bobbin stand) …………………………92

2　For non-stand type (which has no waste-selvage bobbin stand) ………………………………94

[2]　Weft-related Preparations (Mainly Spun Yarn) …………………………………………………………95

[2.1]　Preparing Weft Yarn and Cheeses ………………………………………………………………95

[3]　Lubricants, Cleaning Oil, and Sealant ……………………………………………………………………96

[3.1]　Lubricants ……………………………………………………………………………………………96

1　Lubricant Symbols and the Corresponding Products Commercially Available ………………96

2　Lubricants Required Before Trial Run ……………………………………………………………97

3　Lubricants Required After Production Weaving …………………………………………………100

4　Lubricating Tools …………………………………………………………………………………101

3

5　Storage of Lubricants ………………………………………………………………………………102

[3.2]　Cleaning Oil and Sealant …………………………………………………………………………102

1　Cleaning Oil Required When Unpacking ………………………………………………………102

2　Sealant Required at the Time of Oil Change ……………………………………………………102

4.　APPENDIX ……………………………………………………………………………………………………103

[1]　JAT810 Technical Information …………………………………………………………………………103

[1.1]　Nominal Reed Space and Effective Drawing-in Width ………………………………………103

1　Nominal reed space ………………………………………………………………………………103

2　Effective drawing-in width …………………………………………………………………………103

[1.2]　Machine Weight (excluding EDP) ………………………………………………………………105

[1.3]　Yarn Number Count of Warp ……………………………………………………………………106

[1.4]　Picking Density ……………………………………………………………………………………106

[1.5]　Warp Tension Setting Range ……………………………………………………………………106

[1.6]　Possible Weaving Range (Yarn density vs. Yarn number count) ……………………………106

[1.7]　Fabric Examples …………………………………………………………………………………107

[2]　Network application ………………………………………………………………………………………108

[2.1]　Scope of your work ………………………………………………………………………………108

[2.2]　Network Connection Concept ……………………………………………………………………110

[2.3]　Network Design ……………………………………………………………………………………112

[2.4]　Piping Work ………………………………………………………………………………………120

[2.5]　Wiring Sample Diagram …………………………………………………………………………122

[2.6]　Network Cable Connector Installation Method …………………………………………………123

[2.7]　Network Cable Connection to the Machine ……………………………………………………126

[2.8]　Connection with Customer's Network …………………………………………………………127

[3]　TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) ……………………………………131

[3.1]　TMS Scanner Overview …………………………………………………………………………131

[3.2]　Features of TMS Scanner ………………………………………………………………………132

[3.3]　Connection between Looms and Data Collection Boards (LTB4) ……………………………135

1　Communication Method between LTB4 Boards and Computer ………………………………135

2　Conditions for Connecting LTB4 to The Loom …………………………………………………136

3　Loom Side Signal I/F Circuit Diagram ……………………………………………………………136

4　Time Chart …………………………………………………………………………………………137

5　Checking Connection between Loom and LTB4 ………………………………………………137

6　Management of Looms Connected to TMS Scanner …………………………………………137

[3.4]　Studying Loom Connection to TMS Scanner PC ………………………………………………138

1　Prepare The Plant Layout Drawing ………………………………………………………………138

2　Indicate The Computer Mounting Positions in The Plant Layout Drawing ……………………138

3　Study The Cabling Routes and Cable Lengths on The Layout Drawing ……………………139

4　Cautions for TMS Scanner Communication ……………………………………………………139

[3.5]　Works after Determining TMS Scanner Introduction …………………………………………142

1　Matters to be Checked upon Determining Introduction (Discussion between The Customer

and Us) ………………………………………………………………………………………………142

2　Signal Conduit Installation Work (Customer's Work) …………………………………………142

3　Sending The Cable and Scanner PC (Our Work) ………………………………………………142

4　Preparation of The TMS-PC (Customer's Work) ………………………………………………142

5　Cable Installation, and TMS Scanner Setting and Connection (Customer's Work) …………143

4

1.　Preparations for Introducing the Machine

　Complete the following preparations:

□ Building construction and floor work (Irregularity in the floor levelness: 5 mm or less, Surface

irregularities of the floor where the legs of the machine are to be positioned: 1 mm or less)

□ Foundation work, floor marking, and anchor bolt laying work*

(* This job is not required if you select the gluing installation method.)

□ Power wiring (to the installation position of machines) and installation of circuit breakers on the

switchboard

□ Pneumatic piping (to the installation position of machines)

□ Installation of air compressor(s)

□ Air-conditioning work

2.　Preparations for Installation

　Complete the following preparations:

□ Arrangement of workers

□ Setting-up of forklift, hand lifts, and small jacks

□ Procurement of Quick-hardening cement (for bolting installation) and Araldite or Sikadur (for

gluing installation)

□ Customs clearance for machines

□ Receiving and carrying machines to your factory

Installation can be started at this stage.Toyoda service personnel can be dispatched

at this stage.

3-1. nstallation of Weaving Machines and

Related Facilities3-2. Preparations for Weaving Start-up

　Complete the following preparations under the

on-site

supervision

of

Toyoda

service

personnel:

Complete the following preparations:

□ Warp yarn preparation

□ Unpacking and installation of machines □ Procurement of weft yarn, leno yarn,

waste-selvage yarn, and additional yarn□ Leveling of machines

□ Installation of EDP stand(s) □ Installation of winder for weft cheeses

□ Installation of cheese stand(s) □ Installation of leno yarn winder

□ Power wiring to machines

(main power and inverter power)

□ Installation of waste-selvage yarn winder

□ Procurement of oil and grease

□ Pneumatic piping to machines

Adjustment and Trial Run

Weaving Start-up

Start of Production

OUTLINE

OF

INSTALLATION

WORK

Items marked with a box □ are jobs which you should do. Use the list given below as a check list.

OUTLINE OF INSTALLATION WORK

1

Introduction

There is no such thing as a perfectly safe machine when improper handling or

ignoring precautions stands in the way. Any incorrect usage could possibly

result in a serious bodily injury, in the worst case it could cause death, and/or

substantial property damage.

TOYOTA has done everything possible to assure optimum safety. However, it

cannot be completed without your understanding and efforts.

It is impossible for the manufacturer to take into account individual

operating conditions of the machinery at the user site and prepare an

instruction manual covering all information relating to the machine

operation. We, therefore, ask you to establish your own individual safety

standards for each safe job of installation, operation, adjustment, and

maintenance, by referring to this guide.

S.　

SAFETY

[1]　

Safe

Work

S.　SAFETY

2

For example

1．When anchor bolts, power cable conduits

and air inlet piping are spread out before

installation, mark them clearly with

brightly colored cloth or a flag so that

workers can avoid tripping or hitting the

machine and carriers against them during

installation.

2．If there is any unstable footing due to any

pits (for exhaust, piping, wiring, or other

purposes) which are dangerously

uncovered, put on a temporary cover to

prevent falling accidents.

3．Use specified tools matched to the job to

be done.

[1.1]　Rules for Installation Work

1　Before Installation

(1) Check the safety rules and the workmanship standards for the plant.

(2) Make sure that all personnel involved know the nature of the job and the installation

procedure, and agree as to the best way to get them done.

(3) For jobs requiring a group effort, choose a supervisor whose instructions should be followed

thoroughly by all.

(4) For jobs requiring a group effort, agree beforehand on words or gestures for giving and

confirming signals.

(5) Wear safety shoes.

(6) Check the work places and their surroundings. If any unsafe point is found, take the

necessary action to make it safe.

　　

　　

S.　SAFETY

3

(1) Always wear a helmet whenever

installation is being carried out at the

same time as other jobs, such as

construction and piping.

(2) Always wear gloves whenever there is

the

possibility

of

injuring

hands

or

fingers.

(3) Never use gloves if there is the

possibility of their becoming caught in a

rotating section of the machine.

(4) Never get oil or grease on the floor, since

these can cause slipping accidents.

(5) Always provide a stable platform or

scaffold for those jobs in places too high

to reach from the floor.

(6) Never climb onto a heavy hoisted object

nor get under it.

(7) Keep your tools, parts, devices and

instruments neatly arranged, and

observe the following rules:

1．Put them where they are not likely to

fall down.

2．Whenever standing or leaning them

against something else, do what is

necessary to prevent them from

falling over.

3．Whenever piling round bars or pipes,

do what is necessary to prevent them

from falling down.

(8) Observe the following rules when

conducting a group effort:

1．Choose a supervisor whose

instructions should be followed

thoroughly by all.

2．Agree beforehand on words or

gestures for giving and confirming

signals.

3．Be especially careful when handling

heavy objects. If the weight exceeds

20 kg, two or more workers should

handle them.

2　During Installation

1)　General points for installation work

　

　

　

　

　　

S.　SAFETY

4

(1) Before bringing in machinery, always

prepare well-maintained carriers.

Carriers Q'ty Specifications

Forklift

(or wrecker)1

3.5 t

(Reed space:150-190 cm)

Hand lift 2 3.0 t or more

Small jack 2 1.5 t or more

Wooden block 4 Approx. 90×150×60 mm

(2) Never

lift

the

machine

or

load

any

higher

than

200

mm

above

the

floor

during

transport.

(3) Never stand in small spaces between the

machine/load and the wall during

transportation.

(4) Always assign a guide and transport

according to his or her instructions.

The guide should pay sufficient attention

to any protruding parts on the transport

route.

(5) Whenever inserting wooden blocks under

the machine/load, never let fingers get

between the machine/load and floor.

(6) Always push hand carts when carrying

loads.

Never pull them.

(7) Fix the load with a rope or other means if

necessary, to prevent the load from

falling down during transport.

(8) When putting a lift beneath the machine,

make sure that its hook catches the place

between the back and front cross rails

and balances it right and left securely.

2)　Transport

　　

　　

S.　SAFETY

5

(1) Parts are coated with rust-preventive oil.

Take necessary action so they will not

slip when carrying them.

(2) When washing parts, use waterproof

paper to prevent the floor from becoming

stained.

(3) Use Nippon Oil Corporation's New-sol

Deluxe or equivalent cleaning fluid.

Never use trichloroethylene-base

cleaning fluid; otherwise, the painting

will peel off or discolor.

(4) Never put anything on the parts storage

area, passages, or footing area.

(1) When using a small jack, apply it to two

points underneath the front and back

cloth rails and make sure that it catches

them securely.

(2) When conducting a group effort, agree

beforehand on words or gestures for

giving and confirming signals.

(3) Whenever inserting fiber packings under

the bottom of the machine's feet or

removing them during the levelling

work, never let fingers get between the

packings and the floor.

(1) Never allow non-qualified workers to

carry out connection or disconnection of

the primary power lines.

(2) Before starting wiring work, be sure to

check that the main circuit breaker is

open and the warning notice (tag) is put

up for all to see.

(3) Before starting wiring work, be sure that

the line is not active.

(4) Check that the plant power grounding

line is connected to the PE terminal in

the control box.

(5) Check the wiring and connection for no

abnormality.

3)　Unpacking and cleaning

　　

4)　Levelling work

　　

5)　Wiring work

S.　SAFETY

6

3　Before Trial Run

(1) Clear away bolts, nuts, tools and other unnecessary things around, on and under the machine.

(2) Check that all sections of the machine are securely tightened and that the safety covers are

on.

4　During Trial Running

(1) Check the rotating direction for: the main motor, drum motor, and electrical let-off motor.

Also check the rotating direction of forward/reverse inching.

(2) Check the functions of each of the stop motions and limit switches.

S.　SAFETY

7

(1) Never allow non-qualified workers to

carry out connection or disconnection of

the primary power lines.

(2) Never try live-wire operation when

changing the wiring on the machine.

(3) Never start the machine without

communicating your intention to

co-workers or without confirming their

answer to your signal.

(4) Never touch rotating or operating parts

until the machine comes to a complete

stop.

(5) Never operate the machine in clothes

which could become entangled in the

rotating parts.

(6) Never remove any of the warning notice,

caution plates or instruction plates from

the machine, no matter what.

[1.2]　Rules for Safe Operation

1　General Rules

1)　Absolute precautions

　　

　　

　　

2)　Handling abnormal situations

(1) Always turn the power off before making any adjustments or repairs to cor

(2) If you turn off the machine, be sure to put up the warning notice on the power switch.

(3) The temporary warning notice (tag) should be removed only by the person who put it up,

once it has become unnecessary.

3)　Other precautions

(1) The supervisor should make sure that each worker sufficiently observes all safety rules.

(2) Observe the safety codes and regulations enforced in individual countries.

S.　SAFETY

8

2　Precautions for Weaving

1)　Starting

(1) Make sure that there is no one beside or behind the machine.

(2) When two or more workers are to handle a job, they must always communicate through

words or gestures before starting the job.

(3) Before pressing any switches on the machine, be sure to identify them to prevent mistakes.

2)　During weaving

(1) No one other than the person in charge must take recovery action if any of the electrical

parts in the control box operates so as to cause the machine in operation to either stop or

become non-workable.

(2) While the machine is in operation:

1．Never touch the running portion.

2．Never open or remove any of the safety covers.

3．Never try to remove yarn or fly.

(3) Do not operate the machine in these types of clothes:

1．Loose fitting jacket

2．Long sleeves with buttons

3．Work cloths with buttons sticking out in front

4．Sandal-type shoes

(4) Never put scissors or tools in a non-flap breast pocket.

S.　SAFETY

9

(5) If the machine stops, check

・the signal indicator 1,

・the warning lamp 2 on each of the

operation panels, and

・the function panel to see whether

warning icon 3 appears.

1．If only warning lamp 2 lights:

It means that the pick finder is in

operation.

The machine is temporarily on halt

and will restart running, so never

reach out towards the movable parts

or the working area while warning

lamp 2 lights.

2．If the signal indicator 1 flashes (in

case of standard setting), warning

lamp 2 lights and warning iron 3 is

displayed:

It means that the Toyota Automatic

Pick Operator (TAPO) is in operation.

The machine is temporarily on halt

and will restart running, so never

reach out towards the movable parts

or the working area while these

indications are on.

　　

S.　SAFETY

10

[1.3]　Rules for Maintenance

1　Before Maintenance Work

1)　Checking the work procedure

Check the work procedure with co-workers in advance. Be sure to inform the operators that the

machine is to be stopped, and always put up the maintenance notice (specified by the plant) on

the power switches.

2)　Checking the jigs and tools

Select and inspect the jigs and tools for the job purpose. Use spanners and wrenches suitable for

the sizes and locations of bolts and nuts.

3)　Keeping things neat and tidy

Determine the storage location for disassembled parts, making sure that passages are clear for

operators.

S.　SAFETY

11

(1) If you stop the machine for maintenance,

be sure to put up the warning notice

saying

"DON'T

TURN

THE

SWITCH

ON".

(2) Never put tools or any items on top of the

machine whether it is in operation or on

halt.

Otherwise, they may fall into the

machine, causing parts damage or even

bodily injury.

(3) Never use compressed air for cleaning

your skin. It may cause infection if your

skin has any open wounds.

(4) When using lubricant, paint, adhesive,

sealant, or detergent, put on the

protectors, safety gloves, and safety

goggles to protect your skin and eyes

from those materials.

Such materials may cause bodily

damage. If your skin or eyes become

contaminated, wash the affected part at

once and get appropriate medical care.

When using any detergent, always

ventilate the workshop sufficiently.

Follow the instructions provided by the

material manufacturer or supplier.

(5) For any work which could damage the

eyes, always wear safety goggles.

2　Precautions for Maintenance Personnel

　　

　　

S.　SAFETY

12

For safety, be sure to turn off the machine before starting maintenance work. At the same time,

be sure to put up the maintenance notice (specified by the plant) on the switches.

For jobs to be carried out with the power kept on, observe the following instructions.

3　During Maintenance Work

1)　Basic maintenance procedure

(1) Stop the machine by pressing the STOP switch.

(2) Inch the machine so that the heald frames become aligned or leveled.

For electronic shedding, secure the frame stopper before turning off the main power.

(3) Press the BRAKE RELEASE switch to make sure that the reed will not move. (In the case

of the electronic dobby, turning off the machine may turn the crank, resulting in collapsed

patterns.

(4) Turn off the machine.

(5) Check that the machine is stopped and then start maintenance work.

2)　Basic rules for maintenance jobs with the power being ON

(1) If you need to run the machine, inch it (in slow speed).

(2) When conducting a group effort to run the machine, agree beforehand on words or gestures

for giving and confirming signals. Always put up the maintenance notice (specified by the

plant) on the switches to prevent other persons from turning on or off the machine

unexpectedly.

(3) For the dobby being used, be sure to observe the instructions given in [3.1], steps (2) and (3)

above in order to remove load from the machine before starting maintenance jobs.

If the dobby is used, an unbalanced load may be applied to the machine depending upon

weaving structure. Under such a condition, if the power to the machine is accidentally cut

off due to lightning or any other power failure, then the machine may idle. It is

DANGEROUS.

4　Lubrication

(1) Make sure that the machine has stopped before greasing of the bearings or gears.

(2) Always wipe up oil spilled on the floor after supplying oil to the oil bath.

(3) Waste oil drained from the oil bath should be disposed of in containers specified by the plant.

S.　SAFETY

13

Even after the main switch (main circuit breaker CB1) on the control box is turned off, the

groupcontrol inverter power is fed to the terminal board (TB3) and the primary side of the magnet

switch (MSI). Take extra care.

Optional SC inverter power will be cut off if you turn off the main switch (CB1).

[1.4]　Rules for Operating or Checking the Electrical Devices

(1) All operating and checking jobs must be carried out by persons with appropriate special

qualifications (e.g., duly trained persons or electrical experts).

(2) Always turn off the main switch before opening the control box.

(3) After turning off the main switch, be sure to put up the warning tag "NEVER switch on" on the

main switch.

(4) Handle an electrical component or part only when no power is supplied to it. Note that the

primary side terminals of the main switch are applied with a voltage even when it is turned off.

(5) Voltage application may be needed for checking control system functions. Be especially careful

when conducting such a job.

(6) Use the measuring devices and tools, all kept in proper condition.

(7) When connecting the power supply to the loom, always connect the protective wire (green or

yellow/green spiral) first to the PE terminal. For disconnection, be sure to disconnect the

protective wire last of all.

(8) During electrical installation work, the observer responsible for security of the workers must

absolutely, without fail, attend at the field. The observer should be limited to someone with

know-how concerning electrical troubles.

(9) Never try to modify an electrical unit or device because it may cause a malfunction or accident.

If it is inevitable, please consult with us.

S.　SAFETY

14

(1) Make sure that the building has been

completed enough to protect the machines

and related facilities from rain and wind.

(2) Make sure that the width and height of the

carrying-in entrance are enough to carry in

the machines laid on a forklift horizontally.

NOTE: Refer to the illustrations below and

the

dimensions

given

on

the

next

page.

When carrying in those machines having a reed

space exceeding 280 cm, choose the capacity and

number of forklifts working together to ensure

safety without dropping or overturning.

1.　

PREPARATIONS

FOR

INTRODUCING

THE

MACHINE

[1]　

Building

　　

　　

1.　PREPARATIONS FOR INTRODUCING THE MACHINE

15

Crank Shedding Motion (CS, CM)

Nominal Reed

Space (cm)W(mm)

H (mm) D (mm)

φ800F φ930F φ1000F φ800F φ930F φ1000F

R/S 150 3007 1712 1842 1912 1700 1727 1822

190 3407 1712 1842 1912 1700 1727 1822

280 4307 1712 1842 1912 1700 1727 1822

Negative Tappet Cam Shedding Motion (TN)

Nominal Reed

Space (cm)W(mm)

H (mm) D (mm)

φ800F φ930F φ1000F φ800F φ930F φ1000F

R/S 150 3030 1750 1880 1950 1700 1727 1822

190 3430 1750 1880 1950 1700 1727 1822

230 3830 1750 1880 1950 1700 1727 1822

280 4330 1750 1880 1950 1700 1727 1822

Positive dobby (DE)

Nominal Reed

Space (cm)W(mm)

H (mm) D (mm)

φ800F φ930F φ1000F φ800F φ930F φ1000F

R/S 150 3512 1712 1842 1912 1700 1727 1822

190 3912 1712 1842 1912 1700 1727 1822

230 4312 1712 1842 1912 1700 1727 1822

280 4812 1712 1842 1912 1700 1727 1822

Positive Tappet Cam Shedding Motion (TP)

Nominal Reed

Space (cm)W(mm)

H (mm) D (mm)

φ800F φ930F φ1000F φ800F φ930F φ1000F

R/S 150 3325 1712 1842 1912 1700 1727 1822

190 3725 1712 1842 1912 1700 1727 1822

280 4625 1712 1842 1912 1700 1727 1822

340 5265 1712 1842 1912 1700 1727 1822

360 5515 1712 1842 1912 1700 1727 1822

390 5815 1712 1842 1912 1700 1727 1822

Electronic Shedding Motion (EC、ES、EB)

Nominal Reed

Space (cm)

W (mm) H (mm) D (mm)

EC ES EB φ800F φ930F φ1000F φ800F φ930F φ1000F

R/S 150 3474 3315 3007 1245 1375 1445 1700 1727 1822

190 3874 3715 3407 1245 1375 1445 1700 1727 1822

230 4274 4115 3807 1245 1375 1445 1700 1727 1822

NOTE: If the nominal reed space of your machine is not given in the above tables, obtain the width (W) in

the extrapolation or interpolation method.

NOTE: See page 96 in Chapter 4 for the approximate weight of the loom.

　

NOTE: If the nominal reed space of your machine is not given in the above tables, obtain the width (W) in

the extrapolation or interpolation method.

NOTE: See page 96 in Chapter 4 for the approximate weight of the loom.


16

Build up the foundation of the weaving machine

as shown at left. The structure of the foundation

is the same for all of the gluing installation

method, bolting installation method, and

on-the-floor installation.

ATTENTION

The foundation will greatly influence the degree

of vibration which the machine will cause.

For constructing the foundation, consult your

professional builder by referring to the drawings

submitted to you.

・The pressure-withstanding strength of

concrete should be 26.5 MPa (270 kgf/cm2) or

greater.

ATTENTION

The compressive strength shall be measured

according to JIS A 1108 (Method of Test for

Compressive Strength of Concrete).

If any other standard is applied, check

satisfaction of the value specified in the JIS

(Japanese Industrial Standard) by converting the

measured value.

[2]　

Foundation

Work

There are three types of installation methods for theweaving machines:

　・Gluing installation

　・Bolting installation

　・On-the-floor installation

The bolting installation method may be divided into either straight-bolting or L-bolting installation. This

manual describes the straight-bolting installation method.

If Sikadure (explained later) is selected as the bonding method, the steel packing is to be used for

leveling instead of felt packing.

[2.1]　Structure of Foundation


17

・The details of the iron net are shown at left.

Employ either the underground feeding system

((A) shown at left) or the pit feeding system (B)

depending upon your factory environments;

either one has advantages and disadvantages.

For factories which are to use the ever-popular

automatic delivery systems, the overhead feeding

system (suspension from the ceiling) may be

recommended in order to avoid interference with

wiring and piping of weaving machines.

Required wiring

Power routing for the weaving machine(s) and

inverter(s) (Other related wirings, e.g., for

monitoring and automatic delivery systems)

Required piping

Air

pipes

(Other

related

piping,

e.g.,

water

piping)

ATTENTION

Conduits for network cabling is necessary in

order to adopt the FACT (TOYOTA FACTORY

MANAGEMENT SYSTEM).

Take it into consideration from the plant

designing stage by referring to Appendix 4-2.

(1) Any irregularity ((A) shown at left) in the

floor levelness should be 5 mm or less for

the gluing installation and bolting

installation. It should be 3 mm or less for

the on-the-floor installation.

(2) Surface irregularities (B) of the floor where

the legs of the machine are to be positioned

should be 1 mm or less.

　

NOTE: These floor surface conditions will

influence the degree of machine

vibration regardless of the selected

installation method.

　　

[2.2]　Laying the Foundation for Wiring and Piping

[2.3]　Floor Surface Conditions

　　


18

IMPORTANT

If you are responsible for the preparation of the glue, prepare it before the start of installation

work.

IMPORTANT

If you are responsible for the preparation of the quick-hardening cement and straight bolts,

prepare them before the start of installation work, as well as preparing M16 nuts and 6-class

washers.

Sikadur

Product name: Sikadur 31 Adhesive (Epoxy type)

Manufacturer: Sika Ltd.

・Agent in Japan: Sika Japan Ltd., Nagoya branch　Tel: +81 52 218 8200

Fax: +81 52 218 8211

・Agents or Distributors in Asia:

Sika Hongkong, Ltd. Sika Korea Ltd.1507-11, 15/F, Block A

New Trade Plaza

STTL 372-6, On Ping Street

Shatin N. T.

HONG KONG

#304 KooSoo-ri

Miyang - Myeon

Ansong-City Kyunggi-do, 456-840

Korea (South)

Tel: +852 2 686 8108 (Nation code: 852) Tel: +82 31 677 5555

Fax: +852 2 645 3671 Fax: +82 31 677 5557

P.T. Sika Nusa Pratama Sika Kimia Sdn. Bhd.JL. Raya Cibinong - Bekasi

Km.20

Lismununggal, Cileungsi

Bogor 16820

Indonesia

Lot 689 Nilai

Industrial Estate

71800 Nilai, Negeri Sembilan

DK

Malaysia

Tel: +62 21 823 0025 Tel: +60 6799 1762

Fax: +62 21 8249 2525 Fax: +60 6799 1980

[2.4]　Preparing Glue or Quick-hardening Cement

■　For the gluing installation method

■　For the straight-bolting installation method

　

—— Reference ——

If you are responsible for the preparation of the glue (for the gluing installation method) or

quick-hardening cement (for the bolting installation method), refer to the recommended products

given below.

■　Glue for the gluing installation method


19

MetalsAdhesive strength

N/mm2 (kgf/cm2)Rupture

Iron 8.8 (90)

Sika primer 2CStainless 6.6 (67)

Aluminum 7.3 (74)

Copper 7.3 (74)

Compressive strength N/mm2 (kgf/cm2)

Type Standard type Delay type

Curing period/

temperature5 °C 10 °C 20 °C 20 °C 35 °C

1 day14.7

(150)

37.2

(380)

24.5

(250)

35.3

(360)

3 days34.3

(350)

39.2

(400)

47.0

(479)

32.3

(329)

46.1

(470)

7 days49.0

(500)

51.0

(520)

56.8

(579)

49.0

(500)

56.8

(579)

(1) Properties (according to the manufacturer's manual)

Tensile & shear strength(Adhesive strength test for metals)

・Conditions

　Surface treatment: Clean with lacquer thinner after polishing with #320 sandpaper

　Hardening time: 7 days at 20°C

・Test method: In accordance with JIS K6850

Compressive strength

・Conditions

　Hardening time:1, 3 and 7 days

　Temperature: 5, 10, 20 and 35°C

・Test method: In accordance with JIS K7208

Reference: If the room temperature is above 20°C, use the delay time to have sufficient allowance in

operation time.

　

　

(2) Execution method

Glue's curing period (guideline)/24 h or more

　

NOTE: If the curing temperature is low (approx. 5 °C), the curing period shall be 3 days or more

as a guideline.


20

Product name: Konishi E200

Manufacturer: Konishi Co., Ltd. http://www.bond.co.jp/

・Osaka Head Office

Address:

2-1-2 Hiranomachi Chuo-ku, Osaka (Sawanotsuru Bld.) 541-0046

Tel: +81 6 6228 2961

・Tokyo Head Office

Address:

2-3 Kanda Nishikicho Chiyoda-ku, Tokyo 101-0054

Tel: +81 3 5259 5737

Properties (according to the manufacturer's manual)

(1) Main ingredient: Base compound: Epoxy resin

Curing compounds: Polythiol, aliphatic polyamine

(2) Applications:

1) Jointing (jointing of new and old concrete, leveling, mortar screed jointing)

2) Anchor securing (securing machine bases, securing of various anchors including widening

and extending of facilities)

3) Injecting (injecting into moisture gaps in inverted construction)

(3) Mechanical properties

1) Compressive strength: 70MPa or higher

(Konishi's specification, in accordance with the compression test in JIS K7208-1995)

2) Modulus of elasticity against compression: 1500Mpa or higher


3) Bend strength: 40MPa or higher


4) Tensile strength: 20MPa or higher


Product name: Sikadur-42

Manufacturer: Sika Ltd. http://www.sika.com/

Sika Japan http://www.jpn.sika.com

・Head Office

Address:

1-1 Nagatoro, Hiratsuka, Kanagawa pref. 245-0021

Tel: +81 463 21 1101

Properties (according to the manufacturer's manual)

(1) Main ingredient: Base compound: Epoxy resin

Curing compound: Denatured aliphatic polyamine

Aggregate: Silica sand, inorganic pigments

(2) Applications:

1) Filling or repairing gaps and openings　

(Filling openings on materials such as concrete, mortar, stone, steel and wood)

2) Grout

(Securing objects such as anchor bolts, machine bases, guard rails and piping)

(3) Mechanical properties

1) Compressive strength: 65MPa or higher

(In accordance with the compression test in JIS K7208-1995)

2) Modulus of elasticity against compression: 6000Mpa or higher


3) Bend strength: 35MPa or higher


■　Quick-hardening cement for the bolting installation method

* If the quick-hardening cement listed above is not available, then check the above tables to find the

properties necessary for an equivalent adhesive.


21

For the straight-bolting installation method

(1) Positioning anchor bolts

Mark the positions of the anchor bolts

according to your floor plan. Make sure

that the bolt positions are within the

tolerance specified at left.

To obtain ℓ 3, use the following formula:

It is recommended that you use a gauge to

eliminate any positioning irregularities

between the weaving machines.

(2) Laying anchor bolts

1．According to the marks made in step

(1), drill anchor bolt holes with the

dimensions shown at left in the floor

with a special drill.

After drilling, clean the inside of those

holes by blowing air into them.

[2.5]　Marking on the Floor

(1) According to your floor plan specifying the layout and spaces between machines, mark one

reference line lengthwise and one crosswise.

(2) According to the machine dimension drawing, mark a front line, a rear line, and side lines for

the machine's feet parallel to the reference lines marked in step (1).

　

NOTES:

・If you have selected the gluing installation method, only the front and side lines are required.

・For the loom dimensions, refer to the drawing submitted from us.

[2.6]　Laying Anchor Bolts (Only for the bolting installation method)

　

　　

　　

　　


22

　 2．Prepare quick-hardening cement.

3．Moisten the inside of the holes with

water.

4．While bleeding air, pour quick-

hardening cement into each of the holes

and put an anchor bolt into it so that

the distance from the top of the anchor

bolt to the floor comes to "A" mm.

　・It is recommended that you make and

use a bolt support as shown at left in

order to prevent bolts from sinking into

the quickhardening cement from their

own weight before it hardens.

　・Pour quick-hardening cement until it

swells around bolts by approx. 5 mm

from the floor surface as shown left.

　 5．After 2 to 3 hours, remove the bolt

support and scrape the quick-hardening

cement swell with a knife or something

similar.

　　

　　


23

Dimensions L2 table

R/S 190 210 230 250

Ｌ2 3020 3220 3420 3620

Middle frame position

R/S - 190 210 230 250

Dimension A N/A 1396 1236 1494

Hole position of control box wires

Specifications Dimension B

Group inverter 395

Individual inverter 485

EXAMPLE: Floor Plan for Negative Cam Shedding

(For details, refer to the submitted drawings.)

Dimensions L3, L4 table

See other tables for other specifications of weft insertion motions.


24

Dimensions L2 table

R/S 150 170 190 210 230 250

Ｌ2 2597 2797 2997 3197 3397 3597


R/S - 250 280

Dimension A N/A 1592.5



Group inverter 395


EXAMPLE: Floor Plan for Crank Shedding





25

Dimensions L2 table (ES spec.)

R/S 150 170 190 210 230 250

Ｌ2 3064 3264 3464 3664 3864 4164



Group inverter 395


EXAMPLE: Floor Plan for Electronic Shedding Motion





26

Dimensions L2 table

(Stäubli 1781 as an example)

R/S 190 210 230 250 280 340

Ｌ2 3315 3515 3715 3915 4215 4865


R/S - 190 210 230 250 280 340

Dimension A N/A 1396 1236 1494 1592.51349.5

2384.5



Group inverter 395


EXAMPLE: Floor Plan for Positive Cam Shedding Motion





27

Dimensions L2 table

(Stäubli 3220/3260 as an example)

R/S 190 210 230 250

Ｌ2 3502 3702 3902 4102


R/S - 190 210 230 250

Dimension A N/A 1396 1236 1494



Group inverter 395


EXAMPLE: Floor Plan for Positive Dobby Shedding





28

ABSTandem

nozzles

Balloon

cover2C type 4C type 6C type

6C type,

space saving8C type

Applicable

Conical

tandem

N/A 1170 1275 2085 1385 2085

Applicable 1310 1415 2225 1525 2225

Multi

tandemApplicable 1427 1532 2342 1642 2342

EXAMPLE: Difference from Cheese Stands and Weft Insertion Motions


Dimensions L3 differ from the specifications of the weft insertion motions.


29

(1) Non-electronic shedding spec. ： 100 mA or more

(2) Electronic shedding spec. ： 200 mA or more

[3]　

Wiring

(for

looms

other

than

towel

weaving

machine)

[3.1]　In-plant Electric Facilities

The in-plant electric facilities shall be set up as specified below to make the most of the loom

performances while maintaining safety.

For details, consult with electric specialists or electric companies.

1　Power Requirements

The power supply voltage fluctuation shall be the contracted voltage ±5%, the frequency

fluctuation shall be 50/60 Hz ±2.5% and the voltage unbalance between phases shall be within 3%

continuously.

Be especially careful in the electric set-up work so that the supply voltage and frequency do not go

out of the specified ranges above even instantaneously.

2　Earth leakage breaker

Install an earth leakage breaker in the factory switchboard to prevent hazards which may be

occurred by leaked current.

Select an earth leakage breaker in consideration of the high frequency component generated by

the inverter/servo. Please consult with a specialized company.

The standard rating sensitivity current of an earth leakage breaker is shown below for reference.

However, the sensitivity current may change due to a wiring method and cable route length.

3　Class D grounding

Connect the grounding wires to the grounding terminal (marked PE) in the control box.

4　Capacities of non-fuse circuit breakers on switch board

When starting the loom in the delta mode, a rush current at approx. 20 times the motor rated

current flows instantaneously.

Select a circuit breaker whose rating is at least four times the nominal rated current of the motor

for installation on the switchboard.

If the capacity is insufficient, frequent tripping will occur.

5　Cable capacity selection

Frequent warp miss or loom malfuction may occur upon starting of the loom in the delta mode

because of instantaneous voltage drop.

Select a cable capacity so that the total of supply voltage fluctuation and the voltage drop by the

cable is within 10% of the contracted voltage.


30

6　Position for installation of phase compensation capacitor for slow inching specification

If the phase compensation capacitor is installed on the motor side of the loom, the inverter for slow

inching mechanism may be damaged.

Always install it on the power supply side of the inverter.

7　When wiring the loom power cable to the loom, it is recommended to lay them at least 200 mm away from each other to prevent noise generation.

If the inverter power line is connected to the loom using a cable consisting of three power wires

and the grounding wire, do not connect the grounding wire of the inverter cable to that of the

loom.

(Do not use a shielded cable as the inverter power cable. If shielding is required, use a metal

conduit.)

For grounding the loom, use the commercial power cable consisting of three power wires and one

grounding wire and connect the grounding cable of the commercial power cable or connect the

grounding wire provided separately from the power cable.

(Each of the loom and inverter, however, must be grounded according to [ 3 ] Class D grounding.)

8　Line filter installation to counteract radio noise

Listening to radio may become hard because of the influence of noise radiated from a loom that

uses an inverter or an AC servo motor. Insertion of a line filter in the power supply line from the

plant power distribution board to the inverter and loom is an effective countermeasure. Please

consult with an electrician for handling of the line filter.

9　Selection of wire type

Do not use aluminum wire to connect wire to the loom main circuit breaker (CB1) and the circuit

breaker for the loom inverter from the viewpoint to prevent the breaker from generating heat.

Using aluminum wire may cause bad connection to the breaker.


31

Non-fuse circuit breaker capacity

(rated current A)

Rough calculation formula

A ≧ Inverter rating

3 × Power supply voltage × 1.5

Inverter

rating

(kVA)

Power supply voltage

400 V or

above380-350 V 200/220V

15 40 40 75

25 60 75 125

30 75 100 150

[3.2]　Circuit Breakers

*1 Group inverter 2 is not installed in case of individual inverter specification. The group inverter,

group inverter breaker and related wiring shown here, therefore, are unnecessary.

1　Capacity of non-fuse circuit breaker (A) for group inverter

Provide one non-fuse circuit breaker (A) on the inlet side for each group inverter.

(1) The capacity of the non-fuse circuit breaker (A) on the inlet side of the group inverter shall be

determined according to 1.5 times the rating of the inverter used (inverter overload

endurance limit), the type and length of the cable to be used and the capacity of the power

supply transformer in the plant.

(2) The capacities of non-fuse circuit breakers obtained by the rough calculation formula. Please

check if the installed cable can be protected by the non-fuse circuit breaker selected according

to the following table:


32

Shedding motion other than electronic one

Motor capacity

(kW)



A = Motor rated current × 4

200/220V 350-415V 440-480V 550/575V

1.8 40

302.0

2.4 50

2.6

3.0 7540

3.5 100

4.0 100 50 40

5.0 100 75 50 40

7.5 － 100 75 50

Electronic shedding motion

Non-fuse breaker capacity (rated current A)

Motor capacity

(kW)Electronic shedding spec

Power supply voltage (V)

200 220 350 380 400 415 440 460

2.6

Shedding motion for 4 frames 75 60 40 40 40 40 30 30







No.

of

frames 4 6 8 10 12 14 16

Variable x 9500 11900 14000 16200 18500 21000 23900

2　Capacity of non-fuse breaker (B) for loom

(1) The non-fuse circuit breaker for loom is required to be installed on the switchboard for

disconnecting the power for loom maintenance, inspection or troubleshooting.

(2) It is recommended to provide one non-fuse circuit breaker for each weaving machine.

(3) Frequent tripping will occur if the capacity is insufficient.

(4) Determine the capacity of the non-fuse circuit breaker (B) according to the current flowing

through the weaving machine (see Subsect. 1.3.3, [2] and [3]), the types of installed power

transformer and power supply, and the wiring length.

(5) The capacities on non-fuse circuit breakers obtained by the rough calculation formula are

shown in the table below for reference. Please check if the installed cable can be protected by

the breaker selected according to the tables below.


A＝Motor rated current In × 2.5 ＋ x

3 × Power supply voltage (V) ×1.3


33

[3.3]　Cable Capacity

The cable capacity shall be determined according to the motor rated current with the supply voltage

fluctuation and voltage drop. Please consult with the person in charge of electricity or electric

specialists.

1　Supply voltage fluctuation and line voltage drop

(1) The voltage received by the loom drops due to supply voltage fluctuation and the voltage drop

at deltastarting by the cable resistance. Keep the total voltage drop within10% of the contract

voltage.

(2) The voltage drop by supply voltage fluctuation and the voltage drop by cables ① and ② can be

corrected by torque boost effect by the inverter. The maximum inverter voltage up ratio by

torque boosting is 15 to 20% of the standard inverter output (output voltage of the inverter in

loaded state). Therefore, the total voltage drop by supply voltage fluctuation and cables can be

allowed up to this correction limit.


34

No.

of

frames 4 6 8 10 12 14 16

Variable x 9500 11900 14000 16200 18500 21000 23900

Unit (A)

FrequencyMotor

(kW)


200V 220V 350V 380V 400V 440V 500V 550V 575V

50Hz

1.8 8.3 7.5 4.8 4.4 4.2 3.8 3.3 3 2.9

2.6 12 11 6.9 6.3 6 5.5 4.8 4.4 4.2

3.0 14 13 8.1 7.3 7 6.4 5.6 5.1 4.9

3.5 16 15 9.2 8.4 8 7.3 6.4 5.8 5.6

4.0 18 18 10.4 9.5 9 8.2 7.2 6.5 6.3

5.0 22 20 13 12 11 10 8.8 8 7.7

7.5 32 29 19 17 16 15 13 12 11

60 Hz

1.8 8.3 7.5 4.8 4.3 4.1 3.8 3.3 3 2.9

2.6 12 11 7 6.4 6.1 5.5 4.8 4.4 4.2

3.0 14 13 8.3 7.5 7.2 6.5 5.7 5.2 5

3.5 15 14 8.9 8.1 7.7 7 6.2 5.6 5.4

4.0 18 16 10.2 9.3 8.8 8 7 6.4 6.1

5.0 22 20 13 12 11 10 8.8 8 7.7

7.5 32 28 18 17 16 14 13 11 11

2　Current in each loom operation state

NOTE: The loom with an electronic shedding motion requires the additional current besides the

above current to operate the electronic shedding motor. The additionally required current

can be roughly calculated by the formula below:

x

3 × Power supply voltage (V) (A)

　

　

3　Motor rated current In


35

No.

of

frames 4 6 8 10 12 14 16

Variable x 9500 11900 14000 16200 18500 21000 23900

4　Cable selection

Select the cable according to steps [1], [2] and [3].

(1) Obtain the current flowing in cable ① between the circuit breaker on the switchboard and the

group inverter.

Select the cable according to the value obtained by the equation below.

Current value = inverter rating (kVA)× 1.51) × 0.22) × 1.73) / ( 3 × plant supply voltage [V])

[A]1) Inverter short-time overload capacity2) Inverter output voltage/motor rated voltage (Power supply voltage)3) Coefficient considering the loss by inverter high harmonic component, inverter input/

output conversion coefficient and margin

(2) Obtain the current flowing in the cable ② between group inverter and loom.

Obtain the current s at slow operation (3.4 × In) in [2].

The value in [3] is used for In.

　Current value = 3.4 × In

(3) Select cables ① and ② so that the total voltage drop by supply voltage fluctuation and by

cables ① and ② is within 15 - 20%.

(4) Obtain the current flowing in cable ③ between the circuit breaker on the switchboard and

loom.

Obtain the current s at delta starting (20 × In) in [2].

Use the value in [3] for the In.

　Current value = 20 × In

　

NOTE: The electronic shedding loom requires additional current to operate the electronic

shedding motor besides the starting current (20 × In) as the current used for the loom.

The following are the rough calculation formulas for obtaining the total current value.

Current value = 20 × In ＋ x

3 × Power supply voltage (V)

(5) Select cable ③ so that the total voltage drop by supply voltage fluctuation and by cable ③

becomes within 10%.


36

(Unit: mm2)

Power supply

voltageInverter model

Distance

10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m

200V

15 5.5 8 14 22 22 22 30 30 38 38

25 8 14 22 30 38 38 50 50 60 60

30 14 22 30 38 50 50 60 80 80 80

220V

15 3.5 8 14 14 22 22 30 30 30 38

25 5.5 14 22 22 30 38 38 50 50 60

30 8 22 22 30 38 50 60 60 80 80

350V

15 3.5 5.5 8 14 14 14 22 22 22 22

25 3.5 8 14 14 22 22 30 30 38 38

30 5.5 14 14 22 22 30 38 38 50 50

380V

15 3.5 5.5 8 14 14 14 14 22 22 22

25 3.5 8 14 14 22 22 22 30 30 38

30 5.5 14 14 22 22 30 30 38 38 50

400V

15 3.5 5.5 5.5 8 14 14 14 22 22 22

25 3.5 8 14 14 22 22 22 30 30 38

30 5.5 14 14 22 22 30 30 38 38 50

440V

15 3.5 3.5 5.5 8 14 14 14 14 22 22

25 3.5 5.5 14 14 14 22 22 22 30 30

30 5.5 8 14 22 22 22 30 30 38 38

[3.4]　Cable Capacity Calculation Examples (reference examples)

The available cable sizes and characteristics vary with the territory and country and with the

cabling method.

The cable capacity calculation examples described below should be used as reference examples.

[ 1 ] For cables ① and ② connecting the circuit breakers on the switchboard, group inverter(s) and

looms, calculations are made on assumption of the voltage drop by supply voltage fluctuation as

5%, voltage drop by cable ① as 1% and voltage drop by cable ② as 9%.

[ 2 ] The calculation for cable ② between group inverter and loom is an example when the inverter

and loom are directly connected.

[ 3 ] The calculation for cable ③ between the circuit breaker on the distribution board and the loom

assumes 5% voltage drop due to supply voltage fluctuation and 5% voltage drop through cable

③. (For other than electronic shedding motion)

[ 4 ] In case of the electronic shedding motion, Refer to table [4] for the cable ③ between the

distribution board breaker and the loom.

1　Selection of cable ① between circuit breaker on switchboard and group inverter

・These values are calculated on assumption of the supply voltage fluctuation as 5% and voltage

drop by cable as 1%.

・In an area where supply voltage to the switchboard is unstable, please calculate by setting the

voltage drop by cable separately.


37

(Unit: mm2)

Power supply

voltageMotor capacity

Distance

10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m

200V

1.8 3.5 5.5 8 10 14 16 22 22 25 25

2.6 4 8 14 16 22 22 25 35 35 35

3.0 5.5 10 14 22 22 25 35 35 38 50

3.5 5.5 10 16 22 25 35 35 38 50 50

4.0 5.5 14 16 22 30 35 38 50 50 60

5.0 8 14 22 30 35 50 50 60 70 70

7.5 10 22 30 38 50 60 70 70 80 80

220V

1.8 3.5 4 6 10 10 14 16 16 22 22

2.6 3.5 6 10 14 16 22 22 25 30 35

3.0 3.5 8 14 16 22 22 25 35 35 35

3.5 4 10 14 16 22 25 35 35 38 50

4.0 5.5 10 14 22 22 30 35 35 50 50

5.0 6 14 22 25 35 35 50 50 60 60

7.5 8 16 25 35 50 50 60 70 70 70

350V

1.8 3.5 3.5 3.5 3.5 5.5 5.5 6 8 8 10

2.6 3.5 3.5 3.5 5.5 6 8 10 10 14 14

3.0 3.5 3.5 5.5 5.5 8 10 10 14 14 14

3.5 3.5 3.5 5.5 8 8 10 14 14 16 16

4.0 3.5 3.5 5.5 8 10 10 14 14 16 22

5.0 3.5 5.5 8 10 14 14 16 22 22 22

7.5 3.5 8 10 14 16 22 25 30 35 35

380V

1.8 3.5 3.5 3.5 3.5 3.5 5.5 5.5 5.5 8 8

2.6 3.5 3.5 3.5 4 5.5 6 8 8 10 10

3.0 3.5 3.5 3.5 5.5 6 8 10 10 14 14

3.5 3.5 3.5 4 5.5 8 8 10 14 14 14

4.0 3.5 3.5 5.5 6 8 10 14 14 14 16

5.0 3.5 4 6 8 10 14 14 16 22 22

7.5 3.5 5.5 10 14 14 16 22 22 25 30

400V

1.8 3.5 3.5 3.5 3.5 3.5 4 5.5 5.5 6 8

2.6 3.5 3.5 3.5 4 5.5 5.5 8 8 10 10

3.0 3.5 3.5 3.5 5.5 5.5 8 8 10 10 14

3.5 3.5 3.5 4 5.5 6 8 10 10 14 14

4.0 3.5 3.5 4 5.5 8 10 10 14 14 14

5.0 3.5 4 5.5 8 10 14 14 16 16 22

7.5 3.5 5.5 8 10 14 16 22 22 22 25

415V

1.8 3.5 3.5 3.5 3.5 3.5 3.5 4 5.5 5.5 6

2.6 3.5 3.5 3.5 3.5 5.5 5.5 6 8 8 10

3.0 3.5 3.5 3.5 4 5.5 6 8 8 10 10

3.5 3.5 3.5 3.5 5.5 5.5 8 8 10 10 14

4.0 3.5 3.5 4 5.5 8 8 10 10 14 14

5.0 3.5 3.5 5.5 8 8 10 14 14 16 16

7.5 3.5 5.5 8 10 14 14 16 22 22 25

440V

1.8 3.5 3.5 3.5 3.5 3.5 3.5 4 5.5 5.5 5.5

2.6 3.5 3.5 3.5 3.5 4 5.5 5.5 6 8 8

3.0 3.5 3.5 3.5 3.5 5.5 5.5 6 8 8 10

3.5 3.5 3.5 3.5 4 5.5 6 8 8 10 10

4.0 3.5 3.5 3.5 5.5 6 8 8 10 10 14

5.0 3.5 3.5 5.5 6 8 10 10 14 14 16

7.5 3.5 4 6 10 10 14 16 16 22 22

2　Selection of cable ② between inverter and loom






38

(Unit: mm2)

Power supply


Distance

10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m

200V

1.8 5.5 10 14 22 25 30 35 38 50 50

2.6 8 14 22 25 35 50 50 60 60 70

3.0 8 16 25 35 38 50 60 60 70 70

3.5 10 22 25 35 50 60 60 70 70 80

4.0 10 22 35 38 50 60 70 70 80 80

5.0 14 25 35 50 60 70 80 80 120 120

7.5 16 35 50 70 80 80 120 #N/A #N/A #N/A

220V

1.8 4 8 14 16 22 25 30 35 35 38

2.6 5.5 14 16 22 30 35 38 50 50 60

3.0 8 14 22 25 35 38 50 60 60 70

3.5 8 16 22 35 35 50 60 60 70 70

4.0 8 16 25 35 38 50 60 70 70 70

5.0 10 22 35 50 60 60 70 80 80 100

7.5 14 30 50 60 70 80 80 120 120 #N/A

350V

1.8 3.5 3.5 5.5 6 8 10 14 14 14 16

2.6 3.5 5.5 8 10 14 14 16 22 22 22

3.0 3.5 5.5 8 10 14 16 22 22 22 25

3.5 3.5 5.5 10 14 14 22 22 22 25 30

4.0 3.5 6 10 14 16 22 22 25 30 35

5.0 4 8 14 16 22 25 30 35 35 50

7.5 6 14 22 25 30 35 50 50 60 60

380V

1.8 3.5 3.5 4 5.5 8 8 10 10 14 14

2.6 3.5 3.5 5.5 8 10 14 14 16 16 22

3.0 3.5 4 6 10 10 14 16 16 22 22

3.5 3.5 5.5 8 10 14 14 16 22 22 25

4.0 3.5 5.5 8 14 14 16 22 22 25 30

5.0 3.5 8 10 14 22 22 25 30 35 35

7.5 5.5 10 14 22 25 30 35 38 50 50

400V

1.8 3.5 3.5 3.5 5.5 6 8 10 10 14 14

2.6 3.5 3.5 5.5 8 10 10 14 14 16 16

3.0 3.5 4 6 8 10 14 14 16 22 22

3.5 3.5 5.5 8 10 14 14 16 22 22 22

4.0 3.5 5.5 8 10 14 16 22 22 22 25

5.0 3.5 8 10 14 16 22 22 25 30 35

7.5 5.5 10 14 22 22 25 35 35 38 50

415V

1.8 3.5 3.5 3.5 5.5 5.5 8 8 10 10 14

2.6 3.5 3.5 5.5 6 8 10 14 14 14 16

3.0 3.5 3.5 5.5 8 10 10 14 14 16 22

3.5 3.5 4 6 8 10 14 14 16 22 22

4.0 3.5 5.5 8 10 14 14 16 22 22 22

5.0 3.5 5.5 10 14 14 22 22 22 25 30

7.5 4 8 14 16 22 25 30 35 35 50

440V

1.8 3.5 3.5 3.5 4 5.5 6 8 8 10 10

2.6 3.5 3.5 4 5.5 8 10 10 14 14 14

3.0 3.5 3.5 5.5 8 8 10 14 14 14 16

3.5 3.5 3.5 5.5 8 10 14 14 14 16 22

4.0 3.5 4 6 8 10 14 14 16 22 22

5.0 3.5 5.5 8 10 14 16 22 22 25 25

7.5 3.5 8 14 14 22 22 25 30 35 35

3　Selection of cable ③ between circuit breaker on switchboard and loom






39

(Unit: mm2)

Power supply

voltage

Electronic

shedding spec

Distance

10 20 30 40 50 60 70 80 90 100

200V

4 8 14 22 30 35 50 50 60 60 70

8 8 14 22 30 35 50 60 60 70 70

12 14 16 22 35 38 50 60 60 70 70

16 16 16 25 35 50 50 60 70 70 80

220V

4 5.5 14 16 22 30 35 38 50 50 60

8 6 14 22 25 35 35 50 50 60 60

12 10 14 22 25 35 35 50 50 60 60

16 14 14 22 25 35 38 50 60 60 70

350V

4 3.5 5.5 8 10 14 14 16 22 22 22

8 3.5 5.5 8 10 14 14 16 22 22 25

12 5.5 5.5 8 10 14 16 22 22 22 25

16 6 6 8 10 14 16 22 22 25 25

380V

4 3.5 4 5.5 8 10 14 14 16 22 22

8 3.5 4 6 8 10 14 14 16 22 22

12 4 4 6 10 10 14 14 16 22 22

16 5.5 5.5 8 10 14 14 16 22 22 22

400V

4 3.5 3.5 5.5 8 10 14 14 14 16 22

8 3.5 4 5.5 8 10 14 14 16 16 22

12 3.5 4 6 8 10 14 14 16 22 22

16 5.5 5.5 6 8 10 14 14 16 22 22

415V

4 3.5 3.5 5.5 6 8 10 14 14 14 16

8 3.5 3.5 5.5 8 10 10 14 14 16 16

12 3.5 3.5 5.5 8 10 10 14 14 16 22

16 5.5 5.5 5.5 8 10 14 14 16 16 22

440V

4 3.5 3.5 5.5 5.5 8 10 10 14 14 14

8 3.5 3.5 5.5 6 8 10 10 14 14 16

12 3.5 3.5 5.5 6 8 10 14 14 14 16

16 4 4 5.5 8 8 10 14 14 16 16

4　Selection of cable ③ between circuit breaker on switchboard and electronic shedding loom

Main motor capacity: 2.6kW






40

[3.5]　Group Inverter

1　Determination of installing location

To minimize the voltage drop, select a location to minimize the distance between the inverter and

loom. (See page 41 for the capacity of the cable between the inverter and loom.)

2　Major specifications, dimensions and weight of inverter


41

3　Wiring method between inverter and loom

・ Bus type wiring is generally adopted for wiring between the inverter and looms. Please

consult with the electric specialist for the wiring work.

・ When the number of looms is small, each loom may be connected using one cable to the

inverter. Up to six looms, however, can be connected to each inverter, however, since three

pairs of three output terminals (TB) are provided and two cables can be connected to each

pair. When the number of looms exceeds six, use bus type cabling.

・ Up to 100 looms may be wired to a group inverter.

4　Cautions for wiring

(1) The allowable fluctuation of the input voltage to the inverter is ±10% of the rated voltage. If

this is not satisfied, install a transformer on the power supply side for regulation.

(2) Is a distributor is required for wiring from the inverter to looms, it shall be provided by the

customer.

(3) There are three output terminals in the inverter terminal block (TB). Up to two looms are

allowed to be connected to one terminal.


42

(1) Towel loom (electronic shedding spec.) ： 200 mA or more

(2) Towel

loom

(excluding

electronic

shedding

spec.) ： 100 mA or more

[3T]　

Wiring

(for

towel

weaving

machine)

NOTE: For the wiring of the looms other than the towel weaving machine with separate inverter, refer to

page 34.

[3T.1]　In-plant Electric Facilities

The in-plant electric facilities shall be set up as specified below to make the most of the loom

performances while maintaining safety.

For details, consult with electric specialists or electric companies.

1　Power Requirements

The power supply voltage fluctuation shall be the contracted voltage ±5%, the frequency

fluctuation shall be 50/60 Hz ±2.5% and the voltage unbalance between phases shall be within 3%

continuously.

Be especially careful in the electric set-up work so that the supply voltage and frequency do not go

out of the specified ranges above even instantaneously.

2　Earth leakage breaker

Install an earth leakage breaker in the factory switchboard to prevent hazards which may be

occurred by leaked current.

Select the earth leakage breaker in consideration of the high-frequency component generated by

the inverter or the servo motor. Please consult with a specialized company.

The standards of the rated sensitivity current of the earth leakage breaker as reference are given

below.

The sensitivity current is subject to change according to the cable connection method or the length

of the circuit.

3　Class grounding

Connect the grounding wires to the grounding terminal (marked PE) in the control box.

(Please consult with an electrician for grounding based on the construction standards.)

4　Capacities of non-fuse circuit breakers on switch board

When starting the towel loom (excluding electronic shedding spec.), approx. 6 to 7 times the motor

rated starting current flows spontaneously.

When starting the towel loom (electronic shedding spec.), approx. 20 times the motor rated

starting current flows spontaneously.

Insufficient capacity will cause tripping easily.

Refer to Subsection 1.3.2. for the capacity of non-fuse circuit breakers.


43

5　Cable size selection

Inferior quality of the fabric or frequent occurrence of the weft error may be caused at the time of

starting unless a cable of the appropriate capacity is selected. This is because the rush current at

starting the loom is very large.

Select a cable of appropriate capacity so that the electric current can flow for consecutive

operation and so that it retains the voltage drop by rush current within 5%.

6　Line filter installation to counteract radio noise

Listening to a radio may become hard because of the influence of noise radiated from a loom that

uses an inverter or an AC servo motor. Insertion of a line filter in the power supply line from the

plant power distribution board to the inverter and loom is an effective countermeasure. Please

consult with an electrician for handling of the line filter.

7　Selection of wire type

Do not use aluminum wire to connect wire to the loom main circuit breaker (CB1) from the

viewpoint to prevent the breaker from generating heat.

Using aluminum wire may cause a bad connection to the breaker.

[3T.2]　Circuit Breakers


44


Motor

capacityPower supply voltage

200V/220V 350V - 415V 440V 460V/480V

4kW 75A 40A 30A 30A

7.5kW 100A 50A 40A 40A


Motor capacity

(Kw)

Electronic

shedding spec.

Power supply voltage（V）

200 220 350 380 400 415 440 460 480

2.6

12 Frame spec. 125 125 75 75 60 60 60 50 50

14 Frame spec. 150 125 75 75 75 60 60 60 60

16 Frame spec. 150 125 100 75 75 75 75 60 60

No. of frames 12 14 16

Variable x 22000 24500 27400

1　Capacity of non-fuse breaker (A) for loom

(1) The non-fuse circuit breaker for loom is required to be installed on the switchboard for

disconnecting the power for loom maintenance, inspection or troubleshooting.

(2) It is recommended to provide one non-fuse circuit breaker for each loom.

(3) Frequent tripping will occur if the capacity is insufficient.

(4) Choose the capacity of the non-fuse circuit breaker in reference to the below table.

The installed cable must be protected by the non-fuse circuit breaker selected.

Note that these values do not include the power consumption of a jacquard.

　

　

Non-electronic shedding spec.

Electronic shedding spec.


A＝Motor rated current In × 2.5 ＋ x

3 × Power supply voltage (V) ×1.3


45

Motor rated current: In

MotorPower supply voltage

200V 220V 350V 380V 400V 415V 440V 460V 480V

4.0kW 20A 18A 11.2A 10A 10A 9.2A 9A 8.4A 8.4A

7.5kW 35A 32A 20A 18A 18A 17A 16A 15A 15A

[3T.3]　Cable Capacity

Select a cable of appropriate capacity that retains the voltage drop within 5% in consideration of the

current for each loom operation state and the cable resistance caused by the distance.

1　Current in the loom operation state (Excluding the jacguard)

Non-electronic shedding spec.

・ In addition to the above, a current of8270

3 × Power supply voltage (A) flows through the

machine excluding the power consumption of the motor.

2　Calculating current for cable selection

Calculation formula for the current of cable ① between circuit breaker on switchboard and loom

(excluding jacquard)

　Current at the start of the machine

　　＝8270

3 × Power supply voltage ＋Motor rated current × 7

　Current during operation

　　＝8270

3 × Power supply voltage ＋Motor rated current


46

Motor rated current: In

MotorPower supply voltage

200V 220V 350V 380V 400V 415V 440V 460V 480V

2.6kW 12 11 6.9 6.3 6 5.8 5.5 5.4 5.4

No. of frames 12 14 16

Variable x 22000 24500 27400

3　Current in the loom operating condition


For the electronic shedding spec., the electronic shedding current is added in addition to above.

The added current can be roughly calculated by the formula below:

x

3 × Power supply voltage (V) (A)

　

　

4　Calculation formula for selecting a cable type

Current calculation formula on cable (1) between the switchboard breaker and the loom

Current at starting

　＝x

3 × Power supply voltage ＋Motor rated current × 20

Current during operation

　＝x

3 × Power supply voltage ＋Motor rated current


47

(Unit: mm2)

Power supply


Distance

10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m

200V4kW 5.5 10 16 22 25 35 35 50 50 60

7.5kW 10 16 25 35 50 60 60 70 70 80

220V4kW 5.5 10 14 22 22 25 35 35 38 50

7.5kW 10 14 22 30 35 50 50 60 70 70

350V4kW 3.5 3.5 5.5 8 8 10 14 14 16 16

7.5kW 4 5.5 8 14 14 16 22 22 25 30

380V4kW 3.5 3.5 4 5.5 8 10 10 14 14 14

7.5kW 3.5 5.5 8 10 14 14 16 22 22 25

400V4kW 3.5 3.5 4 5.5 6 8 10 10 14 14

7.5kW 3.5 4 6 10 10 14 16 16 22 22

415V4kW 3.5 3.5 3.5 5.5 6 8 8 10 10 14

7.5kW 3.5 4 6 8 10 14 14 16 22 22

440V4kW 3.5 3.5 3.5 5.5 5.5 8 8 10 10 10

7.5kW 3.5 3.5 5.5 8 10 10 14 14 16 22

460V4kW 3.5 3.5 3.5 4 5.5 5.5 8 8 10 10

7.5kW 3.5 3.5 5.5 8 8 10 14 14 14 16

480V4kW 3.5 3.5 3.5 3.5 5.5 5.5 6 8 8 10

7.5kW 3.5 3.5 5.5 6 8 10 10 14 14 16

[3T.4]　Cable Capacity Calculation Examples (reference examples)

The available cable sizes and characteristics vary with the territory and country and with the

cabling method.

The cable capacity described below should be regarded as reference examples.

* These sample calculations are made on the assumption of the voltage drop by cable ① as 5%

(excluding the jacquard).

1　Cable size on cable ① between the switchboard breaker and the loom

Non-electronic shedding spec


48

(Unit: mm2)

Power supply

voltage

Electronic

shedding spec.

Wiring distance

10 20 30 40 50 60 70 80 90 100

200V12 14 16 25 35 38 50 60 60 70 70

16 22 22 25 35 50 50 60 70 70 80

220V12 14 14 22 25 355 38 50 60 60 70

16 16 16 22 25 38 80 80 60 60 70

350V12 5.5 5.5 8 10 14 16 22 22 25 25

16 8 8 8 14 14 16 22 22 25 30

380V12 5.5 5.5 8 10 14 14 16 22 22 22

16 6 6 8 10 14 14 16 22 22 22

400V12 5.5 5.5 6 8 10 14 14 16 22 22

16 6 6 8 10 10 14 16 16 22 22

415V12 4 4 5.5 8 10 14 14 14 16 22

16 5.5 5.5 5.5 8 10 14 14 16 2 22

440V12 4 4 5.5 8 8 10 14 14 14 16

16 5.5 5.5 5.5 8 10 10 14 14 16 16

460V12 3.5 3.5 5.5 6 8 10 10 14 14 16

16 5.5 5.5 5.5 8 10 10 14 14 16 16

480V12 3.5 3.5 4 5.5 8 10 10 14 14 14

16 5.5 5.5 5.5 6 8 10 10 14 14 16

2　Cable size on cable ① between the switchboard breaker and the loom


Main motor capacity　2.6 kw


49

・Dry Dew point (under compression): 10°C

Use a dryer to remove moisture.

・Not contaminated (oilless) Oil content: 0.1 ppm or less

Please inquire of the compressor manufacturer about the details.

・Constant pressure Compressor discharge pressure:

0.8 to 1.0 MPa G (8 to 10 kg/cm2 G)

Recommended input pressure to the weaving machine:

Maximum working pressure +0.1 MPa G (+1 kg/cm2 G)

The minimum required input pressure to the loom depends on the

reed space, revolving speed and weft yarn type.

(The pressure loss will increase if the pipe is small in diameter or

has many bends.)

Pressure variation:

Nominal pressure ±0.05 MPa G (±0.5 kg/cm2 G)

(The compressor capacity is given in Subsection 1.4.2.)

・ Suitable temperature It is desirable that the temperature of the discharged air be almost

equal to that of the weaving room.

[4]　

Air

Compressor

[4.1]　Compressed-air Requirements for Air Jet Weaving Machines and Precautions for Piping

Compressed air to be used for weft insertion should satisfy the following requirements in order to

prevent weft miss and ensure fabric quality:

・ Precautions for piping

1．When using sealing liquid such as screw locking agent, ensure that the liquid does not run

out. Wipe it away if it runs out.

2．When using pipe-washing agent, be sure to wash the pipes with water after neutralization

washing.

3．When using the spray type leak detection agent to prevent leakage from piping, ensure that

the agent does not adhere to the resin or rubber parts because it may adversely affect such

parts. Also when applying rust-preventive agent to the pipes, ensure that the agent does not

adhere to the resin or rubber parts.


50

TypeScrew

compressor Turbo

compressorReciprocating

compressorSpecifications

Compressed

air Small

pressure

fluctuationNo

fluctuation

(oil-free)

Wide

range

from

low

to

high

pressure

Vibration Weak Weak Strong

Noise Soft Soft Loud

Efficiency High High High

to

low

SizeSmall

(mainly,

less

than

150

kw)

Medium

to

large

(150

kw

and

over)Small

to

medium

Maintenance

cost Middle Low High

Continuous

operation Good Most

suitable Not

good

Where Q ： Total air volume required (m3/h (ANR)) (*1)

Qo：Air consumption per weaving machine (m3/h (ANR))

Kz： Piping loss rate (0.2, taking into account air leakage from pipes)

No：Number of weaving machines

[4.2]　Choice of Air Compressor Type and the Number of Compressors

It is recommended that you use a screw or turbo compressor for air jet weaving machines which

features small pressure fluctuation, weak vibration, soft noise, high compression efficiency and low

discharge temperature. (See the comparison table below.)

1　Calculating air volume required for weaving machines

Q = Qo × (1 + Kz) × No (m3/h (ANR))... ①

・ The required air quantity marked with (*1) varies depending upon the reed space, machine

speed, and weft number count. If you inform TOYODA of your fabric style and machine speed,

we will furnish you with the air volume right for you.

・ The above air volume and air consumption should be measured at 20°C under 0.10 MPa (1.03

kgf/cm2).


51

Where a ：Compressor load factor

This should be 0.85 or less for reciprocating compressors and 0.90 or less for

screw or turbo compressors.

Q ：Total air volume required (m3/h (ANR))

Qc：Air discharge volume per compressor (m3/h (ANR)) (*2)

Nc：Number of compressors required

(1) For reciprocating compressors

0.85 × Qc × Nc ≥ Q

Then, Qc × Nc ≥ Q

0.85 or Qc × Nc ≥ 1.412 × Qo × No

(2) For screw or turbo compressors

0.9 × Qc × Nc ≥ Q

Then, Qc × Nc ≥ Q 0.9 or Qc × Nc ≥ 1.333 × Qo × No

2　Calculating the capacity and the number of air compressors required

a = Q

Qc × Nc .................... ②

According to formulas ① and ② ,

・ For the air discharge volume per compressor marked with (*2), refer to the compressor

manufacturers' catalogues. The major compressors are given on page 56.

・ It is recommended that a spare compressor be prepared in order to prevent your production

from becoming interrupted at the time of compressor breakdown or periodical maintenance.

・ For controlling the compressor capacity, be sure to choose an automatic unloader type.


52

Where W : Total power consumption (kWH)

W1 :Motor power consumption (kWH per motor) =

Motor rated output

Motor efficiency

(The motor efficiency can be assumed as 0.9.)

a : Compressor load factor

(0.85 or less for reciprocating compressors, 0.90 or less for screw or turbo

compressors)

b : Power ratio of unloaded compressor with relative to full-loaded compressor

0.20 to 0.25 for reciprocating compressors

0.20 to 0.40 for screw compressors

(The power ratio varies depending upon the compressor model and capacity

control method.)

0.20 to 0.25 for turbo compressors

n : Number of compressors

B' : Power ratio with relative to the ratio of the required air volume and

compressor discharge volume

3　Calculating the approximate power consumption of compressor

(1) For oil-free reciprocating compressors, oil-free screw compressors, and turbo compressors

　　W = W1 × n × [a + b (1 – a)]

(2) For oil injection screw compressors

　　W = W1 × n × B'

(3) For compressors with their shaft input power known

　　W = Shaft input power × n [a + b (1 – a)]

　 NOTE: Generally, the power consumption W1 should be calculated with the shaft power not

with the motor output.

To obtain approximate power consumption, however, calculate it with the motor

output since the shaft power and motor efficiency vary depending upon motor models

Reference: Compressor manufacturers and types


53

Manufacturer Lubricated type Unlubricated type

IHI － TX, TRA, TRE, and TRX types

Atlas GA type ZR type

Kobe Steel HM type ALE type

Hitachi S and M types DSP and SDS types

Mitsui Seiki Z and ZV types ZUV type

Contact of compressor manufacturer

IHI

[Domestic]

Corporate Management Division

IHI Compressor and Machinery Co., Ltd., Nagoya Office

30 Honjintori, 2 Chome

Nakamura-ku, Nagoya, Aichi Pref.

453-0041 Japan

TEL: 052-482-3301 FAX: 052-482-3302

[Overseas]

Compressor Marketing & Sales Group

IHI Corporation

Toyosu IHI Building 1-1, Toyosu 3-chome, Koto-ku, Tokyo

135-8701 Japan

TEL: 03-6204-7328 FAX: 03-6204-8710

[HP]

Japan: http://www.ihi.co.jp/compressor/

Overseas: http://www.ihi.co.jp/compressor/en/


54

[4.3]　Layout Examples of Air Compressors and Related Equipment

1　Turbo type oil-free compressor

The filter is unnecessary for most oil-free compressors. However, consider the necessity of the

filter depending on the environment of installation.

2　Packaged oil-free screw (dry screw) compressor

3　Packaged oil injection screw compressor

4　Oil-free reciprocating compressor

NOTES:

・The compressors and dryers in the above examples should have fly/fleece prevention filters.

・For the detailed installation procedures of the compressors and related equipment, follow the

instructions provided by the relevant compressor maker.


55

[4.4]　Piping

1　Compressor room

(1) Always mount a bypass at the filter position. This allows you to change the filter element

without stopping the compressor.

(2) When using an oil injection compressor "OSP type", mount differential pressure gauges before

and after the oil removing filter for early detection of a clogged filter.

(3) Be sure to provide a drain port at a pipe rising portion.

2　Weaving room

(1) The main pipe in the weaving room should be looped. Connect the main pipe and each

weaving machine with a branch pipe.


56

Nominal diameterOD (mm) ID (mm) Section (cm2)

A B

6 1/8 10.5 6.5 0.33

8 1/4 13.8 9.2 0.66

10 3/8 17.3 12.7 1.27

15 1/2 21.7 16.1 2.04

20 3/4 27.2 21.6 3.66

25 1 34.0 27.6 5.98

32 11/4 42.7 35.7 10.01

40 11/2 48.6 41.6 13.59

50 2 60.5 52.9 21.98

65 21/2 76.3 67.9 36.21

80 3 89.1 80.7 51.15

90 31/2 101.6 93.2 68.22

100 4 114.3 105.3 87.09

125 5 139.8 130.8 134.37

150 6 165.2 155.2 189.18

175 7 190.7 180.1 254.75

200 8 216.3 204.7 329.10

225 9 241.8 229.4 413.31

250 10 267.4 254.2 507.51

300 12 318.5 304.7 729.18

(2) Determine the pipe diameter according to the airflow rate.

Criteria for determining the main pipe diameter

・240 m3/H ............21/2 B (65A) or over

・480 m3/H ............3B (80A) or over

・12,000 m3/H .......5B (125A) or over

(3) Use the rustproof pipes (for example, galvanized ones).

3　Mounting drain ports and valves

(1) Mount drain ports at the pipe rising positions, and at intervals of 20 m on the main pipe.

(2) Mount valves at the delivery port of the air dryer and the branching portions.

4　Other precautions

(1) When laying pipes, clean them so that no oil or chips remain inside.

(2) After piping work and before connecting the pipes to the weaving machines, blow air into the

pipes to clean them.

(3) Check the pipeline for air leakage. If any leakage is detected, repair the pipeline.

(4) Lay pipes with downward inclination in the flowing direction so as not to cause drain

accumulation in the piping.


57

Yarn typeSpun yarn Filament yarn

Conditions

Temperature 25 to 30°C 20 to 25°C

Humidity (RH) 65 to 75% 65 to 70%

Temperature, humidity, and air circulation Controllable Controllable

Air circulation frequency (No. of times/hour) 12 to 15 12 to 15

Location Luminance (lux)

Warping 150 to 300

Sizing 150 to 300

Winder 150 to 300

Drawing-in through healds 300 to 750

Weaving room 300 to 750

Maintenance room 150 to 300

Cloth inspection 750 to 1500

Office 750 to 1500

[5]　

Other

Equipment

[5.1]　Temperature Control and Air Conditioning

To maintain the optimum operating condition of the weaving machine, it is important to keep the

weaving room at a constant temperature and humidity.

It is recommended that the weaving room be conditioned as listed below. The optimum temperature

and humidity will vary depending upon yarn type and sizing.

If the room temperature drops excessively in winter, sizing agent on warp will become hard, causing

frequent warp breaks, weft miss due to shed opening failure, and other weaving problems.

[5.2]　Lighting

The table below is based on the JIS. The luminance should be constant and measured at a height of

85 cm above the floor.

[5.3]　Prevention from Fly, Fleece, and Dust

The mechanisms of the weaving machine are covered to prevent fly, fleece, and dust from getting

into them. Such covering is, however, not sufficient, so the weaving factory itself should have some

preventions against fly, fleece, and dust.

It is recommended that your factory be equipped with an overhead cleaner (travelling cleaner) and

automatic dust collector which can:

a) Reduce the cost of cleaning by hand, with a minimum of machine stops for cleaning.

b) Decrease weft misses, weft breaks, warp breaks due to fly, fleece, or dust.

c) Decrease the weaving-in problems of fly, fleece, and waste yarn.

d) Improve the working environment.


58

Group inverter

(magnet contactor)

SC inverter

(relay)Name Operation

MSL CRLContactor or relay for commercial

power supplyON during continuous running

MSF CRFContactor or relay for forward

revolution

ON during forward revolution

(normal running or slow inching)

MSR Note 1 Contactor for reverse revolutionDuring reverse revolution (slow

inching)

Towel potion inverter (relay) Name Operation

CRY Normal running relay ON during normal running

CRF Forward slow inching relay ON during forward slow inching

CRR Reverse slow inching relay ON during reverse slow inching

[5.4]　Separate Take-up Motion

Connect the power supply to the separate take-up motion as shown below. Since this is a typical

example, however, it is not always applicable to all separate take-up motions.

1　Power supply to separate take-up motion

When operating the separate take-up motion using the plant power supply, it may be connected to

the secondary side of the no-fuse circuit breaker (NF1) in the loom control box, but limit the power

consumption by the separate take-up motion to within 500 W. If it requires more than 500 W,

provide a separate power supply. To supply the plant power from the loom control box, use

terminals R1, S1 and T1.

If 200 VAC is required as the power supply to the separate take-up motion, use terminals U2, V2

and W2 in the loom control box. The power consumption by the separate take-up motion in this

case should also be limited to within 500 W.

2　Running/forward signal

If the run, forward and reverse signals from the loom are required, use the magnet contactor

auxiliary or relay terminals.

(1) Other than towel loom

Note 1: In the SC inverter type model, the reverse signal relay is not provided in the loom control

box.

If the reverse signal is necessary, replace it with a combination of the CRF (forward slow

inching relay) and MSY(normal running contactor).

Connect the normally close contact (closed in other than forward revolution) of CRF with

the normally open contact (closed in other than normal running) of MSY in series to

replace the reverse signal.

(2) Towel loom


59

[CN36 pin assignment]

Pin No. Signal name Pin No. Signal name

A1 B1

A2 Separate take-up, stop input (92) B2

A3 Separate take-up, stop input (E) B3

3　Loom stop signal from separate take-up motion

To stop the loom by an instruction from the separate take-up motion, provide a relay contact

(normally open) at the separate take-up motion, and connect it to pin Nos. 92 and E of CN36 (see

below for pin assignment) of the loom I/O-1 board.

Since the connector with a cable is delivered in case of the separate take-up (preparation type),

perform cable-to-cable connection.


60

A : Has experience with similar machines and can be relied on to a certain extent.

B : Can do simple jobs under instructions given by a worker of level A.

C : Can assist workers of level A or B.

Electric : Can repair weaving machines.

Tools Quantity Tools Quantity

Hammer, 1-2 pound 2 Forklift, 3.5t or more 1

Bar, 1.5 m ×φ40 2 Hand lift, 3t or more 2

Large pincers 2 Small jack, 1.5t or more 2

Wooden bar, 120 mm square 4/machine

Name Quantity Specifications

Vinyl (rubber) hose Approx. 1 m/machineInside Dia.: φ20, Pressure-withstanding

strength: 1.18 MPa (12 kg/cm2) or more

Hose band 1/machine

Hose nipple 1/machine For φ20, PT 1/2

Stop valve* 1/machine PT 1/2

Nipple* 1/machine PT 1/2

* When preparing these parts, refer to "Air Piping Work to the Weaving Machine" given in

Subsection 2.2.4, [ 2 ].

2.　

INSTALLATION

WORK

[1]　

Preparations

for

Installation

[1.1]　Arrangement of Workers

Arrange the workers for installation by referring to the table given below. This table is an example

for installing 50 weaving machines, starting on April 1 and setting-up four machines a day.

* Worker's skill level

[1.2]　Setting-up of Unpacking and Carrying-in Tools

Set up unpacking and carrying-in tools listed below.

NOTE: The leveller will be prepared by Toyoda service personnel.

[1.3]　Preparation of Piping

Prepare pipes and related parts listed below.

2.　INSTALLATION WORK

61

Before starting the carrying-in and installation of weaving machines, be sure to read Chapter S.

SAFETY and observe the instructions given there.

[2]　

Installation

Work

[2.1]　Positioning of the Weaving Machine

Before carrying the weaving machine into the weaving room, it is recommended that you remove the

wooden frame (located at the bottom of the weaving machine) outside the weaving room. This is

because it may be impossible to remove the lower wooden frame due to the limited space inside the

room.

Lift down the weaving machine from the forklift at the specified installation position and place the

machine with bars exactly according to the reference lines and markings on the floor.

[2.2]　Jobs to be Done before Securing the Legs of the Weaving Machine

(1) Remove the rust-preventive paper and plastic bags from the machine.

(2) Take off the cloth roller and dropper bar from the machine and carry them to the specified place.

(3) Install

the

beam

curtain,

warp

arrangement

springs,

and

signal

indicator

to

the

specified

positions.

(4) Wipe off oil from the back roller, easing roller, dropper box, and side frames.

(5) Check the quantity of the accessories according to the packing list.


62

ATTENTIONWhen a weaving machine exposed to cold

outdoor atmosphere is brought into a warm

indoor location, all machine parts will be

covered with condensed water droplets. This

condensation will cause immediate rust due to

oxidation of the metal surfaces.

Bring the machine indoors and leave it in its

packed state for a while until it reaches room

temperature.

・When two or more workers are to handle

a job, they must always communicate

through words or gestures before

starting the job.

・When inserting fiber packings between

the machine's feet and the floor or

removing them during levelling work,

never let fingers get beneath the feet.

(1) Place levels 3 on side frames 1 and

rocking shaft 2 as shown at left, and

check the levelness of the machine

lengthwise and crosswise.

The allowable irregularity in the

machine levelness is one increment of the

level and no warp is allowed.

TIP: An irregularity of 0.5 mm/m in the

levelness will register as one increment

off in the level window.

　

[2.3]　Installation

1　Levelling the weaving machine

　　

　　


63

(2) If the machine is not level, make it level

with packings.

Listed below are packings available for

weaving machines.

Type Thickness Application

Felt

packing2 mm

To compensate for the

surface irregularity of the

floor.

(This type should be used

only for the gluing

installation method using

Araldite.)

Steel

packing

1, 2, or

3.2 mm

Correct loom leveling using

a combination of three

packing types (in

thickness).

　 Insert felt packings or steel packings

under the bottom of the side frames' feet

as shown at left.

　4: Felt packing

　5: Steel packing

　6: Side frame's foot

NOTE: Felt packing 4 should always be

the bottom layer of the packings.

NOTE: Packings should be exactly under

the bottom of the side frames' feed

as shown at left.

In

the

case

of

aeropad

specification

a. No frame feet

Bond the steel packing on the side frame's

feet using Araldite.

b. With frame feet

Insert the steel packing between the side

frame's and frame feet, and fix both feet by

tightening the bolt.

When inserting packings beneath the

machine, lift up the weaving machine with

small jacks 7 which should be applied to front

cloth rail 8 and back cloth rail 9 as shown at

left.

　　

　　


64

As shown below, install the cheese stand base

to the floor with roundhead bolts according to

your floor plan.

2　Installing the cheese stand base

1)　Installation with roundhead bolts

　　

2)　Installation with anchor bolts

As shown below, install the cheese stand base to the floor with anchor bolts according to your

floor plan.

3)　Mounting the cheese stand

Refer to the "JAT810 INSTRUCTION MANUAL", Chapter 5, Section 5.1.


65

When moving the EDP stand, have at least two workers handle the job. It is very HEAVY.

Using a cart will make this job easier.

As shown in the left figure, the EDP inverter

circuit board is installed in the EDP stand.

Connect the wire and optical fiber cable that

extends from the main unit of the weaving

machine.

(1) EDP.POWER wire

Connect the EDP.POWER of the relay

connector with the EDP.POWER wire that

extends from the main unit of the machine

around the location near the wire

insertion hole at the bottom of the EDP

stand.

(2) EDP.DC wire

Connect the EDP.DC of the relay

connector with the EDP.DC wire that

extends from the main unit around the

location near the wire insertion hole at the

bottom of the EDP stand.

3　Installing the EDP stand

1)　Positioning the EDP stand

Refer to JAT810 INSTRUCTION MANUAL, Chapter 5 Picking Motion.

2)　Wiring and piping between the main unit and EDP stand

　　


66

(3) Optical fiber cable

Connect the optical fiber cable with the

optical fiber connector that is on the EDP

inverter circuit board.

　

ATTENTION

　Take care not to bend the optical fiber

cable at sharp angles because it is

easily affected by bending stress.

Destination of the optical fiber cable connection

No. of colorsEDP inverter

circuit boardOptical fiber connector

Optical fiber cable extending from the

main unit (Specified in tube band)

2-colorEI1 PJ1 receiving EDP1 →

PJ2 transmitting EDP1/2 ←

4-colorEI1 PJ1 receiving EDP1 →

EI2 PJ2 transmitting EDP1/2 ←

6-color

EI1 PJ1 receiving EDP1 →



PJ2 transmitting EDP3/4 ←

8-color





　　

(4) EDP push valves piping

Connect the air hose piping that extends from the main unit at the relay area near the

insertion hole at the bottom of the EDP stand.


67

4　Control box support

(1) Attach the support to the control box stay so that the door can be opened/closed smoothly.

The components of the support differ depending on the frame foot/no frame foot as shown

below.


68

(2) Method of adjustment

1．Loosen nut A at the mounting area on

the back of the control box [Fig. 1].

　 2．Loosen nut 4, and turn the jack bolt 4

until the upper surface of the main

unit and the upper surface of the door

are nearly aligned [Figs. 2 and 3].

　 3．Fasten nut A in (1) above and nut 4 of

the jack bolt.

　　

　　

　　


69

Before starting the job below, make sure that

the main switch on the workshop switchboard

is turned OFF and then put up the "DON'T

TURN THE SWITCH ON" notice tag on the main

switch.

(1) Connect the grounding wire to the

grounding terminal 3 (marked PE) in the

lower part of the control box.

(2) Connect the main power line with the main

circuit breaker (CB1) 1 located inside the

main control box.

(3) When the group inverter is to be used,

connect the inverter power line with the

breaker 2 (CB4) located inside the main

control box.

NOTE: This wiring work is not necessary

for individual inverters (SC

inverters) since it has been finished

before delivery from the factory.

Just proceed to (1) and (2) above.

(1) Before connecting the pipe with the

weaving machine, blow the pipe out with

compressed air to clean out the inside.

(2) Connect pipe 2 with pipe joint 1 of the

machine.

(3) Turn cock 3 downwards to supply

compressed air to the machine.

　

NOTE: For the detailed air piping work

to the weaving machine, refer to

the next page.

[2.4]　Wiring and Piping to Weaving Machines

1　Wiring

2　Piping


70

IMPORTANTShown below are air pipes and related parts required before the start of the trial run.

Parts A to E below are to be prepared by you for air piping.

③ Grease nipples are provided in two types for ø19.5 and ø25.5. The sizes of parts to be

prepared vary with the type. Please check the type used on your machine and order the parts by

referring to the parts list below.

φ19.5 → For a reed space of 250 cm or less

φ25.5 → For a reed space of 280 cm or more/jaquard opening (full reed space)

(The above may be inapplicable in case of a special specification.)

Parts Name φ19.5 (PT1/2) φ25.5 (PT3/4)

A Hose band －－

BVinyl (rubber) hose, inside dia. φ20 and pressure-

withstanding

strenght

of

1.18

MPa

(12kg/cm2)

or

more

Inside dia.

φ19.0

Inside dia.

φ25.0

C Hose nipple φ19.5（PT1/2） φ25.5（PT3/4）

D Stop valve PT1/2 PT3/4

E Nipple PT1/2 PT3/4

—— Reference —— Air Piping Work to the Weaving Machine


71

・When two or more workers are to handle a job, they must always communicate through words or

gestures before starting the job.

・When handling warp beams, their flanges and gears, take extra care. They are HEAVY.

(1) [At the warp beam gear side]

Determine distance L1 according to

warp beam flange diameter 2a and warp

beam diameter 1b by referring to the

table below.

(Reference)

Yarn Beam Holder：T5 typeWarp

beam

flange

dia.

2a

(mm)

Warp

beam

dia.

1b

(mm)L1 (mm)

φ800φ150 215

φ178 215

φ930, 940 φ178 230 *1

φ1000 φ178 230

*1:

At using the warp beam φ800, 215

Yarn Beam Holder：T6 typeWarp

beam

flange

dia.

2a

(mm)

Warp

beam

dia.

1b

(mm)L1 (mm)

φ800φ150

230

φ178

φ930, 940φ178

φ214

φ1000φ178

φ214

(2) Make a mark on warp beam 1 "L1" mm

3.　

PREPARATIONS

FOR

WEAVING

START-UP

[1]　

Warp-related

Preparations

In the preparations described in this section, the following accessories should be prepared by either your

company or Toyoda depending upon the specifications. Be sure to check which is responsible for those

preparations. If you are responsible, prepare them before the weaving start-up.

□ Warp beam(s) with flange and bearings

□ Droppers

□ Healds

□ Heald frame

□ Reed

□ Winder for leno selvage yarn

[1.1]　Mounting the Warp Beam(s) and Procuring Warp Yarn

1　Mounting a single beam

3.　PREPARATIONS FOR WEAVING START-UP

72

away from its left end 1a with a felt pen

or something similar.

NOTE: Refer to the submitted drawing

for detailed dimensions.

(3) Screw-in warp beam flange 2 over warp

beam 1 in the direction of "A" until the

flange's inside becomes aligned with the

mark made in step (2).

・For making the screwing-in job

easier, apply grease or oil to the

threaded section.

(4) Set warp beam gear 4 onto warp beam 1

and turn gear 4 so that eight bolt holes

provided in gear 4 become aligned with

those in beam 1, and the three bolt holes

in gear 4 come close to those in flange 2.

(5) Secure warp beam gear 4 to warp beam 1

with eight bolts. Then, turn gear 4 until

three large bolt holes in gear 4 become

aligned with those in flange 2 and secure

gear 4 to flange 2 with three bolts.

(6) [Opposite to the warp beam gear side]

Make a mark on warp beam 1 "Drawing-

in width" 0 +10 mm away from the mark

made in step (2).

　

ATTENTION

　Listed below are minimum effective

drawing-in widths relative to the

nominal reed spaces.

Nominal reed space

R/S (cm)

Min. effective

drawing-in width (cm)

150Nominal reed space

– 60 cm

170Nominal reed space

– 70 cm190

210

230

Nominal reed space

– 80 cm

250

280

336

340

360

390

　　


73

(7) Screw-in warp beam flange 3 over warp

beam 1 in the direction of "B" until the

flange's inside becomes aligned with the


NOTE: For making the screwing-in job

easier, apply grease or oil to the

threaded section.

(8) Screw-in flange ring 5 also over warp

beam 1 in the direction of "B" until the

gap from the end of flange 3 to that of

ring 5 comes to 3 to 5 mm.

Align bolt holes provided in ring 5 with

those in flange 3, then tighten bolts.

(For LH beam)

(1) [Opposite to the warp beam gear side]

Set center flange 6 onto warp beam 7 and

set center flange ring 5 so that bolt holes

provided in ring 5 become aligned with

those in flange 6 and beam 7.

(2) Secure ring 5 to beam 7 with six bolts.

Then, align bolt holes in flange 6 with

those in ring 5 and tighten four bolts.

(3) [At the warp beam gear side]

Install side flange 4, beam gear 2, and

beam gear ring 8 onto warp beam 7 as

shown at left.

Bolts 1 and 3 should be temporarily

tightened.

(4) Turn beam gear 2 by hand so that the

distance from the end of center flange

ring 5 to the machined inside end of gear

2 comes to (Drawing- in width ÷ 2 + 50)

mm, then secure gear 2 with bolts 1.

(5) Turn side flange 4 by hand so that the

inside end of center flange 6 to that of

flange 4 comes to (Drawing-in width ÷ 2 –

55) mm, then secure flange 4 with bolts

3.

　

NOTE: At the RH side of the let-off

motion, install the RH beam in

the same manner as for the LH

beam.

　

　　

2　Mounting twin beams

　

　　

　　


74

R/S LO

DW : Drawing-in width

LO : Genuine Toyota standard twin beam dimensions

280 1960

336 2240

340 2310

360 2410

390 2560

Unit: mm

Dimension A~ R/S336 : 510-(R/S-DW)/2

R/S340 ～ : 510-(R/S+50-DW)/2

Dimension B~ R/S336 : 381-(R/S-DW)/2

R/S340 ～ : 381-(R/S+50-DW)/2

(1) [Mounting a yarn beam gear side]

Make a mark on 90 mm away from the

side of yarn beam 1 with a felt pen or

something similar.

(2) Screw-in yarn beam flange 2 from the

direction of "A" until the flange's inside

becomes aligned with the mark made in

step (1).

• For making the screwing-in job easier,

apply

grease

or

oil

to

the

threaded

section.

3　Mounting a grand beam of towel loom

　　


75

(3) Set yarn beam gear 4 onto yarn beam 1

and turn yarn gear 4 so that the holes

(eight large holes) provided in yarn beam

gear 4 become aligned with those in yarn

beam 1. Then, turn yarn beam flange 2

until the bolt holes (three small holes) on

yarn beam gear 4 become aligned with

those in yarn beam flange 2.

(4) Tighten yarn beam 1 and yarn beam gear

4 with eight bolts. Then, align the bolt

holes between yarn beam flange 2 and

yarn beam gear 4, and tighten three bolt

7 sequentially.

(5) [Mounting a flange opposite to the yarn

beam gear side]

Make a mark on 1 mm drawing-in width

on the right side from the mark made in

step (1).

　

NOTE: The minimum effective

drawing-in width relative to each

drawing-in width is -70 cm.


direction of "B" until inside the yarn

beam flange 3 becomes aligned with the


・For making the screwing-in job easier,

apply grease or oil to the threaded

section.

(7) Screw-in flange ring 5 also in the

direction of "B" until the gap from the

end of yarn beam flange 3 to that of

flange ring 5 comes to 3 to 5 cm. Align

bolt holes provided in flange ring 5 with

those in yarn beam flange 3, then tighten

bolts.

　　

　　


76


Make a mark on 117.5 mm away from

the side a of yarn beam 1 with a felt pen

or something similar.



becomes aligned with the mark made in

step (1). For making the screwing-in job

easier, apply grease or oil to the threaded

section.

(3) Screw-in ring 5 onto yarn beam 1, and

set yarn beam flange 2 with three fixing

bolts (82101-10035).


so that the holes (eight large holes)

provided in yarn beam gear 4 become

aligned with those in yarn beam 1. Then,

tighten yarn beam 1 and yarn beam gear

4 with eight bolt 8 to align the bolt holes

of yarn beam gear 4.

*For X = 106 to 155 mm, use the

mounting method described above.


Make a mark on the position to fix a

flange with a felt pen or something

similar.



becomes aligned with the mark.

• For making the screwing-in job easier,

apply

grease

or

oil

to

the

threaded

section.


and turn yarn beam gear 4 so that the

holes (eight large holes) provided in yarn


beam 1.

Turn yarn beam flange 2 until the bolt

holes (three small holes) on yarn beam


beam flange 2.

(4) Tighten yarn beam 1 and yarn beam

4　Mounting a pile beam of towel loom

1)　Standard case (using a flange ring)

　　

2)　Not using a flange ring (setting a left flange to the left side)


77

gear 4 with eight bolt 8. Then, align the

bolt holes between yarn beam flange 2

and yarn beam gear 4, and tighten three

bolt 7 (82101-10045 or 82101-10055)

evenly and sequentially.

(5) [Mounting a flange opposite to the yarn

beam gear side]

Make a mark on "Drawing-in width – (2

× Selvage textural width) + 0 to 10 mm"

= L mm from the right side on the mark

made in step (1).

　

NOTE:　The minimum effective

drawing-in width relative to

each drawing-in width is -70 cm.


direction of "B" until inside yarn beam

flange 3 becomes aligned with the mark

made in step (5).

・For making the screwing-in job easier,

apply grease or oil to the threaded

section.

(7) Screw-in flange ring 5 also in the

direction of "B" until the gap from the

end of yarn beam flange 3 to that of

flange ring 5 comes to 3 to 5 cm. Align

bolt holes provided in flange ring 5 with

those in yarn beam flange 3, then tighten

bolts.

　　

　　


78

1 : Warp beam gear

2 : Warp beam flange

A : Warp letting-off direction

B : Warp taking-up direction in sizing

ATTENTIONBe careful with the warp taking-up direction

when sizing.

5　Winding warp onto a warp beam

6　Preparing warp yarn

When preparing warp yarn, be sure to observe the following:

(1) Procure warp yarn and complete warp preparatory processes according to the schedule

without any delay.

It seems that some new weaving plants cannot set warp beams due to the late arrival of warp

or late preparatory

processes (such as winder, warper, sizing, and drawing-in processes), even after the

completion of machine installation and trial run.

(2) Procure warp yarn with the following quality:

• Knotless

• Proper fluff binding

(3) Wind warp yarn on warp beams so that

・the winding hardness is proper and

・the winding shapes are uniform at both ends

High-density carded yarn, T/C yarns, and acrylic yarns are difficult to handle. Since the fabric

quality and　operating efficiency will be directly affected by the quality of the preparatory

processes, be sure to complete　optimum preparatory processes for the quick and effective

start-up of weaving.


79

IMPORTANTCheck whether you are responsible for the preparation of the droppers. If you are responsible,

prepare them before the start-up of weaving.

Closed

Uster

type

Type Closed

type Open

type

DimensionsUster

type Barber

Colman

typeFor

Uster

pinning

machines

Length

(L)

Thickness 0.15

mm

0.2

mm

0.3

mm

0.4

mm

0.5

mm

0.15

mm

0.2

mm

0.3

mm

0.4

mm

0.15

mm

0.2

mm

0.3

mmWidth

(W)

145

mm

(8)

mm 0.92

g 1.2

g 1.9

g 0.9

g 1.2

g 1.9

g 0.79

g 1.1

g 1.7

g

9 1.06 1.06 1.4

11 1.42 1.9 2.9 3.9 4.75 1.3 1.9 2.9 3.9 1.7 2.5

165

mm

(8) 1.2 1.9

9

11 2.2 3.3 4.4 1.9 2.9

Warp yarn

Dropper

weight (g)Tex count Meter count

English number count

Silk denierCotton yarn

Worsted

yarnWool yarn Linen yarn

Up to 1190 or

greater

54 or

greaterUp to 100 Up to 1.0

11 to 18 56 to 90 32 to 5450 or

greater

90 or

greater100 to 160 1.0 to 1.5

18 to 25 40 to 56 24 to 32 36 to 50 65 to 90 160 to 220 1.5 to 2.0

25 to 32 32 to 40 18 to 24 28 to 36 52 to 65 220 to 290 2.0 to 2.5

32 to 40 25 to 32 15 to 18 22 to 2848 or

greater42 to 52 290 to 360 2.5 to 3.0

40 to 72 14 to 25 8 to 15 12 to 22 27 to 48 23 to 42 360 to 660 3.0 to 4.0

72 to 100 8 to 14 5 to 8 Up to 12 16 to 27 14 to 23 660 or greater 4.0 to 6.0

[1.2]　Preparing the Droppers

–– Reference –– Choosing the Droppers

　　The following data comes from the ISO and Groz-Beckert catalogues.

(1) Dropper types

(2) Warp yarn count and suitable dropper weight


80

IMPORTANTCheck whether you are responsible for the preparation of the healds. If you are responsible, prepare

them before the start-up of weaving.

Flat

steel

heald Overall

lengthMax.

densityYarn

number

count

Type

Cross

section

size

Mail

sizeEnd-loop

spacing

(L

mm)

Si m

pl ex

Dupl ex

Optimum

yarn

count

Metric

count

Tex

count

English

number

count

Denier

Cotton Silk

mm mm 280 300 302 330 /Cm /Cm Nm Tt NeB Td

GROBEXO 5.5×0.30 6.5×1.8 8 – 14 72 8 650

5.5×0.23

*1 5.5×1.2 20 34 30 20 300

5.5×0.25 *1 20

5.5×0.30 18

GROBIM

O

5.5×0.30 5.5×1.2 1534

or

greater

30

or

less

20

or

greater

300

or

less

(From

the

Grob

catalogue))

NOTES:1．Healds with the dimensions marked with *1 should be used only when warp density is

extremely high.

2．For filament yarn or high-speed operation, the end-loop spacing "L" should be 280 mm.

3．Healds with end-loop spacing of 300 mm may not be available in the market.

4．For weaving with spun yarn, healds with end-loop spacing of 302 mm or 330 mm are

recommended for tappet cam shedding or dobby shedding, respectively.

5．Mails are provided in the center of the overall length. The sectional dimensions of the

carrying rods (carrier rods) are 9.5 × 1.5 mm.

[1.3]　Preparing the Healds

–– Reference –– Steel Heald Specifications

(1) Flat steel heald (reinforced type)


81

Riderless, flat heald Overall lengthMax.

densityYarn number count

Remark

s

Cross

section

size

Mail size End-loop spacing (L mm)

Si m

plex

Duplex

Optimum yarn count

Silk

denier

Metri c

count

Tex

count

English number

count

Cot

tonWool

Lin

en

mm mm(11")

280

(12")

306

(13")

331

(14")

356

(15")

382

(16")

407

(17")

433/Cm /Cm Nm Tt NeB NeK NeL Td

5.5×0.23

○

14 2030 20 30 3005.5×0.25 5.5×1.2 34

5.5×0.3 12 18

5.5×0.23

○

85.5×0.25 6.5×1.8

5.5×0.3 7

14 72 8 12 6505.5×0.38 7

6/7.2×0.3 6.5×1.8 14

5.5×0.3○

4250 2 4 ―8×2.5 4

5.5×0.38 4

NOTES:1．The Grob inox is made of stainless strip steel; the Grob extra is made of hardened &

tempered spring strip steel.

2．Duomix = solomix + intermix

3．The sectional dimensions of the carrying rods are 16 × 2.1 mm.

4．For air jet weaving machines, the end-loop spacing should be 331 mm (13").

(2) J-type riderless, flat steel heald (Uster auto drawing-in type)


82

Riderless, flat heald Overall lengthMax.

densityYarn number count

Cross

section

size

Mail size End-loop spacing (L mm)

Si m

plex

Duplex

Optimum yarn count

Silk

denier

Metri c

count

Tex

count English number

count

Cotton Wool Linen

mm mm(11")

280

(12")

306

(13")

331

(14")

356

(15")

382

(16")

407

(17")

433/Cm /Cm Nm Tt NeB NeK NeL Td

5.5×0.23

○

14 2030 20 30 3005.5×0.25 5.5×1.2 34

5.5×0.8 12 18

5.5×0.23

○

85.5×0.25 6.5×1.8

5.5×0.3 7

14 72 8 12 6505.5×0.38 7

6/7.2×0.3 6.5×1.8 14

5.5×0.3○

4250 2 4 ―8×0.25 4

5.5×0.38 4

5.5×0.23

○

12

250 2 4 ―※8×3.8 4

5.5×0.25 12

5.5×0.3 10

5.5×0.38 8

NOTES:1．Mail sizes marked with an asterisk (*) are for Barber Colman type; other mail sizes are

for Uster type.

2．The sectional dimensions of the carrying rods are 22 × 1.7 mm.

3．For air jet weaving machines, the end-loop spacing should be 331 mm (13").

(3) C-type riderless, steel heald


83

IMPORTANTCheck whether you are responsible for the preparation of the reed and prepare it before the

start-up to weaving.

・ When you handle a reed, ensure to pay

extra attention not to hit something to the

reed.

Metals such as scissors or tools in

particular are hard enough to damage the

dents just by touching it slightly.

・ Hold the reed in its top and bottom channel

parts so as not to touch the dents.

・ When storing the reed, pack it in the

cardboard

case

provided

by

the

manufacturer,

and place it so that the bottom channel

comes downward.

Do not stack it since the reed may be

damaged.

・ Pack or unpack the cardboard case

containing the reed on the workbench.

・ Draw a warp through section "A" as shown

in the figure.

・ Drawing a warp through the area near the

coil spring (Section "B" in the figure) may

cause the coarse reed marks.

・ Abrasion of the reed caused by long-term

use may generate a warp break or fluff of

the yarn.

Confirm there is no abrasion before use.

[1.4]　Preparing the Reed and Drawing in Warp

NOTES ON REED HANDLING

The reed is an important component in running the machine and retaining the fabric quality.

Handle the reed carefully so as not to cause a flaw, dirt, or deformation such as coarse weaving that

may damage the fabric quality or the operation of the machine.

　　

1　Drawing-in width

Refer to 4.1 JAT810 Technical Information for the nominal reed spaces and effective drawing-in

widths.


84

Draw in warp from the left end of the reed (from

the main nozzle side) regardless of the

drawing-in width.

Drawing-in from the 2nd dent

As shown at left, start drawing at the 2nd dent

from the left.

The 1st dent should be reserved for the

following purposes:

・When you use additional yarn, draw

additional yarn and leno yarn through the

1st dent.

・When not using additional yarn, you may

draw leno yarn through the 1st dent since

this sometimes will improve selvage

firmness.

To improve selvage firmness, draw a few more

warps through the 2nd dent than those to be

drawn through other dents. However, drawing

so many warps through the 2nd dent will rather

make selvages poor or result in increased weft

misses (loop).

2　Drawing-in procedure

–– Reference ––

　　For details, refer to the drawings submitted.

NOTE: Tapered reed with LH inlet is recommended for 4- to 6-color picking specifications.


85

This device binds two leno yarns with every

weft yarn at each side of the fabric to produce

a firm selvage construction which will not

become loose if weft yarns are cut.

(1) Leno yarn (which you should procure)

Yarn specifications for leno yarn

• Yarn type:

Same type of two-ply yarn as that for

the ground warp

・Yarn number count:

Almost the same as for the ground

warp or slightly greater than that for

the ground warp

・Primary twist: Z-twist

Final twist: S-twist

If using the same type of yarn as for

ground warp results in insufficient

strength of the fullleno selvage, it is

recommended that finished yarn of 50d

or 75d be used, provided that no problem

occurs in the subsequent processes.

(2) Leno yarn winder (Check whether you

are responsible for the preparation of

this.)

For the handling manner of the winder,

refer to the manufacturer's manual.

　 ATTENTION

　When using the special winder for

winding yarn onto the leno bobbin, do

not increase the yarn takeup tension

excessively by the winder, particularly

when filament yarn is used. Otherwise,

the leno bobbin may be deformed,

making it impossible to set the bobbin

into the bobbin holder.

[1.5]　Preparations for Selvage Construction

1　For Full-leno Selvage Device

　　

　

　　

　　


86

(3) How to draw in leno yarn through the

reed

・At the left side of the machine

Draw in leno yarns ○ through the

same dent through which the leftmost

ground yarns △ are drawn.

If selvages are not well tightened , you

may draw in leno yarns through an

empty dent adjacent to the one

through which the leftmost ground

yarns △ are drawn.

・At the right side of the machine

Draw in leno yarns ○ through an

empty dent adjacent to the one

through which the rightmost ground

yarns △ are drawn.

　

Yarn type symbols:

　○ Leno yarn

　△ Ground yarn

　▲ Waste-selvage yarn

　　


87

This device binds four leno yarns with every

weft yarn at each side of the fabric to produce

a firmer selvage construction than that

produced by the fullleno selvage device,

which will not become loose if weft yarns are

cut.

Half-leno selvages should be produced for

low-density fabrics.

(1) Leno yarn (which you should procure)

・Yarn specifications:

High-quality yarn having less fluff or

burl

As fine and strong as possible

This is because the 4-leno weave

contains many cross sections so that

produced selvages become thick easily.

・Yarn type: Two-ply (or three-ply),

machine sewing thread (parched yarn)

Yarn number count: Higher than that

of ground warp

(Ex.) When the ground warp is C40S',

use leno yarn of C100/2S'.

・If using the same type of yarn as for

ground warp may result in insufficient

strength of half-leno selvages or if the

above specified yarn is not available,

select yarn having similar physical

properties as those specified.

When using the different types of yarn

from the ground warp, make sure that

no problem occurs in the subsequent

processes.

2　For Half-leno Selvage Device (Klöcker)

　　

　

　　


88

(2) Half-leno selvage device (Toyoda is

responsible

for the preparation of this.)

Install the half-leno selvage device before

the start-up of weaving. (It is packed

separately from the weaving machine

proper.)

・The half-leno selvage device should be

installed to the 1st and 2nd heald

frames.

・The standard structure of a half-leno

selvage is a plain weave. However, it

may be a mat weave depending upon

the fabric structure.

(3) How to draw in leno yarn through the

reed

Draw in leno yarns through the reed in

the same manner as for the full-leno

selvage device.

NOTE: For details, refer to the JAT810

INSTRUCTION MANUAL,

Chapter 8, Section 8.2.

　　


89

This device generally feeds two additional

warps into selvages in order to get cleaner

warp separation at the left end of fabrics (at

the weft insertion side), thereby improving

selvage firmness.

(1) Additional yarn (which you should

procure)


Yarn having the same yarn number

count as the ground warp or

Two-ply or three-ply yarn having a

slightly greater number count

CM80/2's, PC90/2's, and CM120/2's as

standard

　・Cheese shape

Additional-yarn cheeses should have

the dimensions and shape of either (A)

or (B) shown at left.

3　For warp-addition device

　　

　

　　

　　


90

(2) How to draw in additional yarn through

the reed

– At the left side of the machine

Thread two additional yarns ● and

leno yarns ○ through an empty dent

adjacent to the one through which the

leftmost ground yarns △ are drawn.

– At the right side of the machine

Thread two additional yarns ● and

leno yarns ○ through an empty dent

adjacent to the one through which the

rightmost ground yarns △ are drawn.

　

Yarn type symbols:

　○ Leno yarn

　△ Ground yarn

　▲ Waste-selvage yarn

　● Additional yarn

　　


91

(1) Waste-selvage yarn

(which you should procure)


EC23/2's as standard

EC24/2's or EC25/2's may be used

provided that they have a strength

equivalent to 23/2's or higher.

　・Cheese shape

Shown at left are the recommended

dimensions and shape of a waste-

selvage cheese.

[1.6]　Preparations for Waste Selvage Device

This device binds weft jetted up to the outside of the right edge of the woven fabric with several

yarns fed from the waste-selvage cheeses (in the stand-equipped type) or with several warps (in the

non-stand type) in order to apply tension to the weft, for an ideal selvage construction.

1　For stand-equipped type (which has a waste-selvage bobbin stand)

　　

　　


92

(2) How to draw in waste-selvage yarn

through the reed

You may draw in waste-selvage yarn in

either of the following ways:

(A) : Standard

　Draw in waste-selvage yarn so that the

leftmost waste-selvage yarn is 1-3 mm

("b" shown at left) away from the right

edge of weft feeler WF1.

(B) : Special

　To make the waste selvage section as

short as possible, draw in waste-

selvage yarn so that the leftmost

waste-selvage yarn is 5 mm ("a" shown

at left) away from the rightmost

ground yarn and the rightmost

waste-selvage yarn is 1-3 mm "b" away

from the left edge of weft feeler WF1.

　

NOTE: This special way may cause a

false stop (even if a weft comes in

normally, the weft feeler stops the

machine). Therefore, use the

standard way (A) except for

specially required cases.

　　


93

(1) Number of waste-selvage yarns: 12 yarns

as standard

If a waste-selvage yarn break occurs

frequently, use 16 yarns; if it does not

occur, you may use 8 yarns.

(2) How to draw in yarns through the healds

Draw two, three, or four yarns through

the 1st, 2nd, 3rd, and 4th heald frames in

this order.

NOTE: If a waste-selvage yarn break

occurs frequently, draw in yarns

through the 1st, 2nd, 1st, and 2nd

heald frames in this order. Do not

use the 3rd and 4th heald frames.

(3) How to draw in yarns through the reed

Draw in yarns through the reed in the

same manner as for the stand-equipped

type.

For 8 yarns : 2 ends/dent



2　For non-stand type (which has no waste-selvage bobbin stand)

This non-stand type uses ground warps of yarn number count 7's to 40's.

　　


94

Weft cone (cheese) specifications

Traverse width 6" or less (For fine count yarns, 3" recommended)

Winding angle 3°30' for thick count yarns and 5° 57' for medium and fine count yarns

Winding hardness 50°to 70°(A cheese may collapse if the shore hardness or winding hardness is low.)

Twill angle The smaller the better (Be careful of yarns sticking among themselves.)

Knot Knotless yarns are better (below 3 mm).

Ribbon winding Apply the ribbon brake.

Bobbin diameter For T/C45, 300 to 330 mm max. recommended

Steam set Effective in some cases.

Number of winds The more the better

Yarn

type

Pure

cotton

yarnPolyester

yarn

blended

with

35%

cotton

Yarn

spun

by

ring

spinning

(Carded

yarn)

Yarn

spun

by

ring

spinning

(Combed

yarn)

Yarn

spun

by

open

end

spinning

Yarn

count

(Ne)10 16 20 30 40 30 40 50 60 80 20 34 45

Item

Yarn

count

fluctuation

rate0

or

less 2.0 2.0 2.0 2.5 1.8 1.8 1.9 1.9 1.9 1.6 1.9 1.9%

Single

ply

yarn

strength840

or

more 10.2 400 260 200 290 215 200 170 130 310 380 270g

Strength

fluctuation

rate8.8

or

less 10.2 10.3 10.7 11.0 8.4 9.5 9.3 10.2 10.9 9.9 10.2 11.9%

Minimum

single

ply

yarn

strength 705

or

more 420 335 220 165 245 175 165 140 110 260 310 215

g

Elasticity % 7.4

or

more 6.7 6.5 6.0 5.7 6.0 5.6 5.6 5.5 5.5 7.3 10.5 9.5

U

% 10.8

or

less 12.5 13.5 15.1 15.7 10.8 12.0 12.1 12.8 13.2 11.8 11.9 13.0

CV

% 13.5

or

less 15.6 16.9 18.9 19.6 13.5 15.0 15.1 16.0 16.5 14.8 14.9 16.3

IPI

value/

1000

m

Thin 1

or

less 4 30 60 80 6 15 20 30 60 4 6 20

Thick 20

or

less 100 240 450 520 50 105 60 95 160 20 55 100

NeP 20

or

less 100 200 420 600 50 90 85 115 140 310 80 110

[2]　

Weft-related

Preparations

(Mainly

Spun

Yarn)

[2.1]　Preparing Weft Yarn and Cheeses

Air jet weaving machines whose weft insertion speed exceeds 1500 m per minute (Reed space: 190

cm, machine speed: 790 rpm) require not only high-quality weft yarn but also high-quality weft

cones (cheeses). This is because the smooth release of weft from cheeses becomes more important as

the machine speed increases.

Generally, in those machines with a single drum, the weft insertion speed of 1100 m per minute

(Reed space: 190 cm, machine speed: 580 rpm) is the limit at which cheeses can follow the weft

releasing speed.

To weave at a speed of 1100 m per minute or more, it is recommended that double drums (2-color

drums) be employed for reducing the weft releasing speed on each drum to half.

––– Reference –––– Physical properties required for weft yarn (Minimum values)


95

Type of lubricants Oil Grease

SymbolA B C D E F

Manufacturer

MobilVacuoline528

(VG150)

・Mobilgear

600XP150

・SHC629

・Spartan EP150

・Mobil 600W

Cylinder Oil

・Mobil 600W Super

Cylinder Oil

・Mobil Vacuoline

546

Mobilux EP2 Mobilux EP0

Shell

・Tellus Oil S2M

C150

・Morlina S2

BA150

・Omala S2 G150

・Omala S4 GX150

・Morlina S1B 460

・Valvata Oils J460

・Alvania Grease

S2

・Sunlight

Grease 2

・Gadus S2

VV2202

・Alvania EPR0

・Sunlight

Grease 0

・Gadus S2

VV2200

JX

Nippon

Oil

and

Energy

・FBK Oil RO150

・Super Malpas

DX150

BONNOC M150Worm Gear Lub

380(N)

・Epinoc Grease

AP (N)2

・Multinoc

Grease 2

Epinoc Grease

AP(N)0

Idemitsu OilDaphne Mechanic

Oil 150

・Daphne Super

Gear Oil 150

・Daphne Gear Oil

150

Daphne Worm Gear

Oil 460

・Daphne Eponex

EP No.2

・Daphne Eponex

SR No.2

・Daphne Eponex

EP No.0

・Daphne Eponex

SR No.0

COSMO

Lubricants

COSMO ALLPUS

150COSMO Gear SE150 COSMO Gear W460

COSMO Grease

Dynamax No.2

COSMO

Centralized

Grease No.2

Kyodo Oil Unilube DL No.2 Unilube DL No.0 GC Grease350

Yanase OilYS Hightac

HG150

YS Hightac Eco Gear

150YS

High

Lub

MGN10Multi EP Grease

No.2

Multi EP Grease

No.0

British Petroleum

(BP)

BPENEGOL

HLP150

・BPENAGOL

GR-XP150

・Castrol ALPHASP150

・Castrol ALPHASYN

EP150

Castrol TRIBOL

800/460

・BPENEGOL

MM-EP2

・Castrol

Spheerol EPL2

・BPENEGOL

MM-EP0

・Castrol

Spheerol EPL0

TOTAL Sarkan C150・CARTER EP150

・CARTER SH150CYLC460 Multis EP2 Multis EP0

Always use the recommended lubricants in the table above.

[3]　

Lubricants,

Cleaning

Oil,

and

Sealant

[3.1]　Lubricants

1　Lubricant Symbols and the Corresponding Products Commercially Available

NOTES:

(1) See the explanation on later pages for the portions corresponding to the use codes.

(2) Refer to the instruction manual supplied from each manufacturer for lubrication of the dobby,

positive dobby and jacquard machine.


96

Lubricant

typeSymbol Lubricating points Quantity per machine

Oil

A*1 RH cutter and full-leno selvage device*2 A little

B

Tappet cam box (spun cam specification)*3

LH & RH tucker housings9ℓ

Tappet cam box (filament cam specification)*3

LH & RH tucker housings12ℓ

Grease D Bearings, gears, and springs A little

Lubricant

typeSymbol Lubricating points Quantity per machine

OilA RH cutter and full-leno selvage device*1 A little

B RH & LH tucker housings*2 A little

Grease D Bearings and gears A little

タイプオイル量 (L)

1671 7

1681 7

1781 10

　

2　Lubricants Required Before Trial Run

1)　For negative tappet cam shedding motion

*1 For applying oil A, use the oiler (Tool No. 695) provided with the machine.

*2 No oiling is required for the half-leno selvage device.

*3 The tappet cam box and the tucker housings (if the tuck-in device is selected) are not

lubricated when the machine leaves Toyoda. Apply oil before the trial run.

2)　For positive cam shedding motion

Refer to the instruction manual provided by the respective manufacturer for type or the

quantity of the oil that is applied to the positive cam shedding box.

*1 No oiling is required for the half-leno selvage device.

*2 The tucker housings (if the tuck-in device is selected) are not lubricated when the machine

leaves Toyoda.

Apply oil before the trial run.

Please refer to Stäubli's instruction manual for the grease type and the amount of use for

Stäubli's positive cam shedding motions.

As a reference, the lubricating oil table as of January 2017 is as follows.


97

for 1781*e32D, 1781*e32F, 1691*e32D,

1692*e32D, 1691*e22N, 1692*e22N

for 1671*e22D, 1681*e22D

タイプオイル量 (L)

S3060 7

S3220 7.6

S3260 8

S3222 8.1

　

　

　　

　　

　　

3)　For crank shedding motion (single-harmonic, multi-link)

Prepare the same type of oil and grease as that of the positive cam shedding motion specified in

[3.2] above.

4)　For electronic dobby

For the lubricant type and quantity to be applied to the dobby, refer to the manufacture's

manual.

For other sections of the machine, prepare the same type of oil and grease as that of the positive

cam shedding motion specified in [2.2] above.

　


Stäubli's positive cam shedding motions.As a reference, the lubricating oil table as of January

2017 is as follows.


98

　

　

　　


99

Lubricant

typeSym bol Lubrication points Quantity per machine

Oil

A RH cutter and full-leno selvage motion *1 A little

B RH & LH tucker housings *2 A little

Electronic shedding motion reduction gear7ℓ (Shedding motion

for 16 frames)

GreaseD Bearings and gears A little

F Electronic shedding bearings *3 50 g

Lubricant type Symbol Lubricating points Quantity per machine

Oil

ARH & LH gearing boxes 4.4 ℓ (2.2 ℓ for each box)

RH cutter and chains A little

B

Tappet cam box (in negative shedding motion)

　　　　　　　　　　Spun cam specification8.5 ℓ

Tappet cam box (in negative shedding motion)

　　　　　　　　　　Filament cam specification11.5 ℓ

Electronic shedding motion reduction gear7 ℓ (Shedding motion for

16 frames.)

RH & LH tucker housings0.24 to 0.30 ℓ

(0.12 to 0.15 ℓ for each)

Electrical leno selvage motion 0.15 ℓ (0.075 ℓ for each)

C

Let-off drive box (single beam) 2.4 ℓ

Let-off drive boxes (twin or double beam) 4.8 ℓ

Electronically

controlled

take-up

motion

reduction

gear 1 ℓ

Grease

D Bearings, gears, and springs A little

E Grease tank for the centralized lubrication system 400 g

F Electronic shedding bearings *3 50g

5)　For electronic shedding motion

*1. Not required for the customers that selected half-leno selvage motion.

*2. The tucker housings (for the customers that selected the tuck-in device) are not lubricated

when the machine leaves Toyota. Apply oil before the trial run.

3　Lubricants Required After Production Weaving

Prepare oil and grease by referring to the quantity listed below.

After approx. 60 million picks (approx. 1 to 3 months) from the first operation, it is necessary to

replace the oil for the gearing box, tappet cam box, tucker housings, let-off drive box, electronically

controlled take-up motion reduction gear and electronic shedding motion reduction gear. The

grease for the electronic shedding bearings should be replaced monthly. Be sure to order the

specified oil according to the schedule.

　


Stäubli's positive cam shedding motions.


100

1. Oil drainer (Commercially available)

NOTE: For the manufacturer names,

refer to Chapter 4, Section 4.2.

2. Oil drainer attachment (Product No. 743)

3. Grease gun (Product No. 769-1)

4. Oiler (Product No. 695)

5. Oiler (Commercially available)

6. Oiler (Commercially available)

7. Brush (Commercially available)

　

NOTES:

・Tools numbered (such as Product

No.77140-00001-**) are included in the

tool kit provided with the machine.

・Commercially available tools should be

set up by your company.

4　Lubricating Tools

　　

　　

　　


101

(1) Seal up the lubricant containers and

place them in a well-ventilated room

separated from the weaving rooms and

machine rooms.

(2) Avoid storing lubricants for more than 1

year, since even high-quality lubricants

may deteriorate as time passes.

(3) Never mix different brands of grease or

oil.

5　Storage of Lubricants

　　

[3.2]　Cleaning Oil and Sealant

1　Cleaning Oil Required When Unpacking

When the machine leaves Toyoda, the back roller, easing roller, and breast beams are coated with

rust-preventive oil. To wipe off the oil easily, use the cleaning oil specified below.

Recommended cleaning oil: NIPPON OIL CORPORATION New-sol Deluxe or its equivalent

Never use trichloroethylene-base cleaning fluid. This type of fluids may mar or discolor the finish.

2　Sealant Required at the Time of Oil Change

Remove the plug when changing the oil in the right and left gear ring boxes, and tappet cam

(negative shedding) box.

When resetting the plug, apply sealant (Three-bond 1215 made by ThreeBond, Co., Ltd. or

equivalent) on the threaded part.


102

140, 150, 170, 190, 210, 230, 250, 280, 300, 336, 340, 360, 390 cm

Nominal reed

space (cm)Maximum

Minimum

Single beam Twin beam

140-150See the table

right.

Nominal reed space

–60 cm –

170-250Nominal reed space

–70 cm (T500 type:

-60cm)

280-336Nominal reed space

–70 cm340-390Nominal reed

space

Table - 1

Nominal reed

space (cm)Shedding type Heald frame type Selvage type

Max. effective

drawing-in

width

(mm)

140 ～ 336 Positive Dobby Riderless Full-leno selvage (M) -5

Half-leno selvage 0

Full-leno selvage (E) 0

Tucked-in selvage -35

Rod Change

(Flat Heald)

Full-leno selvage (M) -5

Half-leno selvage 0



Positive Cam

(Convertible

Dobby)

Riderless Full-leno selvage (M) -5

Half-leno selvage 0



Rod Change

(Flat Heald)


Half-leno selvage 0



Positive Cam Riderless Full-leno selvage (M) -5

Half-leno selvage 0



Rod Change

(Flat Heald)


Half-leno selvage -5

Full-leno selvage (E) -5


4.　

APPENDIX

[1]　

JAT810

Technical

Information

[1.1]　Nominal Reed Space and Effective Drawing-in Width

1　Nominal reed space

2　Effective drawing-in width

4.　APPENDIX

103

Nominal reed

space (cm)Shedding type Heald frame type Selvage type

Max. effective

drawing-in

width

(mm)

140 ～ 336 Negative Cam

( ～ R/S230)


Half-leno selvage 0



Rod Change

(Flat Heald)





Crank

( ～ R/S336)


Half-leno selvage 0



Rod Change

(Flat Heald)





New E-Shed Riderless

(118, 155mm stave)


Half-leno selvage 0



Rod Change

(Flat Heald)

(110, 120mm stave)





340 ～ 390 Positive Dobby Riderless Full-leno selvage (M) 0

Half-leno selvage 0



Rod Change

(Flat Heald)

Full-leno selvage (M) 0

Half-leno selvage 0



Positive Cam

(Convertible

Dobby)

Riderless Full-leno selvage (M) 0

Half-leno selvage 0



Rod Change

(Flat Heald)


Half-leno selvage 0



Positive Cam Riderless Full-leno selvage (M) 0

Half-leno selvage 0



Rod Change

(Flat Heald)


Half-leno selvage 0



4.　APPENDIX

104

Shedding type Negative tappet

cam shedding

motion (TN)

Positive cam

shedding motion

(TP)

Single-harmonic

shedding

motion (CS)

Electronic

dobby (DE)

Electronic

sheddingReed space

R/S (cm)

150 2750 2750

TN –250 TN +350TN +450

170 2850 2850

190 2950 2950

210 3050 3050

230 3150 3150

250 3250 3250

280 3350 3350

336 3650

340 3700

360 3800

390 4000

[1.2]　Machine Weight (excluding EDP)

4.　APPENDIX

105

Spun yarn Ne5-100’s

Filament yarn 7-1000d

Glass fiber 42-1340 dtex

Wool yarn Nm 14-64

Take-up drive Specifications Picking density

Electric take-upStandard 24-300 yarns/inch

Coarse density 9-100 yarns/inch

Mechanical take-up Glass fiber 9-100 yarns/inch

Yarn type Warp tension setting range (kgf)

Spun yarnStandard density 300-500

Low density 10-150

Filament yarn 30-300

[1.3]　Yarn Number Count of Warp

[1.4]　Picking Density

[1.5]　Warp Tension Setting Range

NOTES:

・In case of twin beams, the total tension setting range of both RH and LH warp beams should be 30

to 500 kg. The setting range of each beam should be 15 to 250 kg.

・If the reed space is 360 or 390 cm, however, the total tension of both RH and LH warp beams

should be set within the range from 30 to 600 kg, and the tension of each beam within the range

from 15 to 300 kg.

[1.6]　Possible Weaving Range (Yarn density vs. Yarn number count)

The graph below shows the possible weaving range for spun yarn.

4.　APPENDIX

106

Yarn type R/S Fabrics

Spun

150① Poolin (208)

1/1

PC45×PC45

136×72×1210

190② Calico

1/1

C40×C40

78.9×63.5×1840

③ Poolin (168)

1/1

PC45×PC45

110×76×1687

④ Imitation poplin

1/1

PC45.4×PC45.4

121.92×63.5×1650

⑤ Down-proof

1/1

CM40×CM40

120×110×1775

⑥ Denim (14.5 oz)

3/1

C7×C6

65×48×1666

⑦ Twill

2/1

PC23.6×PC14

108.2×47×1614

280⑧ Percale

1/1

PC36×PC34

92×83 ×2286

⑨ Percale

1/1

PC34×PC34

92×83×2540

340⑩ Percale

1/1

PC34.5×PC34.5

92× 77×3250

Yarn type R/S Fabrics

Filament

150⑪ Bemberg taffeta

1/1

BB50d×BB75d

123×84×1270

170⑫ Filament satin

4/1

PES45d×PES45d

172.1×96.5×1700

190⑬ Lining (Acetate taffeta)

1/1

AC75d×AC75d

121.92×80.01×1490

⑭ Impression fabric

1/1

PA40d×PA40d

155.95×109.2×1830

250⑮ Umbrella cloth

1/1

PA40d×PA40d

152.4×111.8×2360

[1.7]　Fabric Examples

4.　APPENDIX

107

[2]　

Network

application

You can use our network applications (optional) specified below by connecting the Toyota Air Jet Loom

with the network.

・TMS (TOYOTA Monitoring System)

・FACT (TOYOTA Factory Management System)

[2.1]　Scope of your work

・ Designation of options

Since the network board and software CD-ROM are necessary, please inform Toyota of these

network options when determining the machine specifications.

・ Network design based on the connection study diagram

Study the machine connection method by entering the wiring route in the plant layout drawing.

Please prepare the network design appropriate for your plant by referring to 4.2.3 "Network

Design" and determine the required cable length as well as the quantities and installation

positions of switching hubs and routers.

・ Network construction

Network cables should be laid under the plant floor with protecting metal conduits for

prevention of noise and damage. The power supply (100 VAC or 200 VAC) for the line

concentrators (switching hubs) for network construction is also required. Please perform piping,

network cabling, and power supply equipment installation by referring to 4.2.4 "Piping Work".

・ Preparation of equipment and materials

Please prepare the equipment and material listed in 1. to 5. below.

Determine the necessary quantities by referring to "4.2.3 5) Network Equipment Selection and

Ordering".

1. Computer

(Selection standards)

・PC/AT compatible machine preinstalled with "Microsoft windows 7, 8.1, and 10" as the OS.

・CPU: Frequency at or above 3 GHz (recommended)

・Memory: 4 GB or more (recommended)

・LAN: Ethernet port installed as network interface (compatible with 1000, 100, or 10BASE-T)

・HDD: Hard disk with an empty space of 10 GB or more in drive C

・Required peripherals: Display unit, keyboard, mouse, desk, and chair

USB drive (The machine can be operated by data collection from the

memory card while the network is down.)

2. Software

・Microsoft Internet Explorer version 11 or later

・Microsoft Excel 2010, 2013, and 2016 (NOTE: 32-bit only)

Remarks

(1) Microsoft IIS (Internet Information Service) should be uninstalled, if installed on the

designated PC, because it prevents the normal operation.

(2) All programs including the OS should be installed on the C drive.

4.　APPENDIX

108

3. Switching hubs

(Selection standards)

・All ports must support 1000, 100, or 10BASE-T.

・At least 1,000 MAC address entries should be provided.

・Built-in power supply (since the adapter type involves possible jack disconnection)

・Desirably without a cooling fan (because the fan is likely to be broken)

4. Router (when the number of looms is 200 or more)

(When connecting looms to the customer's intracompany network)

・All ports must support 1000, 100, or 10BASE-T.

・Built-in power supply (since the adapter type involves possible jack disconnection)

・Desirably without a cooling fan (because the fan is likely to be broken)

・A local router function should be provided. The local router function allows independent IP

address

assignment

to

each

router

port

for

mutual

communication

between

different

networks.

・The local router function, if used, allows inter-connection between different networks as

follows:

　・Please contact us if you need further details of these units and their ordering information.

　NOTE: When connecting looms to the customer's intracompany network, always use a router

to separate the looms from the customer's intracompany network. (See 4.2.8

"Connection with Customer's Network".)

5. Network cable

・Must use category 5 or above.

・Straight connection is necessary.

Note: Installation work materials such as metal conduits and power cables are also required.

If you have any problem with 1) to 5) for TMS introduction, please consult with the Service or

Sales Department of Toyota Industries Corporation.

4.　APPENDIX

109

[2.2]　Network Connection Concept

For networking in a plant, connect the network boards (optional) in respective loom control panels

using switching hubs.

・ Key Points for Wiring Design

・Maximum number of looms to be connected to a network should be about 200 units. If more

than 200 units need to be connected, separate the network using a router. (One network: Max.

200 units including other connecting devices than the looms.)

・Use a switching hub to connect each loom (network board) in the form of star connection.

・Determine the switching hub location so as to limit each network cable length within100 m.

・Do not increase the number of switching hubs at will by taking possible communication delay

into consideration. (Design cascading with 10 stages as the upper limit.)

・Determine the switching hub ports in consideration of the number of looms, their layout, etc.

・For noise prevention in the plant, pass the network cables in dedicated metal conduits. If

metal conduits cannot be laid, use network cables with shielding wires. Provide a distance of

at least 300 mm from the power line, and ground the shielding wire on the side of the

switching hub.

・When connecting looms to the customer's intracompany network, always use a router to

separate the looms from customer's intracompany network.

4.　APPENDIX

110

・ Terminology

・Switching hub

A concentrator for accommodating network cables with a switching function.

The switching function refers to a function for reading the MAC address for the destination

terminal in the data frame and sending the data only to the port where the destination

terminal is connected.

・MAC address

Hardware address to be set up for identifying the device to be connected in the network.

・1000, 100, 10BASE-TX, 10 BASE-T

LAN transmission line specifications standardized by 802.3 Sub-committee of IEEE (Institute

of Electric and Electronics Engineers).

・Full/half duplex communication

In data communication, full duplex means data transmission in both directions at a time

between two data terminals while half duplex means data transmission only in one direction

at a time.

・Router

A device for connecting multiple networks.

・Cascade stages

The number of stages when increasing the number of devices by connecting switching hubs

and other connecting devices by means of network cables.

4.　APPENDIX

111

Plant layout example

(Prepare a drawing allowing precise grasp of space and other dimensions.)

[2.3]　Network Design

Network design is made for the following purposes:

　・To determine the laying routes of network cables and the power line.

　・To determine the lengths and quantities of necessary materials.

　・To determine the locations for installation of the computer, switching hubs and the router.

　

The network is designed according to the following steps:

　(1) Preparing the plant layout

　(2) Dividing the looms into groups as required

　(3) Determining the locations of the computer, router and switching hubs

　(4) Checking the network wiring routes

　(5) Network equipment selection and ordering

(1) Preparing the plant layout

・Prepare the plant layout that allows precise grasp of dimensional information such as the

plant area, pole positions and computer room position.

・If loom positions are not described I the plant layout drawing, enter their positions. Each loom

may be drawn as a rectangle. The loom length and positions, however, should be drawn as

accurate as possible.

4.　APPENDIX

112

(2) Dividing looms into groups as required

• To network over 200 looms, divide the looms into groups, each consisting of within 200 looms.

　・If the row of looms is long, the network cable length may exceed 100 m. (The network cable

must not be extended beyond 100 m.)

Grouping of looms may make the wiring route study easier.

4.　APPENDIX

113

(3) Determining the locations of the computer, router and switching hubs

・The computer, switching hubs, and the router as network components are precision electronic

devices. They should be installed in places that can be protected from fluffs and condensation

or housed in metal boxes.

・The power supply (100 VAC or 200 VAC) for the network devices is necessary. Select the

locations where the power supply can be used.

・Please study while checking the wall and poles to confirm possibility of actual installation.

　 Note: The computer is a precision electronic device. Select a location where it can be protected

from fluffs and condensation.

　・If a router is necessary for networking over 200 looms, determine the place for router

installation.



If it is to be installed inside the plant, house it in a metal box for protection.

Set the router according to the instruction manual for the selected router.

4.　APPENDIX

114

　・Relaying switching hubs are necessary for connecting looms to the network. First determine

their positions.



If it is to be installed inside the plant, house it in a metal box for protection.

　

　

　・Determine the places for installing switching hubs for loom connection.

・The number of looms to be connected to each switching hub depends on the number of its

ports. (8, 16 or 24 ports are general.)

・The total number of switching hubs will decrease if the number of ports in each switching hub

is greater. Such problems as long wiring path and complicated wiring routes, however, may

arise.

・Determine the switching hub positions on the layout drawing in consideration of the wiring

routes.

4.　APPENDIX

115

(4) Checking the network wiring routes

・Be sure that the planned network devices can be connected without any problem.

・Be sure that there is no obstacle in the route to make wiring impossible.

・Be sure that the network cable length does not exceed 100 m in any place. Since actual wiring

requires leading-in from under the floor into the loom and switching hub box, provide a

sufficient margin in length calculation.

　・If any obstacle exists in the planned route, change the wiring route.

・If the network cable length exceeds 100 m, add a relaying switching hub (a small one having

about 8 ports) for extension within the route.

4.　APPENDIX

116

Network connection diagram example

　・If there is no problem with the network wiring route, enter all routes in the plant layout

drawing to complete the "network connection diagram".

　 Note: Always connect each loom and switching hub, or between switching hubs using one

independent cable in the form of star connection. Please be noted that the above figure

has omitted portions.

4.　APPENDIX

117

Network device power cabling diagram example

　・Network devices require the power supply. Add the power cable route, where new power line

installation work is necessary, to the plant layout drawing to make the "network device power

cabling diagram".

　・Submit the network connection diagram and network device power cabling diagram to the

person or company in charge of installation when requesting the design and installation of

actual piping.

4.　APPENDIX

118

Network connection diagram example

A： Computer 1 set

B： Router (in the case of over 200 looms) 1 unit

C： Relaying switching hubs 2 units

D： Switching hubs for loom connection 8 units

E： Network cable Calculate the required length based on

the drawing.

(5) Network Equipment Selection and Ordering

・Select and order equipment and materials based on the network connection diagram.

　・The necessary equipment and materials for the above figure as an example are as follows:

Notes:

・For selection standards, refer to 4.2.1 "Scope of your work".

・Select each switching hub having the number of ports for connecting the number of devices.

・Metal conduits and power cable are also required.

4.　APPENDIX

119

[2.4]　Piping Work

・ The piping work for network wiring is described also in 4.2.2 Key Points for Design. Install

exclusive metal conduits for noise prevention. (See the figure below.)

　 (*) Since the rising length from the trunk line metal conduit to the loom varies with the actual

piping method, provide sufficient margin (about 4 to 5 m) when calculating the cable length

beforehand.

Note: Install a metal conduit to pass the cable from each loom to the respective switching hub.

The diameter of the metal conduit rising from the trunk metal conduit to the loom must

be Dia. 30 mm or above, and the diameter of the trunk conduit should be determined

according to the number of network cables.

・ Prepare the power supply (100 or 200 VAC) for each switching hub at each place for installation.

If a shielded cable is used as a network cable, a grounding wire is necessary. Use the common

power supply and grounding for all switching hubs. If the power supply voltage is not stable, use

a UPS (uninterruptible power supply) for stabilized power supply. (See 4.2.5 "Wiring Sample

Diagram".)

　

Note: The computer is a precision electronic device. Select a location where it can be protected

from fluffs and condensation. If it is to be installed inside the plant, house it in a metal box

for protection.

4.　APPENDIX

120

Switching hub box manufacturing example

・ Make a metal box as shown below to fix each switching hub in it.

・ The switching hub should be made removable for easy maintenance.

・ Provide a household power outlet and a grounding connection port in the box.

・ Fix (or bury) each metal box on (or in) the plant wall.

4.　APPENDIX

121

[2.5]　Wiring Sample Diagram

4.　APPENDIX

122

[2.6]　Network Cable Connector Installation Method

(What must be prepared)

　・Network cable (*)

　・Connectors (*)

　・Nippers

　・Special network cable crimping tool

　

Note: The network cable is available in single core type and multiple core (stranded core) type.

Prepare connectors that match the purchased cable type.

(What should be prepared for easy operation)

・Special network cable holding tool (for neat arrangement of the core conductors.)

・Exclusive network cable tester (to be used upon communication abnormality occurrence.)

Installation procedure

(1) Strip the cable outer insulation with nippers. Operate carefully so as not to damage the core

conductors.

4.　APPENDIX

123

(2) Arrange the core conductors as illustrated below.

(3) Cut the core conductors with nippers for neat arrangement.

(4) With the metal terminals of the connector facing upward, insert the arranged conductors into

the connector.

4.　APPENDIX

124

(5) After checking if the inserted connectors are in the specified order, crimp them using the special

crimping tool.

4.　APPENDIX

125

[2.7]　Network Cable Connection to the Machine

Connect the network cable on the loom side to the daughter board (network interface card) on the

control board in the control box.

4.　APPENDIX

126

[2.8]　Connection with Customer's Network

(1) Introduction

For connection with the customer's network, install a router to separate the loom TMS network

from the customer's network.

If directly connected, the data on the customer's network side may flow into the loom TMS

network side to overload loom task processing, possibly causing temporary failure in loom

network communication. (Ethernet CH1 error)

(2) Router installation example

Example of connection with

1．(Loom TMS network (172. 17. 1. ***)

2．(Customer's company network (123. 456. 78. ***)

4.　APPENDIX

127

(3) Rough description of connection method

The explanation here is for connecting the two following networks using a router:

Since the router setting method varies with the machine model, only rough explanation is given

here.

　 1．Router installation

The router with two or more network ports can be assigned with an IP address and a sub-net

mask at each port.

　　　Connect the router set as shown above to two networks.

4.　APPENDIX

128

　 2．Computer setting

The computer can basically communicate only with the computer belonging to the same

network. For communication with a computer in a different network, it is necessary to send

the data to the router once, from which it is to be sent to the computer in the different

network. This router is called the default gateway.

Add default gateway setting to the network setting of the computer.

Set the IP address assigned to the router port as the default gateway.

　 REFERENCE: If the default gateway has already been set to the computer, the plant network

may already consist of two or more networks with the router already belonging to

a network. In that case, it is necessary to set the routing information to the loom

network additionally to the existing router. Similar setting is also necessary for

the router added for loom network connection. (It is necessary to set static/

dynamic routing.)

　

Ask the plant network manager for the setting.

4.　APPENDIX

129

In the case of above setting;

Sub-net mask: 255.255.255.0

Default gateway: 172.17.1.254

are internally set.

　 3．Loom setting

Loom setting should also be changed as the computer setting.

In case of simple setting, the sub-net mask and default gateway cannot be changed.

4.　APPENDIX

130

[3]　

TMS

Scanner

(TOYOTA

MONITORING

SYSTEM

SCANNER)

[3.1]　TMS Scanner Overview

Use of the TMS (Toyota Monitoring System) scanner exclusively for the JAT810 / 710 loom will

enable the operation data of other weaving machines (JAT610, LW600, and looms of other makes) to

be collected and displayed by the TMS. (Fig. 1)

　

In the TMS scanner, the data collection board (LTB4) collects the loom parallel monitor signals as

the operation data. The dedicated computer (TMS scanner PC) collects and stores the data of all

looms by serial communication from LTB4.

　

The TMS can collect data from the TMS scanner PC, and summarize the operation data of the

JAT810 / 710 and the TMS scanner PC into the same report and graph.

Fig. 1 TMS Scanner Overview

4.　APPENDIX

131

○: Not restricted △: Restricted ×: Unusable

Data by shift JAT810 / 710 JAT610, etc.

● Shift report ○ △

● Style report ○ △

● Production output graph ○ ○

● Operation rate graph ○ ○

● Stop cause graph ○ △

● Looming list and forecast ○ ○

● Stop history ○ ×

Machine data JAT810 / 710 JAT610, etc.

● Operation status display ○ ○

● Data collection (network) ○ ○

● Data reading (memory card) ○ ×

● Link to loom screen ○ ×

● Loom time setting ○ ×

● Cloth/beam list setting × ○

● Other list setting × ○

● Cloth/beam maintenance × ○

[3.2]　Features of TMS Scanner

Understand the features of the TMS scanner, and check if the TMS scanner system satisfies

customer requirements.

・ The TMS scanner PC is a computer system on assumption of continuous operation for full 24

hours.

・ To

ensure

stabilized

operation,

we

will

supply

the

hardware

such

as

the

computer,

uninterrupted

power supply (UPS), and hard disk drive (HDD).

・ The TMS scanner PC is wholly operated from the TMS.

・ The TMS cannot be installed on the TMS scanner PC because it is a dedicated computer.

Install the TMS on a separate computer.

・ Up to 800 looms can be connected to one TMS scanner PC. If the number of looms exceeds 800,

two TMS scanner PCs (mater and sub) are necessary. The maximum total number of JAT810 /

710 looms connected to the TMS and other looms connected to the TMS scanner PC(s) is 1,000.

・ The table below shows the restrictions on TMS functions of the looms (JAT610, etc.) for data

collection by the TMS scanner in comparison with those for JAT810 / 710.

　

　

(1) Restriction of TMS Functions by Loom Type

4.　APPENDIX

132

Data by operator JAT810 / 710 JAT610, etc.

● Operator report ○ ×

● Production output graph ○ ×

● Operation rate graph ○ ×

Setting JAT810 / 710 JAT610, etc.

● Report setting ○ ○

● IP address setting ○ ○

● Password setting ○ ○

Scanner setting JAT810 / 710 JAT610, etc.

● Style setting × ○

● Shift schedule setting × ○

● Unit setting × ○

● Loom name and specification setting × ○

● Password setting × ○

Data editing JAT810 / 710 JAT610, etc.

● Edit data submenu ○ ○

● Export to CSV file ○ ○

Table 1. Stop Causes Collectable by TMS Scanner

Stop cause JAT810 / 710 TMS scanner (JAT610, etc.)

Warp miss (upper) ○ △ (Counted as warp miss)

Warp miss ○ ○

Selvage miss ○ ○

Leno miss (left) ○ ○

Leno miss (right) ○ △ (Counted as leno miss (left))

Weft miss ○ △ (wholly counted as WF1 miss)

Warp out ○ ○

Cloth doffing ○ ○

Manual stop ○ ○

Power OFF ○ ○

Other ○ ○

(2) Stop causes that can be collected from the looms other than JAT810 / 710 are as follows:

4.　APPENDIX

133

ATTENTION

・Do not install the TMS and other software on the TMC scanner PC. Otherwise, normal operation

may fail.

・Because of this reason, a separate computer for TMS installation is necessary.

(3) TMS Scanner PC Configuration

・ The TMS scanner PC is exclusively for the TMS scanner.

・ The TMS scanner PC consists of the PC itself, uninterrupted power supply (UPS), display, and

keyboard.

4.　APPENDIX

134

ATTENTIONFor TMS scanner communication, the upstream and downstream cables form one loop. Star

connection using a hub as in the Ethernet is not made. In the TMS scanner, each loop is called a

channel.

[3.3]　Connection between Looms and Data Collection Boards (LTB4)

To introduce the TMS scanner, it is necessary to connect looms to LTB4 boards.

Check if the looms to be monitored allow connection with the LTB4 boards.

1　Communication Method between LTB4 Boards and Computer

The data collection board (LTB4) collects the loom parallel monitor signals such as the production

pulse, stop signal and stop cause signal. LTB4 sends the collected data to the TMS scanner PC by

serial communication (RS485).

4.　APPENDIX

135

2　Conditions for Connecting LTB4 to The Loom

To connect LTB4 to each loom, the following power voltage and signals must be supplied from the

loom:

・ Necessary power voltage

・12 VDC (LTB4 board drive voltage)

　Voltage: +11.5 to +12.5

　Current consumption: Within 0.5 A

・ Necessary signals

・Production pulse signal (mandatory):

Production pulse signal output at a rate of one pulse per pick

・Stop signal (run/stop) (mandatory):

Signal that is open during running and close during stopping

・Weft miss stop signal:

Signal that is close during a weft miss

・Warp miss stop signal:

Signal that is close during a warp miss

・Selvage miss stop signal:

Signal that is close during a selvage miss

・Leno miss stop signal:

Signal that is close during a leno miss

・Manual stop signal:

Signal that is close during manual stop occurrence

3　Loom Side Signal I/F Circuit Diagram

The recommended signal I/F circuit on the loom side is shown below. Since the production pulse

signal repeats ON and OFF at a high speed, a transistor is used.

Example of recommended output I/F circuit diagram (loom side)

4.　APPENDIX

136

Model

name

Manufacturer

nameQuantity

Power

supply

Mandatory

signalsI/F circuit Remarks (lacking signal, etc.)

JAT810 /

710TOYOTA ○ ○ ○ Connected directly to TMS

JAT610 TOYOTA ○ ○ ○ Connected

to

TMS

via

TMS

scanner

LW600 TOYOTA ○ ○ ○ Connected

to

TMS

via

TMS

scanner

Total

ATTENTIONThe TMS totals the looms summarized in the table above into the same report so long as the total

number of looms is within 1,000.

4　Time Chart

The time chart is shown below.

・ Please contact us when connecting our JAT610 or LW600.

・ Contact the respective loom manufacturer when connecting the loom of other make.

*1. Ta: Loom stop output delay time = 50 msec max.

5　Checking Connection between Loom and LTB4

・ 12-VDC power supply is mandatory

・ Production pulse and run/stop signals are mandatory.

・ If no other signal exists, LTB4 counts it as "other stop".

・ Check if the signal I/F circuit on the LTB4 side is suitable for LTB4.

・ Contact us when connecting our JAT610 or LW600.

・ Consult with the loom manufacturer when connecting a loom of other make.

6　Management of Looms Connected to TMS Scanner

Summarize JAT810 / 710 looms connected to the TMS directly and other looms (JAT610/600,

LW600 and looms of other makes) connected to the TMS via the TMS scanner in a table as shown

below.

4.　APPENDIX

137

Example of plant layout drawing

(Prepare a drawing allowing dimensional grasp of size, etc.)

ATTENTIONComputers are precise electronic devices. Select the positions that can be protected from flies and

dewing.

[3.4]　Studying Loom Connection to TMS Scanner PC

1　Prepare The Plant Layout Drawing

・ The plant layout drawing is to study the cable lengths and computer mounting positions.

Prepare a drawing allowing correct indication of dimensional information such as the plant

size, computer room position, etc.

・ If the loom positions are not shown in the layout drawing, indicate them in the drawing. Each

loom may be abbreviated as a rectangle but with correct length and in correct position.

・ In case different models like JAT810 / 710 and JAT610 are mixed, distinguish the models in

different colors.

2　Indicate The Computer Mounting Positions in The Plant Layout Drawing

・ Indicate

the

mounting

positions

of

two

computers:

TMS

scanner

computer

and

TMS

computer.

4.　APPENDIX

138

3　Study The Cabling Routes and Cable Lengths on The Layout Drawing

Pay attention to the following points in the study.

4　Cautions for TMS Scanner Communication

・ The upstream and downstream cables form a loop in TMS scanner communication.

Star

connection

using

a

hub

as

in

the

Ethernet

is

not

adopted.

In

TMS

scanner

communication,

each loop is called a channel.

4.　APPENDIX

139

・ The TMS scanner PC may be provided with serial communication ports for up to eight

channels.

They are indicated by channel numbers S1-01 through S1-08.

Addresses 1 to 127 may be assigned to each channel of LTB4.

Each loom ID for identification is determined by combining the serial communication channel

number and the LTB4 address. For example, the ID of the loom with 1 as its LTB4 address

connected to communication port channel 1 is indicated as "S1-01. 001".

・ Determine the connection route for each channel to restrict the number of looms to about 100

(127 max.).

・ If the total number of looms exceeds 800, use two TMS scanner PCs (master and sub) for

connection.

(The ID of each loom connected to the sub TMS scanner PC becomes S2-]].]].)

・ It is also possible to use two TMS scanner PCs (master and sub) for easier cable routing.

・ The total of JAT810 / 710 looms connected directly to the TMS and other looms like JAT610

connected via TMS scanner PCs must not exceed 1,000.

・ Use special-purpose communication cables that can be supplied from us.

・ Use conductive metal conduits for passing communication cables. In the neighborhood of the

power cable, use a separate conduit line and provide a minimum distance of 0.5 meter (for

protection from noise). Communication cable conduits may be installed either underground or

overhead.

Select whichever one according to the situation in the customer's plant.

4.　APPENDIX

140

・ Underground conduit installation

・ Overhead conduit installation

4.　APPENDIX

141

CPU : Operation frequency at 3 GHz or above (recommended)

Memory : 4 GB or above (recommended)

HDD : Hard disk with an empty space of 10 GB or more in drive C

LAN : Installation of Ethernet port as the network interface.

(Should match 100BASE-TX or 10BASE-T.)

OS : Microsoft Windows 7, 8.1 and 10

Others : Display, keyboard, mouse, etc.

The TMS requires application software: Microsoft Internet Explorer

version 11 or later, and Microsoft Excel 2010, 2013 or 2016 (NOTE: 32-bit

only).

[3.5]　Works after Determining TMS Scanner Introduction

The section explains our works and the works to be done by the customer after determining TMS

scanner introduction.

1　Matters to be Checked upon Determining Introduction (Discussion between The Customer and Us)

・ Confirmation of the model and number of looms to be connected to the TMS

・ Loom layout check

・Signal cable conduit installation work method

・Number of channels

・Cable length

* We will prepare the loom connection diagram and check it with the customer.

2　Signal Conduit Installation Work (Customer's Work)

・ Conduct the signal conduit installation work as described in 4.3.4 "Studying Loom Connection

to TMS Scanner PC".

3　Sending The Cable and Scanner PC (Our Work)

・ We will send the required cables and scanner PCs as checked in [ 1 ] above.

* The customer should check the contents of the supplied goods.

4　Preparation of The TMS-PC (Customer's Work)

・ Aside from the scanner PC sent in [ 3 ], a computer installed with TMS is necessary.

(This is unnecessary if the TMS for JAT810 / 710 has already been operating.)

・ To prepare it anew, the following recommended conditions must be satisfied:

　　Machine compatible with preinstalled model PCAT allowing full running of "Microsoft

Windows 7, 8.1 and 10"

4.　APPENDIX

142

5　Cable Installation, and TMS Scanner Setting and Connection (Customer's Work)

・ Perform cabling as explained in 4.3.4 "Studying Loom Connection to TMS Scanner PC".

・ Perform TMS scanner setting.

・ Check the connection between the TMS and TMS scanner.

　

* This work requires supervision by our service engineer. Please ask us to dispatch the

service engineer according to your work execution schedule.

4.　APPENDIX

143

Documents

Model JAT810 - Toyota Textile Machinery...TEXTILE MACHINERY DIVISION 1, Toyodacho 2-chome, Kariya-shi, Aichi, 448-8671 JAPAN T E L : +81 566 27 5316 F A X: +81 566 27 5301 Thank you