Model JAT810 - Toyota Textile Machinery...TEXTILE MACHINERY DIVISION 1, Toyodacho 2-chome,...
Transcript of Model JAT810 - Toyota Textile Machinery...TEXTILE MACHINERY DIVISION 1, Toyodacho 2-chome,...
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
(Konishi's specification, in accordance with the compression test in JIS K7208-1995)
3) Bend strength: 40MPa or higher
(Konishi's specification, in accordance with the compression test in JIS K7203-1995)
4) Tensile strength: 20MPa or higher
(Konishi's specification, in accordance with the compression test in JIS K7113-1995)
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
(In accordance with the compression test in JIS K7208-1995)
3) Bend strength: 35MPa or higher
(In accordance with the compression test in JIS K7203-1995)
■ 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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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)
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
24
Dimensions L2 table
R/S 150 170 190 210 230 250
L2 2597 2797 2997 3197 3397 3597
Middle frame position
R/S - 250 280
Dimension A N/A 1592.5
Hole position of control box wires
Specifications Dimension B
Group inverter 395
Individual inverter 485
EXAMPLE: Floor Plan for Crank Shedding
(For details, refer to the submitted drawings.)
Dimensions L3, L4 table
See other tables for other specifications of weft insertion motions.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
25
Dimensions L2 table (ES spec.)
R/S 150 170 190 210 230 250
L2 3064 3264 3464 3664 3864 4164
Hole position of control box wires
Specifications Dimension B
Group inverter 395
Individual inverter 485
EXAMPLE: Floor Plan for Electronic Shedding Motion
(For details, refer to the submitted drawings.)
Dimensions L3, L4 table
See other tables for other specifications of weft insertion motions.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
26
Dimensions L2 table
(Stäubli 1781 as an example)
R/S 190 210 230 250 280 340
L2 3315 3515 3715 3915 4215 4865
Middle frame position
R/S - 190 210 230 250 280 340
Dimension A N/A 1396 1236 1494 1592.51349.5
2384.5
Hole position of control box wires
Specifications Dimension B
Group inverter 395
Individual inverter 485
EXAMPLE: Floor Plan for Positive Cam Shedding Motion
(For details, refer to the submitted drawings.)
Dimensions L3, L4 table
See other tables for other specifications of weft insertion motions.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
27
Dimensions L2 table
(Stäubli 3220/3260 as an example)
R/S 190 210 230 250
L2 3502 3702 3902 4102
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 Positive Dobby Shedding
(For details, refer to the submitted drawings.)
Dimensions L3, L4 table
See other tables for other specifications of weft insertion motions.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
(For details, refer to the submitted drawings.)
Dimensions L3 differ from the specifications of the weft insertion motions.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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:
1. PREPARATIONS FOR INTRODUCING THE MACHINE
32
Shedding motion other than electronic one
Motor capacity
(kW)
Power supply voltage
Rough calculation formula
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
Shedding motion for 6 frames 75 75 50 40 40 40 40 40
Shedding motion for 8 frames 100 100 50 50 50 40 40 40
Shedding motion for 10 frames 100 100 60 50 50 50 50 40
Shedding motion for 12 frames 100 100 60 60 50 50 50 50
Shedding motion for 14 frames 125 100 75 60 60 60 50 50
Shedding motion for 16 frames 125 125 75 75 75 60 60 60
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.
Rough calculation formula
A=Motor rated current In × 2.5 + x
3 × Power supply voltage (V) ×1.3
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
34
No.
of
frames 4 6 8 10 12 14 16
Variable x 9500 11900 14000 16200 18500 21000 23900
Unit (A)
FrequencyMotor
(kW)
Power supply voltage
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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%.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
・These values are calculated on assumption of the supply voltage fluctuation as 5% and voltage
drop by cable as 9%.
・In an area where supply voltage to the switchboard is unstable, please calculate by setting the
voltage drop by cable separately.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
38
(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 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
・These values are calculated on assumption of the supply voltage fluctuation as 5% and voltage
drop by cable as 5%.
・In an area where supply voltage to the switchboard is unstable, please calculate by setting the
voltage drop by cable separately.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
・These values are calculated on assumption of the supply voltage fluctuation as 5% and voltage
drop by cable as 5%.
・In an area where supply voltage to the switchboard is unstable, please calculate by setting the
voltage drop by cable separately.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
44
Non-fuse breaker capacity (rated current A)
Motor
capacityPower supply voltage
200V/220V 350V - 415V 440V 460V/480V
4kW 75A 40A 30A 30A
7.5kW 100A 50A 40A 40A
Non-fuse breaker capacity (rated current A)
Motor capacity
(Kw)
Electronic
shedding spec.
Power supply voltage(V)
200 220 350 380 400 415 440 460 480
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.
Rough calculation formula
A=Motor rated current In × 2.5 + x
3 × Power supply voltage (V) ×1.3
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
Electronic shedding spec.
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
47
(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
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
Electronic shedding spec.
Main motor capacity 2.6 kw
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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).
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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/
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
1. PREPARATIONS FOR INTRODUCING THE MACHINE
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.
2. INSTALLATION WORK
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
2. INSTALLATION WORK
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.
2. INSTALLATION WORK
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.
2. INSTALLATION WORK
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
2. INSTALLATION WORK
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 →
EI2 PJ2 transmitting EDP1/2 ←
EI3 PJ1 receiving EDP3 →
PJ2 transmitting EDP3/4 ←
8-color
EI1 PJ1 receiving EDP1 →
EI2 PJ2 transmitting EDP1/2 ←
EI3 PJ1 receiving EDP3 →
EI4 PJ2 transmitting EDP3/4 ←
(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.
2. INSTALLATION WORK
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.
2. INSTALLATION WORK
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.
2. INSTALLATION WORK
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
2. INSTALLATION WORK
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
2. INSTALLATION WORK
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
3. PREPARATIONS FOR WEAVING START-UP
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
mark made in step (6).
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
3. PREPARATIONS FOR WEAVING START-UP
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
3. PREPARATIONS FOR WEAVING START-UP
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.
(6) Screw-in yarn beam flange 3 from the
direction of "B" until inside the 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.
3. PREPARATIONS FOR WEAVING START-UP
76
(1) [Mounting a yarn beam gear side]
Make a mark on 117.5 mm away from
the side a 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) Screw-in ring 5 onto yarn beam 1, and
set yarn beam flange 2 with three fixing
bolts (82101-10035).
(4) Set yarn beam gear 4 onto yarn beam 1
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.
(1) [Mounting a yarn beam gear side]
Make a mark on the position to fix a
flange 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.
• For making the screwing-in job easier,
apply
grease
or
oil
to
the
threaded
section.
(3) Set yarn beam gear 4 onto yarn beam 1
and turn yarn beam gear 4 so that the
holes (eight large holes) provided in yarn
gear 4 become aligned with those in yarn
beam 1.
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
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)
3. PREPARATIONS FOR WEAVING START-UP
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.
(6) Screw-in yarn beam flange 3 from the
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.
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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
3. PREPARATIONS FOR WEAVING START-UP
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
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)
3. PREPARATIONS FOR WEAVING START-UP
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)
3. PREPARATIONS FOR WEAVING START-UP
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
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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
3. PREPARATIONS FOR WEAVING START-UP
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
3. PREPARATIONS FOR WEAVING START-UP
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)
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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 specifications:
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
3. PREPARATIONS FOR WEAVING START-UP
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
3. PREPARATIONS FOR WEAVING START-UP
91
(1) Waste-selvage yarn
(which you should procure)
・Yarn specifications:
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)
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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
For 12 yarns : 3 ends/dent
For 16 yarns : 4 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.
3. PREPARATIONS FOR WEAVING START-UP
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 hard- ness 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)
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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.
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.
3. PREPARATIONS FOR WEAVING START-UP
98
3. PREPARATIONS FOR WEAVING START-UP
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.
Please refer to Stäubli's instruction manual for the grease type and the amount of use for
Stäubli's positive cam shedding motions.
3. PREPARATIONS FOR WEAVING START-UP
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
3. PREPARATIONS FOR WEAVING START-UP
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.
3. PREPARATIONS FOR WEAVING START-UP
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
Full-leno selvage (E) 0
Tucked-in selvage -35
Positive Cam
(Convertible
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
Full-leno selvage (E) 0
Tucked-in selvage -35
Positive Cam 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) -10
Half-leno selvage -5
Full-leno selvage (E) -5
Tucked-in selvage -40
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)
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) -10
Half-leno selvage -5
Full-leno selvage (E) -5
Tucked-in selvage -40
Crank
( ~ R/S336)
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) -10
Half-leno selvage -5
Full-leno selvage (E) -5
Tucked-in selvage -40
New E-Shed Riderless
(118, 155mm stave)
Full-leno selvage (M) -5
Half-leno selvage 0
Full-leno selvage (E) 0
Tucked-in selvage -35
Rod Change
(Flat Heald)
(110, 120mm stave)
Full-leno selvage (M) -10
Half-leno selvage -5
Full-leno selvage (E) -5
Tucked-in selvage -40
340 ~ 390 Positive Dobby Riderless Full-leno selvage (M) 0
Half-leno selvage 0
Full-leno selvage (E) 0
Tucked-in selvage -15
Rod Change
(Flat Heald)
Full-leno selvage (M) 0
Half-leno selvage 0
Full-leno selvage (E) 0
Tucked-in selvage -15
Positive Cam
(Convertible
Dobby)
Riderless Full-leno selvage (M) 0
Half-leno selvage 0
Full-leno selvage (E) 0
Tucked-in selvage -15
Rod Change
(Flat Heald)
Full-leno selvage (M) 0
Half-leno selvage 0
Full-leno selvage (E) 0
Tucked-in selvage -15
Positive Cam Riderless Full-leno selvage (M) 0
Half-leno selvage 0
Full-leno selvage (E) 0
Tucked-in selvage -15
Rod Change
(Flat Heald)
Full-leno selvage (M) 0
Half-leno selvage 0
Full-leno selvage (E) 0
Tucked-in selvage -15
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.
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.
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.
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.
・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