JAT810 Installation-Manual ENG

Model JAT810
Profile Reed System

TOYOTA AIR JET WEAVING MACHINE
INSTALLATION GUIDE
(FIRST EDITION)
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:
HEAD OFFICE: TOYOTA INDUSTRIES CORPORATION

TEXTILE MACHINERY DIVISION
1, Toyodacho 2-chome, Kariya-shi, Aichi, 448-8671 JAPAN
PHONE: +81 566 27 5316
FACSIMILE: +81 566 27 5301
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.
Contents
OUTLINE OF INSTALLATION WORK ㌀
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S. SAFETY ㌀
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[1] Safe Work ㌀
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[1.1] Rules for Installation Work ㌀
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[1.2] Rules for Safe Operation㌀㌀㌀㌀
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[1.3] Rules for Maintenance ㌀
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[1.4] Rules for Operating or Checking the Electrical Devices ㌀
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1. PREPARATIONS FOR INTRODUCING THE MACHINE㌀

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[1] Building ㌀
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[2] Foundation Work ㌀
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[2.1] Structure of Foundation ㌀㌀㌀
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[2.2] Laying the Foundation for Wiring and Piping ㌀㌀㌀㌀㌀㌀㌀㌀
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[2.3] Floor Surface Conditions ㌀
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[2.4] Preparing Glue or Quick-hardening Cement ㌀㌀㌀㌀㌀㌀㌀㌀
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[2.5] Marking on the Floor ㌀㌀㌀㌀㌀
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[2.6] Laying Anchor Bolts (Only for the bolting installation method) ㌀㌀
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[3] Wiring (for looms other than towel weaving machine) ㌀㌀㌀㌀㌀
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[3.1] In-plant Electric Facilities ㌀
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[3.2] Circuit Breakers ㌀㌀
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[3.3] Cable Capacity ㌀㌀㌀
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[3.4] Cable Capacity Calculation Examples (reference examples) ㌀㌀
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[3.5] Group Inverter ㌀㌀
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㌀㌀㌀43
[3T] Wiring (for towel weaving machine) ㌀㌀
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[3T.1] In-plant Electric Facilities ㌀
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[3T.2] Circuit Breakers ㌀㌀㌀
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㌀㌀㌀46
[3T.3] Cable Capacity ㌀㌀㌀㌀
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㌀㌀㌀48
[3T.4] Cable Capacity Calculation Examples (reference examples) ㌀㌀
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[4] Air Compressor ㌀㌀
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㌀㌀㌀52
[4.1] Compressed-air Requirements for Air Jet Weaving Machines and Precautions for Piping ㌀
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[4.2] Choice of Air Compressor Type and the Number of Compressors ㌀㌀㌀
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㌀㌀㌀53
[4.3] Layout Examples of Air Compressors and Related Equipment ㌀㌀
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㌀㌀㌀57
[4.4] Piping ㌀
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㌀㌀58
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[5.1] Temperature Control and Air Conditioning ㌀㌀㌀㌀
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[5.3] Prevention from Fly, Fleece, and Dust ㌀
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[5.4] Separate Take-up Motion ㌀㌀
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2. INSTALLATION WORK ㌀
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㌀㌀63
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[1] Preparations for Installation ㌀
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[1.1] Arrangement of Workers ㌀㌀
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[1.2] Setting-up of Unpacking and Carrying-in Tools ㌀
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[1.3] Preparation of Piping ㌀
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㌀㌀㌀64
[2] Installation Work㌀
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㌀㌀㌀65
[2.1] Positioning of the Weaving Machine ㌀
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[2.2] Jobs to be Done before Securing the Legs of the Weaving Machine ㌀
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㌀㌀65
[2.3] Installation ㌀
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㌀㌀66
[2.4] Wiring and Piping to Weaving Machines ㌀㌀㌀
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㌀㌀73
3. PREPARATIONS FOR WEAVING START-UP ㌀

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㌀㌀75
[1] Warp-related Preparations ㌀
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㌀
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[1.2] Preparing the Droppers ㌀㌀㌀㌀㌀
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㌀㌀㌀84
[1.3] Preparing the Healds ㌀㌀
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㌀㌀㌀85
[1.4] Preparing the Reed and Drawing in Warp ㌀㌀㌀
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[1.5] Preparations for Selvage Construction ㌀
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[1.6] Preparations for Waste Selvage Device ㌀㌀
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[2] Weft-related Preparations (Mainly Spun Yarn) ㌀㌀
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[2.1] Preparing Weft Yarn and Cheeses ㌀㌀㌀
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㌀㌀98
[3] Lubricants, Cleaning Oil, and Sealant ㌀
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[3.1] Lubricants ㌀
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[3.2] Cleaning Oil and Sealant ㌀
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㌀㌀㌀104
4. APPENDIX ㌀
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㌀㌀105
[1] JAT810 Technical Information ㌀
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[1.1] Nominal Reed Space and Effective Drawing-in Width ㌀㌀㌀
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㌀㌀㌀105
[1.2] Machine Weight (excluding EDP) ㌀㌀㌀㌀
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㌀㌀㌀108
[1.3] Yarn Number Count of Warp ㌀㌀㌀
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㌀㌀㌀109
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[1.4] Picking Density ㌀
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㌀㌀㌀109
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[1.5] Warp Tension Setting Range ㌀㌀
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㌀㌀109
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[1.6] Possible Weaving Range (Yarn density vs. Yarn number count) ㌀㌀
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㌀㌀㌀110
[1.7] Fabric Examples ㌀㌀
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㌀㌀㌀111
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[2] Network application ㌀
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[2.3] Network Design ㌀㌀
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[2.5] Wiring Sample Diagram ㌀㌀㌀
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[3] TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) ㌀㌀㌀
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[3.1] TMS Scanner Overview ㌀㌀
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[3.2] Features of TMS Scanner ㌀㌀
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[3.3] Connection between Looms and Data Collection Boards (LTB4) ㌀㌀㌀
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[3.5] Works after Determining TMS Scanner Introduction ㌀
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OUTLINE OF INSTALLATION WORK
OUTLINE OF INSTALLATION WORK

Items marked with a box □ are jobs which you should do. Use the list given below as a check list.
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
Toyoda service personnel can be dispatched at

Installation can be started at this stage.
this stage.
3-1. nstallation of Weaving Machines and
3-2. Preparations for Weaving Start-up
Related Facilities
Complete the following preparations under the on- Complete the following preparations:
site supervision of Toyoda service personnel: □ Warp yarn preparation
□ Unpacking and installation of machines □ Procurement of weft yarn, leno yarn, waste-selvage
□ Leveling of machines yarn, and additional yarn
□ 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 □ Installation of waste-selvage yarn winder
(main power and inverter power) □ Procurement of oil and grease
□ Pneumatic piping to machines
Adjustment and Trial Run
Weaving Start-up
Start of Production
1
S. SAFETY
S. SAFETY
[1] Safe Work

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.
2
S. SAFETY
[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.
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.
3
S. SAFETY
2 During Installation
1) General points for installation work
(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.
4
S. SAFETY
2) Transport
(1) Before bringing in machinery, always prepare

well-maintained carriers.
Carriers Q'ty Specifications

Forklift 3.5 t
1
(or wrecker) (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.
5
S. SAFETY
3) Unpacking and cleaning

(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.
4) Levelling work
(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 before-
hand 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.
5) Wiring work
(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 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.
6
S. SAFETY
[1.2] Rules for Safe Operation

1 General Rules
1) Absolute precautions
(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 confirm-
ing 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.
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.
7
S. SAFETY
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.
8
S. SAFETY
(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.
9
S. SAFETY
[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.
10
S. SAFETY
2 Precautions for Maintenance Personnel
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.
11
S. SAFETY
3 During Maintenance Work
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.
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
For jobs to be carried out with the power kept on, observe the following instructions.
(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.
12
S. SAFETY
[1.4] Rules for Operating or Checking the Electrical Devices
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) 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.
13
1. PREPARATIONS FOR INTRODUCING THE MACHINE
1. PREPARATIONS FOR INTRODUCING THE

MACHINE
[1] Building
(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.
14
Crank Shedding Motion (CS, CM)

Nominal Reed H (mm) D (mm)
W(mm)
Space (cm) 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)
W(mm)
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)
W(mm)
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)
W(mm)
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
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.
Electronic Shedding Motion (EC、ES、EB)

Nominal Reed Space W (mm) H (mm) D (mm)
(cm) 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.
15
[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

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 draw-
ings 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 satisfac-
tion of the value specified in the JIS (Japanese
Industrial Standard) by converting the meas-
ured value.
16
・The details of the iron net are shown at left.
[2.2] Laying the Foundation for Wiring and Piping

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 (suspen-
sion 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.
17
[2.3] Floor Surface Conditions

(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.
18
[2.4] Preparing Glue or Quick-hardening Cement

■ For the gluing installation method
IMPORTANT
If you are responsible for the preparation of the glue, prepare it before the start of installation
work.
■ For the straight-bolting installation method

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.
—— 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

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 #304 KooSoo-ri
New Trade Plaza Miyang - Myeon
STTL 372-6, On Ping Street Ansong-City Kyunggi-do, 456-840
Shatin N. T. Korea (South)
HONG KONG
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 Lot 689 Nilai
Km.20 Industrial Estate
Lismununggal, Cileungsi 71800 Nilai, Negeri Sembilan
Bogor 16820 DK
Indonesia Malaysia
Tel: +62 21 823 0025 Tel: +60 6799 1762
Fax: +62 21 8249 2525 Fax: +60 6799 1980
19
(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
Adhesive strength
Metals Rupture
N/mm2 (kgf/cm2)
Iron 8.8 (90)
Stainless 6.6 (67)
Sika primer 2C
Aluminum 7.3 (74)
Copper 7.3 (74)
Compressive strength
・Conditions
Hardening time:1, 3 and 7 days
Temperature: 5, 10, 20 and 35°C
・Test method: In accordance with JIS K7208
Compressive strength N/mm2 (kgf/cm2)
Type Standard type Delay type
Curing period/
5 °C 10 °C 20 °C 20 °C 35 °C
temperature
14.7 37.2 24.5 35.3
1 day
(150) (380) (250) (360)
34.3 39.2 47.0 32.3 46.1
3 days
(350) (400) (479) (329) (470)
49.0 51.0 56.8 49.0 56.8
7 days
(500) (520) (579) (500) (579)
Reference: If the room temperature is above 20°C, use the delay time to have sufficient allowance in
operation time.
(2) Execution method

Glue's curing period (guideline)/24 h or more
NOTE: If the curing temperature is low (approx. 5 °C), the curing period shall be 3 days or more as a
guideline.
20
■ Quick-hardening cement for the bolting installation method

Product name: Konishi E200
Manufacturer: Konishi Co., Ltd. http://www.bond.co.jp/
・Osaka Head Office 2-1-2 Hiranomachi Chuo-ku, Osaka (Sawanotsuru Bld.) 541-0046
Address: Tel: +81 6 6228 2961
・Tokyo Head Office 2-3 Kanda Nishikicho Chiyoda-ku, Tokyo 101-0054
Address: Tel: +81 3 5259 5737
Properties (according to the manufacturer's manual)
(1) Main ingredient: Base compound: Epoxy resin
Curing compounds: Polythiol, aliphatic polyamine
(2) Applications:
1) Jointing (jointing of new and old concrete, leveling, mortar screed jointing)
2) Anchor securing (securing machine bases, securing of various anchors including widening and extending
of facilities)
3) Injecting (injecting into moisture gaps in inverted construction)
(3) Mechanical properties
1) Compressive strength: 70MPa or higher
(Konishi's specification, in accordance with the compression test in JIS K7208-1995)
2) Modulus of elasticity against compression: 1500Mpa or higher
3) Bend strength: 40MPa or higher
4) Tensile strength: 20MPa or higher
Product name: Sikadur-42

Manufacturer: Sika Ltd. http://www.sika.com/
Sika Japan http://www.jpn.sika.com
・Head Office 1-1 Nagatoro, Hiratsuka, Kanagawa pref. 245-0021
Address: Tel: +81 463 21 1101
Properties (according to the manufacturer's manual)
(1) Main ingredient: Base compound: Epoxy resin
Curing compound: Denatured aliphatic polyamine
Aggregate: Silica sand, inorganic pigments
(2) Applications:
1) Filling or repairing gaps and openings
(Filling openings on materials such as concrete, mortar, stone, steel and wood)
2) Grout
(Securing objects such as anchor bolts, machine bases, guard rails and piping)
(3) Mechanical properties
1) Compressive strength: 65MPa or higher
(In accordance with the compression test in JIS K7208-1995)
2) Modulus of elasticity against compression: 6000Mpa or higher
3) Bend strength: 35MPa or higher
* If the quick-hardening cement listed above is not available, then check the above tables to find the properties
necessary for an equivalent adhesive.
21
[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)
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 ℓ3, 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.
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 quickhar-
dening cement from their own weight before
it hardens.
・Pour quick-hardening cement until it swells
around bolts by approx. 5 mm from the floor
surface as shown left.
5．After 2 to 3 hours, remove the bolt support

and scrape the quick-hardening cement swell
with a knife or something similar.
23
EXAMPLE: Floor Plan for Negative Cam Shedding

(For details, refer to the submitted drawings.)
Dimensions L2 table
R/S 190 210 230 250
Ｌ2 3020 3220 3420 3620
Dimensions L3, L4 table

See other tables for other specifications of weft insertion motions.
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
24
EXAMPLE: Floor Plan for Crank Shedding

Dimensions L2 table
R/S 150 170 190 210 230 250
Ｌ2 2597 2797 2997 3197 3397 3597


R/S - 250 280
Dimension A N/A 1592.5

Group inverter 395
25
EXAMPLE: Floor Plan for Electronic Shedding Motion

Dimensions L2 table (ES spec.)

R/S 150 170 190 210 230 250
Ｌ2 3064 3264 3464 3664 3864 4164


Group inverter 395
26
EXAMPLE: Floor Plan for Positive Cam Shedding Motion

Dimensions L2 table
(Stäubli 1781 as an example)
R/S 190 210 230 250 280 340
Ｌ2 3315 3515 3715 3915 4215 4865


R/S - 190 210 230 250 280 340
1349.5
Dimension A N/A 1396 1236 1494 1592.5
2384.5
Group inverter 395
27
EXAMPLE: Floor Plan for Positive Dobby Shedding

Dimensions L2 table
(Stäubli 3220/3260 as an example)
R/S 190 210 230 250
Ｌ2 3502 3702 3902 4102


R/S - 190 210 230 250
Dimension A N/A 1396 1236 1494
Group inverter 395
28
EXAMPLE: Difference from Cheese Stands and Weft Insertion Motions

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

Tandem Balloon 6C type,
ABS 2C type 4C type 6C type 8C type
nozzles cover space saving
Conical N/A 1170 1275 2085 1385 2085
tandem Applicable 1310 1415 2225 1525 2225
Applicable
Multi
Applicable 1427 1532 2342 1642 2342
tandem
29
[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.
(1) Non-electronic shedding spec. ： 100 mA or more
(2) Electronic shedding spec. ： 200 mA or more
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.
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.
30
7 When wiring the loom power cable to the loom, it is recommended to lay them at least 200 mm away from each other
to prevent noise generation.
If the inverter power line is connected to the loom using a cable consisting of three power wires and the
grounding wire, do not connect the grounding wire of the inverter cable to that of the loom.
(Do not use a shielded cable as the inverter power cable. If shielding is required, use a metal conduit.)
For grounding the loom, use the commercial power cable consisting of three power wires and one grounding wire
and connect the grounding cable of the commercial power cable or connect the grounding wire provided
separately from the power cable.
(Each of the loom and inverter, however, must be grounded according to [ 3 ] Class D grounding.)
8 Line filter installation to counteract radio noise
Listening to radio may become hard because of the influence of noise radiated from a loom that uses an inverter
or an AC servo motor. Insertion of a line filter in the power supply line from the plant power distribution board to
the inverter and loom is an effective countermeasure. Please consult with an electrician for handling of the line
filter.
9 Selection of wire type
Do not use aluminum wire to connect wire to the loom main circuit breaker (CB1) and the circuit breaker for the
loom inverter from the viewpoint to prevent the breaker from generating heat.
Using aluminum wire may cause bad connection to the breaker.
31
[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:
Non-fuse circuit breaker capacity

(rated current A)
Inverter rat- Power supply voltage
ing 400 V or
380-350 V 200/220V
(kVA) above
15 40 40 75 Rough calculation formula
25 60 75 125 Inverter rating
A≧ × 1.5
30 75 100 150  3 × Power supply voltage
32
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.
Shedding motion other than electronic one

Motor capacity Power supply voltage
(kW) 200/220V 350-415V 440-480V 550/575V
1.8 40
2.0
30
2.4 50
2.6
3.0 75
40
3.5 100
4.0 100 50 40
5.0 100 75 50 40 Rough calculation formula
7.5 － 100 75 50 A = Motor rated current × 4
Electronic shedding motion

Non-fuse breaker capacity (rated current A)
Motor capacity Power supply voltage (V)
Electronic shedding spec
(kW) 200 220 350 380 400 415 440 460
Shedding motion for 4 frames 75 60 40 40 40 40 30 30
2.6 Shedding motion for 10 frames 100 100 60 50 50 50 50 40
Rough calculation formula

χ
A = Motor rated current In × 2.5 + ×1.3
 3 × Power supply voltage V
No. of frames 4 6 8 10 12 14 16
Variable x 9500 11900 14000 16200 18500 21000 23900
33
[3.3] Cable Capacity

The cable capacity shall be determined according to the motor rated current with the supply voltage fluctuation and
voltage drop. Please consult with the person in charge of electricity or electric specialists.
1 Supply voltage fluctuation and line voltage drop
(1) The voltage received by the loom drops due to supply voltage fluctuation and the voltage drop at
deltastarting by the cable resistance. Keep the total voltage drop within10% of the contract voltage.
(2) The voltage drop by supply voltage fluctuation and the voltage drop by cables ① and ② can be corrected by
torque boost effect by the inverter. The maximum inverter voltage up ratio by torque boosting is 15 to 20%
of the standard inverter output (output voltage of the inverter in loaded state). Therefore, the total voltage
drop by supply voltage fluctuation and cables can be allowed up to this correction limit.
34
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:
χ
A
No. of frames 4 6 8 10 12 14 16
Variable x 9500 11900 14000 16200 18500 21000 23900
3 Motor rated current In

Unit (A)
Motor Power supply voltage
Frequency
(kW) 200V 220V 350V 380V 400V 440V 500V 550V 575V
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
50Hz 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
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
60 Hz 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
35
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×1.5 ×0.2 ×1.7 /  3 ×plant supply voltageV A
1)
Inverter short-time overload capacity
2)
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.
χ
Current value = 20 × In ＋
No. of frames 4 6 8 10 12 14 16
Variable x 9500 11900 14000 16200 18500 21000 23900
(5) Select cable ③ so that the total voltage drop by supply voltage fluctuation and by cable ③ becomes within
10%.
36
[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

(Unit: mm2)
Power supply Distance
Inverter model
voltage 10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m
15 5.5 8 14 22 22 22 30 30 38 38
200V 25 8 14 22 30 38 38 50 50 60 60
30 14 22 30 38 50 50 60 80 80 80
15 3.5 8 14 14 22 22 30 30 30 38
220V 25 5.5 14 22 22 30 38 38 50 50 60
30 8 22 22 30 38 50 60 60 80 80
15 3.5 5.5 8 14 14 14 22 22 22 22
350V 25 3.5 8 14 14 22 22 30 30 38 38
30 5.5 14 14 22 22 30 38 38 50 50
15 3.5 5.5 8 14 14 14 14 22 22 22
380V 25 3.5 8 14 14 22 22 22 30 30 38
30 5.5 14 14 22 22 30 30 38 38 50
15 3.5 5.5 5.5 8 14 14 14 22 22 22
400V 25 3.5 8 14 14 22 22 22 30 30 38
30 5.5 14 14 22 22 30 30 38 38 50
15 3.5 3.5 5.5 8 14 14 14 14 22 22
440V 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
・These values are calculated on assumption of the supply voltage fluctuation as 5% and voltage drop by cable
as 1%.
・In an area where supply voltage to the switchboard is unstable, please calculate by setting the voltage drop by
cable separately.
37
2 Selection of cable ② between inverter and loom

(Unit: mm2)
Motor capacity
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
200V 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
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
220V 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
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
350V 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
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
380V 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
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
400V 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
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
415V 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
38
(Unit: mm2)
Motor capacity
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
440V 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
as 9%.
cable separately.
39
3 Selection of cable ③ between circuit breaker on switchboard and loom

(Unit: mm2)
Motor capacity
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
200V 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
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
220V 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
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
350V 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
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
380V 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
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
400V 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
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
415V 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
40
(Unit: mm2)
Motor capacity
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
440V 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
as 5%.
cable separately.
41
4 Selection of cable ③ between circuit breaker on switchboard and electronic shedding loom
Main motor capacity: 2.6kW
(Unit: mm2)
Power supply Electronic Distance
voltage shedding spec 10 20 30 40 50 60 70 80 90 100
4 8 14 22 30 35 50 50 60 60 70
8 8 14 22 30 35 50 60 60 70 70
200V
12 14 16 22 35 38 50 60 60 70 70
16 16 16 25 35 50 50 60 70 70 80
4 5.5 14 16 22 30 35 38 50 50 60
8 6 14 22 25 35 35 50 50 60 60
220V
12 10 14 22 25 35 35 50 50 60 60
16 14 14 22 25 35 38 50 60 60 70
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
350V
12 5.5 5.5 8 10 14 16 22 22 22 25
16 6 6 8 10 14 16 22 22 25 25
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
380V
12 4 4 6 10 10 14 14 16 22 22
16 5.5 5.5 8 10 14 14 16 22 22 22
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
400V
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
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
415V
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
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
440V
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
as 5%.
cable separately.
42
[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
43
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.
44
[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.
(1) Towel loom (electronic shedding spec.) ： 200 mA or more
(2) Towel loom (excluding electronic shedding spec.) ： 100 mA or more
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.
45
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
46
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.

Power supply voltage
Motor capacity
200V/220V 350V - 415V 440V 460V/480V
4kW 75A 40A 30A 30A
7.5kW 100A 50A 40A 40A
Electronic shedding spec.

Motor capacity Electronic shedding Power supply voltage（V）
(Kw) spec. 200 220 350 380 400 415 440 460 480
12 Frame spec. 125 125 75 75 60 60 60 50 50
2.6 14 Frame spec. 150 125 75 75 75 60 60 60 60
16 Frame spec. 150 125 100 75 75 75 75 60 60
Rough calculation formula

χ
A = Motor rated current In × 2.5 + ×1.3
No. of frames 12 14 16
Variable x 22000 24500 27400
47
[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.
Motor rated current: In

Motor
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
8270
・ In addition to the above, a current of A flows through the machine
 3 × Power supply voltage
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
＝＋Motor rated current × 7
Current during operation

8270
＝＋Motor rated current
48
3 Current in the loom operating condition

Motor rated current: In

Motor
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
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:
χ
A
No. of frames 12 14 16
Variable x 22000 24500 27400
4 Calculation formula for selecting a cable type
Current calculation formula on cable (1) between the switchboard breaker and the loom
Current at starting
χ
＝＋Motor rated current × 20
Current during operation

χ
＝＋Motor rated current
49
[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
(Unit: mm2)
Motor capacity
4kW 5.5 10 16 22 25 35 35 50 50 60
200V
7.5kW 10 16 25 35 50 60 60 70 70 80
4kW 5.5 10 14 22 22 25 35 35 38 50
220V
7.5kW 10 14 22 30 35 50 50 60 70 70
4kW 3.5 3.5 5.5 8 8 10 14 14 16 16
350V
7.5kW 4 5.5 8 14 14 16 22 22 25 30
4kW 3.5 3.5 4 5.5 8 10 10 14 14 14
380V
7.5kW 3.5 5.5 8 10 14 14 16 22 22 25
4kW 3.5 3.5 4 5.5 6 8 10 10 14 14
400V
7.5kW 3.5 4 6 10 10 14 16 16 22 22
4kW 3.5 3.5 3.5 5.5 6 8 8 10 10 14
415V
7.5kW 3.5 4 6 8 10 14 14 16 22 22
4kW 3.5 3.5 3.5 5.5 5.5 8 8 10 10 10
440V
7.5kW 3.5 3.5 5.5 8 10 10 14 14 16 22
4kW 3.5 3.5 3.5 4 5.5 5.5 8 8 10 10
460V
7.5kW 3.5 3.5 5.5 8 8 10 14 14 14 16
4kW 3.5 3.5 3.5 3.5 5.5 5.5 6 8 8 10
480V
7.5kW 3.5 3.5 5.5 6 8 10 10 14 14 16
50
2 Cable size on cable ① between the switchboard breaker and the loom
Main motor capacity 2.6 kw
(Unit: mm2)
Power supply Electronic shed- Wiring distance
voltage ding spec. 10 20 30 40 50 60 70 80 90 100
12 14 16 25 35 38 50 60 60 70 70
200V
16 22 22 25 35 50 50 60 70 70 80
12 14 14 22 25 355 38 50 60 60 70
220V
16 16 16 22 25 38 80 80 60 60 70
12 5.5 5.5 8 10 14 16 22 22 25 25
350V
16 8 8 8 14 14 16 22 22 25 30
12 5.5 5.5 8 10 14 14 16 22 22 22
380V
16 6 6 8 10 14 14 16 22 22 22
12 5.5 5.5 6 8 10 14 14 16 22 22
400V
16 6 6 8 10 10 14 16 16 22 22
12 4 4 5.5 8 10 14 14 14 16 22
415V
16 5.5 5.5 5.5 8 10 14 14 16 2 22
12 4 4 5.5 8 8 10 14 14 14 16
440V
16 5.5 5.5 5.5 8 10 10 14 14 16 16
12 3.5 3.5 5.5 6 8 10 10 14 14 16
460V
16 5.5 5.5 5.5 8 10 10 14 14 16 16
12 3.5 3.5 4 5.5 8 10 10 14 14 14
480V
16 5.5 5.5 5.5 6 8 10 10 14 14 16
51
[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:
・ 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.
・ 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.
52
[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.)
Type
Screw compressor Turbo compressor Reciprocating compressor
Specifications
No fluctuation Wide range from low to
Compressed air Small pressure fluctuation
(oil-free) high pressure
Vibration Weak Weak Strong
Noise Soft Soft Loud
Efficiency High High High to low
Small Medium to large
Size Small to medium
(mainly, less than 150 kw) (150 kw and over)
Maintenance cost Middle Low High
Continuous operation Good Most suitable Not good
1 Calculating air volume required for weaving machines

Q = Qo × (1 + Kz) × No (m3/h (ANR))... ①
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
・ 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).
53
2 Calculating the capacity and the number of air compressors required

Q
a= .................... ②
Qc× Nc
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
According to formulas ① and ② ,
(1) For reciprocating compressors

0.85 × Qc × Nc ≥ Q
Q
Then, Qc × Qc ×Nc≧ or Qc × Nc ≥ 1.412 × Qo × No
0.85
(2) For screw or turbo compressors
0.9 × Qc × Nc ≥ Q
Q
Then, Qc ×Nc≧ or Qc × Nc ≥ 1.333 × Qo × No
0.9
・ 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.
54
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)]
Where W : Total power consumption (kWH)
W1 : Motor rated output
Motor power consumption (kWH per motor) =
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
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
55
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/
56
[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.
57
[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.
58
(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
Nominal diameter
OD (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
(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.
59
[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.
Yarn type
Spun 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
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.
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
[5.3] 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.
60
[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
Group inverter SC inverter

Name Operation
(magnet contactor) (relay)
Contactor or relay for commercial
MSL CRL ON during continuous running
power supply
Contactor or relay for forward revolu- ON during forward revolution (normal
MSF CRF
tion running or slow inching)
MSR Note 1 Contactor for reverse revolution During reverse revolution (slow inching)
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
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
61
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.
[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
62
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

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.
[1.2] Setting-up of Unpacking and Carrying-in Tools
Set up unpacking and carrying-in tools listed below.

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
NOTE: The leveller will be prepared by Toyoda service personnel.
63
[1.3] Preparation of Piping

Prepare pipes and related parts listed below.
Name Quantity Specifications
Inside Dia.: φ20, Pressure-withstanding strength: 1.18
Vinyl (rubber) hose Approx. 1 m/machine
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 ].
64
[2] Installation Work
Before starting the carrying-in and installation of weaving machines, be sure to read Chapter S.
SAFETY and observe the instructions given there.
[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.
65
[2.3] Installation
1 Levelling the weaving machine
ATTENTION
When a weaving machine exposed to cold outdoor
atmosphere is brought into a warm indoor location, all ・When two or more workers are to handle
machine parts will be covered with condensed water a job, they must always communicate
droplets. This condensation will cause immediate rust through words or gestures before start-
due to oxidation of the metal surfaces. ing the job.
Bring the machine indoors and leave it in its packed ・When inserting fiber packings between
state for a while until it reaches room temperature. 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.
66
(2) If the machine is not level, make it level with

packings.
Listed below are packings available for weaving
machines.
Type Thickness Application

Correct loom leveling using a
Steel 1, 2, or
combination of three packing
packing 3.2 mm
types (in thickness).
Insert steel packings under the bottom of the side

frames' feet as shown at left.
4: Steel packing
5: Side frame's foot
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 6
which should be applied to front cloth rail 7 and
back cloth rail 8 as shown at left.
67
2 Installing the cheese stand base

1) Installation with roundhead bolts
As shown below, install the cheese stand base to the
floor with roundhead bolts according to your floor
plan.
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.
68
3 Installing the EDP stand
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.
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
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.
69
(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

EDP inverter Optical fiber cable extending from the main unit
No. of colors Optical fiber connector
circuit board (Specified in tube band)
EI1 PJ1 receiving EDP1 →
2-color
PJ2 transmitting EDP1/2 ←
4-color
EI2 PJ2 transmitting EDP1/2 ←
6-color
PJ2 transmitting EDP3/4 ←
8-color
(4) EDP push valves piping

Connect the air hose piping that extends from the main unit at the relay area near the insertion hole at the
bottom of the EDP stand.
70
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.
71
(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.
72
[2.4] Wiring and Piping to Weaving Machines

1 Wiring
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.
2 Piping
(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.
73
—— Reference —— Air Piping Work to the Weaving Machine

IMPORTANT
Shown 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 －－
Vinyl (rubber) hose, inside dia. φ20 and pressure- Inside dia. Inside dia.
B
withstanding strenght of 1.18 MPa (12kg/cm2) or more φ19.0 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
74
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
・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.
75
1 Mounting a single beam

(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 type
Warp beam
Warp beam
flange dia. L1 (mm)
dia. 1b (mm)
2a (mm)
φ150 215
φ800
φ178 215
*1
φ930, 940 φ178 230
φ1000 φ178 230
*1: At using the warp beam φ800, 215
Yarn Beam Holder：T6 type

Warp beam
Warp beam
flange dia. L1 (mm)
dia. 1b (mm)
2a (mm)
φ150
φ800
φ178
φ178
φ930, 940 230
φ214
φ178
φ1000
φ214
(2) Make a mark on warp beam 1 "L1" mm 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.
76
(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.
(Tightening Torque : 49Nm)
(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 Min. effective

R/S (cm) drawing-in width (cm)
Nominal reed space
150
– 60 cm
170
Nominal reed space
190
– 70 cm
210
230
250
280
Nominal reed space
336
– 80 cm
340
360
390
(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.
77
2 Mounting twin beams

(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.
R/S LO
280 1960
336 2240 DW : Drawing-in width
340 2310 LO : Genuine Toyota standard twin beam dimensions
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
78
3 Mounting a grand beam of towel loom

(1) [Installation on the yarn beam gear side]
Mark the yarn beam 1 85 mm from side “a” with
a felt-tipped pen, etc.
(2) Screw in a yarn beam flange 2 from direction A.
Set the inside of the flange to the marked
position.
・For the ease of screwing, apply grease or oil to
the threaded portion.
Note: The dimension mentioned above repre-

sents the reference dimension.
Fine adjustment should be conducted
depending on your fabric.
(3) Set a yarn beam gear 4 to the yarn beam 1 so that

the bolt holes (large, 8 holes) of the yarn beam
gear 4 match the bolt holes of the yarn beam 1.
Then turn the yarn beam flange 2 so as to have
the bolt holes (small, 3 holes) match the bolt
holes on the yarn beam flange 2.
(4) Tighten the yarn beam 1 and yarn beam gear 4
with 8 bolts 8. Then match the bolt hole position
of the yarn beam gear 4 with the yarn beam
flange 2. Tighten 3 bolts 7 sequentially and
equally.
79
(5) [Flange installation on the side of the counter-

yarn beam gear]
Mark the yarn beam 1 at a point the reed drawing
width of L mm to the right of the marking made
in (1).
NOTE: A minimum effective drawing width to

each nominal reed width is a nominal
reed width minus 70 cm.
(6) Screw in the yarn beam flange 3 from direction
B. Match the marking made in (5) to the inside
of yarn beam flange 3.
・For the ease of screwing, apply grease or oil to
the threaded portion.
(7) Screw in the flange ring 5 also from direction B.
Match the bolt holes of the yarn beam flange 3
and flange ring 5 by providing a clearance of 3 to
5 mm between the end faces of the yarn beam
flange 3 and flange ring 5 and tighten the bolts.
4 Mounting a pile beam of towel loom

1) Standard case (using a flange ring)
(1) Make a mark on 110 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.
Note: The dimension of X mentioned above

represents the reference dimension.
Fine adjustment should be conducted
depending on your fabric.
(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.
80
2) Not using a flange ring (setting a left flange to the left side)
(1) Make a mark on the position to fix a flange with
a felt pen or something similar.
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 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.
81
3) Mounting a flange opposite to the yarn beam gear side

(5) 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.
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.
※In case that left trimmed selvage is taken from the

trimmed selvage stand in accordance with the
specification for left trimmed selvage, the beam
should be set as shown in the figure below.
Also, the maximum textural width is 40 mm
shorter than the drawing-in width (for example, in
case of R/260, the maximum textural width is 2,
560 mm).
＜Gland beam＞
The left flange's inside should become aligned at
the point where X = 125 mm from the end a of yarn
beam.
＜Pile beam＞
The left flange's inside on the left side should
become aligned at the point where X = 150 mm
from the end a of yarn beam.
In the above-mentioned case, both gland beam and

pile beam should be fixed with using flange ring 5.
82
5 Winding warp onto a warp beam

1 : Warp beam gear
2 : Warp beam flange
A : Warp letting-off direction
B : Warp taking-up direction in sizing
ATTENTION
Be careful with the warp taking-up direction when
sizing.
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.
83
[1.2] Preparing the Droppers
IMPORTANT
Check whether you are responsible for the preparation of the droppers. If you are responsible, prepare them before
the start-up of weaving.
–– Reference –– Choosing the Droppers

The following data comes from the ISO and Groz-Beckert catalogues.
(1) Dropper types
Type Closed type Open type
Closed Uster
For Uster pinning
type Uster type Barber Colman type
Dimensions machines
Length Thickness 0.15 0.2 0.3 0.4 0.5 0.15 0.2 0.3 0.4 0.15 0.2 0.3
(L) Width (W) mm mm mm mm mm mm mm mm mm mm mm 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
145 mm 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
(8) 1.2 1.9
9
165 mm
11 2.2 3.3 4.4 1.9 2.9
(2) Warp yarn count and suitable dropper weight

Warp yarn
English number count Dropper weight (g)
Tex count Meter count Silk denier
Cotton yarn Worsted yarn Wool yarn Linen yarn
Up to 11 90 or greater 54 or greater Up to 100 Up to 1.0
11 to 18 56 to 90 32 to 54 50 or greater 90 or greater 100 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 28 48 or greater 42 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
84
[1.3] Preparing the Healds
IMPORTANT
Check whether you are responsible for the preparation of the healds. If you are responsible, prepare them before the
start-up of weaving.
–– Reference –– Steel Heald Specifications

(1) Flat steel heald (reinforced type)
Flat steel heald Overall length Max. density Yarn number count
Optimum yarn count
Cross English
End-loop spacing
section Mail size Simplex Duplex Metric Tex number Denier
Type (L mm)
size count count count
Cotton Silk
mm mm 280 300 302 330 /Cm /Cm Nm Tt NeB Td
5.5×0.30 6.5×1.8 8 – 14 72 8 650
*1
5.5×0.23 5.5×1.2 20 34 30 20 300
5.5×0.25 *1 20
5.5×0.30 18
34 or 30 or 20 or 300 or
5.5×0.30 5.5×1.2 15
greater less greater 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.
85
(2) J-type riderless, flat steel heald (Uster auto drawing-in type)
Max.
Riderless, flat heald Overall length Yarn number count
density
Optimum yarn count

Remarks
Cross section English number Silk deni-
Mail size End-loop spacing (L mm) Simplex Duplex
size Metric count Tex count count er
Cotton Wool Linen
(11") (12") (13") (14") (15") (16") (17")

mm mm /Cm /Cm Nm Tt NeB NeK NeL Td
280 306 331 356 382 407 433
5.5×0.
23
14 20
5.5×0. 5.5×
○ 34 30 20 30 300
25 1.2
5.5×0.
12 18
3
5.5×0.
23
8
5.5×0.
6.5×
25
1.8
5.5×0.
○ 7
3
5.5×0.
7 14 72 8 12 650
38
6.5×
6/7.2×0.3 14
1.8
5.5×0.
4
3
8×2.5 ○ 4 250 2 4 ―
5.5×0.
4
38
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").
86
(3) C-type riderless, steel heald

Riderless, flat heald Overall length Max. density Yarn number count
Optimum yarn count
Cross section English number

Mail size End-loop spacing (L mm) Simplex Duplex Silk denier
size Metric count Tex count count
Cotton Wool Linen
(11") (12") (13") (14") (15") (16") (17")

mm mm /Cm /Cm Nm Tt NeB NeK NeL Td
280 306 331 356 382 407 433
5.5×0.23
14 20
5.5×0.25 5.5×1.2 ○ 34 30 20 30 300
5.5×0.8 12 18
5.5×0.23
8
5.5×0.25
6.5×1.8
5.5×0.3 7
○
5.5×0.38 7 14 72 8 12 650
6/7.2×0.
6.5×1.8 14
3
5.5×0.3 4
8×0.25 ○ 4 250 2 4 ―
5.5×0.38 4
5.5×0.23 12
5.5×0.25 12
※
8×3.8 ○ 4 250 2 4 ―
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").
87
[1.4] Preparing the Reed and Drawing in Warp
IMPORTANT
Check whether you are responsible for the preparation of the reed and prepare it before the start-up to weaving.
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.
・ 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 Drawing-in width
Refer to 4.1 JAT810 Technical Information for the nominal reed spaces and effective drawing-in widths.
88
2 Drawing-in procedure
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 addition-
al 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).
–– Reference ––
For details, refer to the drawings submitted.
NOTE: Tapered reed with LH inlet is recommended for 4- to 6-color picking specifications.
89
[1.5] Preparations for Selvage Construction

1 For Full-leno Selvage Device
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.
90
(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
91
2 For Half-leno Selvage Device (Klöcker)

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) 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.
92
3 For warp-addition device

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 pro-

cure)
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.
93
(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
94
[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)

(1) Waste-selvage yarn
(which you should procure)
EC23/2's as standard
EC24/2's or EC25/2's may be used provided
that they have a strength equivalent to 23/2's
or higher.
・Cheese shape
Shown at left are the recommended dimen-
sions and shape of a waste-selvage cheese.
95
(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.
96
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.
(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
97
[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.
Weft cone (cheese) specifications

Traverse width 6" or less (For fine count yarns, 3" recommended)
Winding angle 3°30' for thick count yarns and 5° 57' for medium and fine count yarns
Winding hardness 50°to 70°(A cheese may collapse if the shore hardness or winding hardness is low.)
Twill angle The smaller the better (Be careful of yarns sticking among themselves.)
Knot Knotless yarns are better (below 3 mm).
Ribbon winding Apply the ribbon brake.
Bobbin diameter For T/C45, 300 to 330 mm max. recommended
Steam set Effective in some cases.
Number of winds The more the better
––– Reference –––– Physical properties required for weft yarn (Minimum values)
Pure cotton yarn
Polyester yarn
Yarn spun
Yarn type Yarn spun by ring spinning Yarn spun by ring spinning blended with
by open end
(Carded yarn) (Combed yarn) 35% cotton
spinning
Yarn count (Ne)
10 16 20 30 40 30 40 50 60 80 20 34 45
Item
Yarn count fluctuation rate

0 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 strength

840 or more 10.2 400 260 200 290 215 200 170 130 310 380 270
g
Strength fluctuation rate

8.8 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
Thin 1 or less 4 30 60 80 6 15 20 30 60 4 6 20
IPI value/
Thick 20 or less 100 240 450 520 50 105 60 95 160 20 55 100
1000 m
NeP 20 or less 100 200 420 600 50 90 85 115 140 310 80 110
98
[3] Lubricants, Cleaning Oil, and Sealant

[3.1] Lubricants
1 Lubricant Symbols and the Corresponding Products Commercially Available
Type of lubricants Oil Grease
Symbol
A B C D E F
Manufacturer
・Mobil 600W Cylinder

・Mobilgear
Oil
600XP150
Mobil Vacuoline528 (VG150) ・Mobil 600W Super Mobilux EP2 Mobilux EP0
・SHC629
Cylinder Oil
・Spartan EP150
・Mobil Vacuoline 546
・Tellus Oil S2M ・Alvania Grease S2 ・Alvania EPR0
・Omala S2 G150 ・Morlina S1B 460
Shell C150 ・Sunlight Grease 2 ・Sunlight Grease 0
・Omala S4 GX150 ・Valvata Oils J460
・Morlina S2 BA150 ・Gadus S2 VV2202 ・Gadus S2 VV2200
・FBK Oil RO150 ・Epinoc Grease AP
JX Nippon Oil and Epinoc Grease AP
・Super Malpas BONNOC M150 Worm Gear Lub 380(N) (N)2
Energy (N)0
DX150 ・Multinoc Grease 2
・Daphne Eponex ・Daphne Eponex
・Daphne Super Gear
Daphne Mechanic Daphne Worm Gear Oil EP No.2 EP No.0
Idemitsu Oil Oil 150
Oil 150 460 ・Daphne Eponex ・Daphne Eponex
・Daphne Gear Oil 150
SR No.2 SR No.0
COSMO COSMO ALLPUS COSMO Grease COSMO Centralized
COSMO Gear SE150 COSMO Gear W460
Lubricants 150 Dynamax No.2 Grease No.2
Kyodo Oil Unilube DL No.2 Unilube DL No.0 GC Grease350
YS Hightac Eco Gear Multi EP Grease No. Multi EP Grease No.
Yanase Oil YS Hightac HG150 YS High Lub MGN10
150 2 0
・BPENAGOL GR-
XP150
British Petroleum ・Castrol Castrol TRIBOL ・BPENEGOL MM-EP2 ・BPENEGOL MM-EP0
BPENEGOL HLP150
(BP) ALPHASP150 800/460 ・Castrol Spheerol EPL2 ・Castrol Spheerol EPL0
・Castrol ALPHASYN
EP150
・CARTER EP150
TOTAL Sarkan C150 CYLC460 Multis EP2 Multis EP0
・CARTER SH150
Always use the recommended lubricants in the table above.
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.
99
2 Lubricants Required Before Trial Run

1) For negative tappet cam shedding motion
Lubricant type Symbol Lubricating points Quantity per machine
A*1 RH cutter and full-leno selvage device*2 A little
Tappet cam box (spun cam specification)*3
9ℓ
Oil LH & RH tucker housings
B
Tappet cam box (filament cam specification)*3
12ℓ
LH & RH tucker housings
Grease D Bearings, gears, and springs A little
*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
A RH cutter and full-leno selvage device A little
Oil
B RH & LH tucker housings*2 A little
Grease D Bearings and gears A little
*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.
Type Oil quantity (L)
1671 7
1681 7
1781 10
100
for 1781*e32D, 1781*e32F, 1691*e32D,

1692*e32D, 1691*e22N, 1692*e22N
for 1671*e22D, 1681*e22D
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.
Type Oil quantity (L)
S3060 7
S3220 7.6
S3260 8
S3222 8.1
101
5) For electronic shedding motion

Lubricant type Sym bol Lubrication points Quantity per machine
*1
A RH cutter and full-leno selvage motion A little
*2
B RH & LH tucker housings A little
Oil
7ℓ (Shedding motion for
Electronic shedding motion reduction gear
16 frames)
D Bearings and gears A little
Grease *3
F Electronic shedding bearings 50 g
*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.

RH & LH gearing boxes 4.4 ℓ (2.2 ℓ for each box)
A
RH cutter and chains A little
Tappet cam box (in negative shedding motion)
8.5 ℓ
Spun cam specification
Tappet cam box (in negative shedding motion)
11.5 ℓ
Filament cam specification
B 7 ℓ (Shedding motion for 16
Oil Electronic shedding motion reduction gear
frames.)
0.24 to 0.30 ℓ
RH & LH tucker housings
(0.12 to 0.15 ℓ for each)
Electrical leno selvage motion 0.15 ℓ (0.075 ℓ for each)
Let-off drive box (single beam) 2.4 ℓ
C Let-off drive boxes (twin or double beam) 4.8 ℓ
Electronically controlled take-up motion reduction gear 1ℓ
D Bearings, gears, and springs A little
Grease E Grease tank for the centralized lubrication system 400 g
F Electronic shedding bearings *3 50g
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.
102
4 Lubricating Tools
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.
5 Storage of Lubricants
(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 deterio-
rate as time passes.
(3) Never mix different brands of grease or oil.
103
[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.
104
4. APPENDIX
4. APPENDIX
[1] JAT810 Technical Information

[1.1] Nominal Reed Space and Effective Drawing-in Width
1 Nominal reed space
140, 150, 170, 190, 210, 230, 250, 280, 300, 336, 340, 360, 390 cm
2 Effective drawing-in width

Nominal reed Minimum
Maximum
space (cm) Single beam Twin beam
Nominal reed space
140-150
See the table –60 cm –
170-250 right. Nominal reed space
280-336
–70 cm (T500 type: Nominal reed space
Nominal reed
340-390 -60cm) –70 cm
space
Table - 1
Nominal reed Max. effective drawing-in
Shedding type Heald frame type Selvage type
space (cm) 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 Full-leno selvage (M) -5
(Flat Heald) Half-leno selvage 0
Positive Cam Riderless Full-leno selvage (M) -5
(Convertible Dobby) Half-leno selvage 0
Positive Cam Riderless Full-leno selvage (M) -5
Half-leno selvage 0
(Flat Heald) Half-leno selvage -5
Full-leno selvage (E) -5
105
4. APPENDIX

140 ～ 336 Negative Cam Riderless Full-leno selvage (M) -5
( ～ R/S230) Half-leno selvage 0
Crank Riderless Full-leno selvage (M) -5
( ～ R/S336) Half-leno selvage 0
New E-Shed Riderless Full-leno selvage (M) -5
(118, 155mm stave) Half-leno selvage 0
(110, 120mm stave) Full-leno selvage (E) -5
106
4. APPENDIX

340 ～ 390 Positive Dobby Riderless Full-leno selvage (M) 0
Half-leno selvage 0
Rod Change Full-leno selvage (M) 0
Positive Cam Riderless Full-leno selvage (M) 0
(Convertible Dobby) Half-leno selvage 0
Positive Cam Riderless Full-leno selvage (M) 0
Half-leno selvage 0
107
4. APPENDIX
[1.2] Machine Weight (excluding EDP)
Shedding type Negative tappet Positive cam Single-harmonic

Electronic Electronic
Reed space cam shedding shedding motion shedding
dobby (DE) shedding
R/S (cm) motion (TN) (TP) motion (CS)
150 2750 2750
170 2850 2850
190 2950 2950
TN +450
210 3050 3050 TN –250 TN +350
230 3150 3150
250 3250 3250
280 3350 3350
336 3650
340 3700
360 3800
390 4000
108
4. APPENDIX
[1.3] Yarn Number Count of Warp
Spun yarn Ne5-100’s

Filament yarn 7-1000d
Glass fiber 42-1340 dtex
Wool yarn Nm 14-64
[1.4] Picking Density
Take-up drive Specifications Picking density

Standard 24-300 yarns/inch
Electric take-up
Coarse density 9-100 yarns/inch
Mechanical take-up Glass fiber 9-100 yarns/inch
[1.5] Warp Tension Setting Range
Yarn type Warp tension setting range (kgf)

Standard density 300-500
Spun yarn
Low density 10-150
Filament yarn 30-300
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.
109
4. APPENDIX
[1.6] Possible Weaving Range (Yarn density vs. Yarn number count)
The graph below shows the possible weaving range for spun yarn.
110
4. APPENDIX
[1.7] Fabric Examples
Yarn type R/S Fabrics

① Poolin (208) PC45×PC45
150 ×1210
1/1 136×72
② Calico C40×C40
190 ×1840
1/1 78.9×63.5
③ Poolin (168) PC45×PC45
×1687
1/1 110×76
④ Imitation poplin PC45.4×PC45.4
×1650
1/1 121.92×63.5
⑤ Down-proof CM40×CM40
×1775
1/1 120×110
Spun
⑥ Denim (14.5 oz) C7×C6
×1666
3/1 65×48
⑦ Twill PC23.6×PC14
×1614
2/1 108.2×47
⑧ Percale PC36×PC34
280 ×2286
1/1 92×83
⑨ Percale PC34×PC34
×2540
1/1 92×83
⑩ Percale PC34.5×PC34.5
340 ×3250
1/1 92×77
Yarn type R/S Fabrics

⑪ Bemberg taffeta BB50d×BB75d
150 ×1270
1/1 123×84
⑫ Filament satin PES45d×PES45d
170 ×1700
4/1 172.1×96.5
⑬ Lining (Acetate taffeta) AC75d×AC75d
Filament 190 ×1490
1/1 121.92×80.01
⑭ Impression fabric PA40d×PA40d
×1830
1/1 155.95×109.2
⑮ Umbrella cloth PA40d×PA40d
250 ×2360
1/1 152.4×111.8
111
4. APPENDIX
[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.
112
4. APPENDIX
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.
113
4. APPENDIX
[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.
114
4. APPENDIX
・ 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.
115
4. APPENDIX
[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.
Plant layout example

(Prepare a drawing allowing precise grasp of space and other dimensions.)
116
4. APPENDIX
(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.
117
4. APPENDIX
(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.
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.
118
4. APPENDIX
・Relaying switching hubs are necessary for connecting looms to the network. First determine their positions.
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.
119
4. APPENDIX
(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.
120
4. APPENDIX
・If there is no problem with the network wiring route, enter all routes in the plant layout drawing to complete
the "network connection diagram".
Network connection diagram example
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.
121
4. APPENDIX
・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".
Network device power cabling diagram example
・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.
122
4. APPENDIX
(5) Network Equipment Selection and Ordering

・Select and order equipment and materials based on the network connection diagram.
Network connection diagram example
・The necessary equipment and materials for the above figure as an example are as follows:
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.
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.
123
4. APPENDIX
[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".)
and condensation. If it is to be installed inside the plant, house it in a metal box for protection.
124
4. APPENDIX
・ 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.
Switching hub box manufacturing example
125
4. APPENDIX
[2.5] Wiring Sample Diagram
126
4. APPENDIX
[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.
127
4. APPENDIX
(2) Arrange the core conductors as illustrated below.
(3) Cut the core conductors with nippers for neat arrangement.
128
4. APPENDIX
(4) With the metal terminals of the connector facing upward, insert the arranged conductors into the connector.
(5) After checking if the inserted connectors are in the specified order, crimp them using the special crimping tool.
129
4. APPENDIX
[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.
130
4. APPENDIX
[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. ***)
131
4. APPENDIX
(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.
132
4. APPENDIX
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.
133
4. APPENDIX
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.
In the case of above setting;
Sub-net mask: 255.255.255.0

Default gateway: 172.17.1.254
are internally set.
134
4. APPENDIX
[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
135
4. APPENDIX
[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

○: 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 × ○
136
4. APPENDIX
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 ○ ○
(2) Stop causes that can be collected from the looms other than JAT810 / 710 are as follows:
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 ○ ○
137
4. APPENDIX
(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.
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.
138
4. APPENDIX
[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).
ATTENTION
For 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.
139
4. APPENDIX
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)
140
4. APPENDIX
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 = 50msec 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.
Model Manufacturer Power Mandatory
Quantity I/F circuit Remarks (lacking signal, etc.)
name name supply signals
JAT810 /
TOYOTA ○ ○ ○ Connected directly to TMS
710
JAT610 TOYOTA ○ ○ ○ Connected to TMS via TMS scanner
LW600 TOYOTA ○ ○ ○ Connected to TMS via TMS scanner
Total
ATTENTION
The 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.
141
4. APPENDIX
[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.
Example of plant layout drawing

(Prepare a drawing allowing dimensional grasp of size, etc.)
2 Indicate The Computer Mounting Positions in The Plant Layout Drawing

・ Indicate the mounting positions of two computers: TMS scanner computer and TMS computer.
ATTENTION
Computers are precise electronic devices. Select the positions that can be protected from flies and dewing.
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4. APPENDIX
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.
143
4. APPENDIX
・ 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.
144
4. APPENDIX
・ Underground conduit installation
・ Overhead conduit installation
145
4. APPENDIX
[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"
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).
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.
146
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Model JAT810

Profile Reed System

HEAD OFFICE: TOYOTA INDUSTRIES CORPORATION

1. PREPARATIONS FOR INTRODUCING THE MACHINE㌀

3. PREPARATIONS FOR WEAVING START-UP ㌀

OUTLINE OF INSTALLATION WORK

Toyoda service personnel can be dispatched at

Adjustment and Trial Run

[1] Safe Work

[1.1] Rules for Installation Work

2．If there is any unstable footing due to any pits (for

(1) Always wear a helmet whenever installation is

(1) Before bringing in machinery, always prepare

Carriers Q'ty Specifications

(2) Never lift the machine or load any higher than

(6) Always push hand carts when carrying loads.

3) Unpacking and cleaning

3 Before Trial Run

4 During Trial Running

[1.2] Rules for Safe Operation

(1) Never allow non-qualified workers to carry out

(4) Never touch rotating or operating parts until the

(6) Never remove any of the warning notice, caution

2) Handling abnormal situations

2 Precautions for Weaving

(5) If the machine stops, check

[1.3] Rules for Maintenance

1) Checking the work procedure

2 Precautions for Maintenance Personnel

1) If you stop the machine for maintenance, be sure

3) Never use compressed air for cleaning your skin.

3 During Maintenance Work

1) Basic maintenance procedure

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

[1.4] Rules for Operating or Checking the Electrical Devices

1. PREPARATIONS FOR INTRODUCING THE

When carrying in those machines having a reed

Crank Shedding Motion (CS, CM)

Electronic Shedding Motion (EC、ES、EB)

[2] Foundation Work

[2.1] Structure of Foundation

・The pressure-withstanding strength of concrete

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

[2.2] Laying the Foundation for Wiring and Piping

[2.3] Floor Surface Conditions

NOTE: These floor surface conditions will

[2.4] Preparing Glue or Quick-hardening Cement

■ For the straight-bolting installation method

■ Glue for the gluing installation method

Product name: Sikadur 31 Adhesive (Epoxy type)

Sika Hongkong, Ltd. Sika Korea Ltd.

P.T. Sika Nusa Pratama Sika Kimia Sdn. Bhd.

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

(2) Execution method

■ Quick-hardening cement for the bolting installation method

Product name: Sikadur-42

[2.5] Marking on the Floor