LWT710 Installation Guide-E.Book

Model LWT710 TOYOTA WATER JET WEAVING MACHINE

INSTALLATION GUIDE

(FIRST EDITION)

Thank you very much for purchasing our LWT710 Water 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 TOKYO BRANCH: Marunouchi Bldg. F29 4-1, Marunouchi 2-chome, Chiyoda-ku, Tokyo, 100-6329 JAPAN PHONE : +81 3 5293-2500 FACSIMILE : +81 3218-0070 OSAKA BRANCH: Room 506, Toyoda Bldg. 3-11, Minamisenba 4-chome, Chuoh-ku, Osaka, 542-0081 JAPAN PHONE : +81 6 6251-3543 FACSIMILE : +81 6 6251-3573

NOTE: 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.

AUGUST, 2008 Ver. 1.10

1 This manual uses the following symbols: , , CAUTION .

(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) CAUTION The CAUTION 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...... 6

Chapter S. SAFTY ...... 7

S.1 Safe Work...... 8 S.1.1 Rules for Installation Work ...... 8 S.1.2 Rules for Safe Operation...... 13 S.1.3 Rules for Maintenance ...... 16 S.1.4 Rules for Operating or Checking the Electrical Devices...... 18

Chapter 1 PREPARATIONS FOR INTRODUCING THE MACHINE...... 19

1.1 Building...... 20

1.2 Foundation Work ...... 22 1.2.1 Wiring for Electric Equipment ...... 23 1.2.2 Floor Surface Conditions...... 38 1.2.3 Ordering Quick-hardening Cement ...... 39 1.2.4 Marking on the Floor ...... 40 1.2.5 Laying Anchor Bolts (Only for the Bolting Installation Method) 40

1.3 Wiring ...... 42 1.3.1 In-plant Electric Facilities...... 42 1.3.2 Circuit Breakers...... 44 1.3.3 Cable Capacity ...... 46 1.3.4 Cable Capacity Calculation Examples (Reference Examples)...... 49 1.3.5 Group Inverter ...... 52

1.4 Water ...... 54 1.4.1 Water Quality...... 54 1.4.2 Water Quantity, Temperature and Pressure ...... 56 1.4.3 Water Treatment ...... 57

1.5 Other Equipment ...... 58 1.5.1 Temperature Control and Air Conditioning...... 58 1.5.2 Lighting...... 58 1.5.3 Separate Take-up Motion...... 59

3 Chapter 2. INSTALLATION WORK ...... 61

2.1 Preparations for Installation ...... 62 2.1.1 Arrangement of Workers ...... 62 2.1.2 Setting-up of Unpacking and Carrying-in Tools...... 62

2.2 Installation Work ...... 63 2.2.1 Positioning of the Weaving Machine ...... 63 2.2.2 Jobs to be Done before Securing the Legs of the Weaving Machine...... 63 2.2.3 Installation ...... 63 2.2.4 Wiring and Piping to Weaving Machines ...... 70

Chapter 3. PREPARATIONS FOR WEAVING START-UP ...... 73

3.1 Warp-related Preparations...... 74 3.1.1 Mounting the Warp Beam(s) and Procuring Warp Yarn ...... 74 3.1.2 Ordering Heald Frames ...... 83 3.1.3 Catch Cord (CC) Heald ...... 85 3.1.4 Ordering and Installing the Reeds ...... 86 3.1.5 Filling Preparation...... 89 3.1.6 Leno Yarn Preparation ...... 89 3.1.7 Catch Cord Yarn...... 90

3.2 Lubricants, Cleaning Oil, and Sealant ...... 91 3.2.1 Lubricants ...... 91 3.2.2 Cleaning Oil and Sealant...... 95

Chapter 4 APPENDIX ...... 97

4.1 TMS (TOYOTA MONITORING SYSTEM)...... 98 4.1.1 Scope of Your Work ...... 98 4.1.2 Network Connection Concept...... 101 4.1.3 Network Design ...... 103 4.1.4 Piping Work ...... 111 4.1.5 Wiring Sample Diagram...... 113 4.1.6 Network Cable Connector Installation Method ...... 114 4.1.7 Network Cable Connection to LWT710 ...... 117 4.1.8 Connection with Customer’s Network...... 118

4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)...... 122 4.2.1 TMS Scanner Overview ...... 122 4.2.2 Features of TMS Scanner ...... 123 4.2.3 Connection between Looms and Data Collection Boards (LTB3) ...... 126 4.2.4 Studying Loom Connection to TMS Scanner PC ...... 130 4.2.5 Works after Determining TMS Scanner Introduction...... 134

4.3 Manufacturers of Weaving-related Machines ...... 136

5 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 Polymortar (for bolting installation) and Araldite or Sikadur (for gluing installation) Customs clearance for machines Receiving and carrying machines to your factory

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

3-1. Installation of Weaving Machines and 3-2. Preparations for Weaving Start-up Related Facilities Complete the following preparations: Complete the following preparations under the on- Warp yarn preparation site supervision of TOYOTA service personnel: Procurement of weft yarn, leno yarn, waste- Unpacking and installation of machines selvage yarn, and additional yarn Leveling of machines Installation of winder for weft cheeses Installation of EDP stand(s) Installation of leno yarn winder Installation of cheese stand(s) Installation of waste-selvage yarn winder Power wiring to machines Procurement of oil and grease (main power and inverter power) Water piping to machine

Adjustment and Trial Run

Weaving Start-up

Start of Production

6 Chapter S. SAFTY

S.1 Safe Work ...... 8

S.1.1 Rules for Installation Work...... 8 [ 1 ] Before Installation...... 8 [ 2 ] During Installation...... 9 [ 3 ] Before Trial Run ...... 12 [ 4 ] During Trial Running ...... 12

S.1.2 Rules for Safe Operation...... 13 [ 1 ] General Rules ...... 13 [ 2 ] Precautions for Weaving ...... 14

S.1.3 Rules for Maintenance...... 16 [ 1 ] Before Maintenance Work...... 16 [ 2 ] Precautions for Maintenance Personnel ...... 16 [ 3 ] During Maintenance Work...... 17 [ 4 ] Lubrication...... 17

S.1.4 Rules for Operating or Checking the Electrical Devices..... 18

7 S. SAFTY

S. SAFTY S.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.

S.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. 4) If the floor surface is slippery due to leaking water, etc., repair water-leaking part to keep the floor surface dry.

8 S.1 Safe Work

[ 2 ] During Installation [ 2.1 ] 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 instru- ments 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.

9 S. SAFTY

[ 2.2 ] Transport (1) Before bringing in machinery, always prepare well-maintained carriers.

Carriers Q’ty Specifications 3.5 t Forklift (or wrecker) 1 (Reed space:150 to 190 cm) Hand lift 2 3.0 t or more Small jack 2 1.5 t or more Approx. Wooden block 4 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 transporta- tion. (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.

10 S.1 Safe Work

[ 2.3 ] 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 since the paint- ing will peel off, discolor, or get cracked (plastic parts). (4) Use neutral detergent for cleaning plastic parts. (5) Never put anything on the parts storage area, passages, or footing area.

[ 2.4 ] 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 beforehand on words or gestures for giving and confirming signals. (3) Whenever inserting or removing the packing under the weaving machine legs during leveling, never let fingers get between the leg and floor surface.

[ 2.5 ] 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.

11 S. SAFTY

[ 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.

12 S.1 Safe Work

S.1.2 Rules for Safe Operation [ 1 ] General Rules [ 1.1 ] 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 communicat- ing your intention to co-workers or without confirming their answer to your signal.

(4) Never touch rotating or operating parts until the machine comes to a complete stop. (5) Never operate the machine in clothes which could become entangled in the rotating parts. (6) Never remove any of the warning notice, caution plates or instruction plates from the machine, no matter what.

[ 1.2 ] Handling Abnormal Situations (1) Always turn the power off before making any adjustments or repairs to correct abnormalities occurring during operation. (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.

DON’T TURN THE SWITCH ON

[ 1.3 ] 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.

13 S. SAFTY

[ 2 ] Precautions for Weaving [ 2.1 ] 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. (4) Make it a standard rule to press “the interlock switch with on hand and another start switch with a different hand (two-hand operation)”.

[ 2.2 ] 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 5) Front hanging neckties 6) Loose hanging hairstyle (4) Never put scissors or tools in a non-flap breast pocket.

14 S.1 Safe Work

(5) If the machine stops, check 1 • 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 signal indicator 1 flashes (in case of stan- 2 dard setting), warning lamp 2 lights and warning icon 3 is displayed: It indicates that the automatic tail end proces- sor 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.

DON'T TOUCH

(6) Put on a gauze mask in the weaving room when the machine is in operation. There will be a lot of invisible fly, fleece or yarn particles floating around.

(7) Put on a pair of ear plugs to protect your ears from noise when working around operating machines for a long time.

15 S. SAFTY

S.1.3 Rules for Maintenance [ 1 ] Before Maintenance Work [ 1.1 ] 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.

[ 1.2 ] 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.

[ 1.3 ] Keeping Things Neat and Tidy Determine the storage location for disassembled parts, making sure that passages are clear for operators.

[ 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.

DON’T TURN THE SWITCH ON

(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.

16 S.1 Safe Work

[ 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.

[ 3.1 ] 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. (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.

[ 3.2 ] 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 struc- ture. 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.

17 S. SAFTY

S.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 group-control 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 “DON’T TURN THE 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.

18 Chapter 1 PREPARATIONS FOR INTRODUCING THE MACHINE

1.1 Building ...... 20 [ 3 ] Motor Rated Current In...... 47 1.2 Foundation Work...... 22 [ 4 ] Cable Selection ...... 48 1.2.1 Wiring for Electric Equipment...... 23 1.3.4 Cable Capacity Calculation Examples (Reference Examples) ...... 49 [ 1 ] Layout of Looms ...... 24 [ 1 ] Selection of Cable c between Circuit [ 2 ] Loom Foundation...... 32 Breaker on Switchboard and Inverter..... 49 1.2.2 Floor Surface Conditions ...... 38 [ 2 ] Selection of Cable d between Inverter 1.2.3 Ordering Quick-hardening Cement ...... 39 and Loom ...... 50 1.2.4 Marking on the Floor ...... 40 [ 3 ] Selection of Cable e between Circuit Breaker on Switchboard and Loom ...... 51 1.2.5 Laying Anchor Bolts (Only for the Bolting Installation Method) .... 40 1.3.5 Group Inverter...... 52 1.3 Wiring...... 42 [ 1 ] Determination of Installing Location ...... 52 [ 2 ] Major Specifications, Dimensions and 1.3.1 In-plant Electric Facilities ...... 42 Weight of Inverter ...... 52 [ 1 ] Power Requirements ...... 42 [ 3 ] Wiring Method between Inverter [ 2 ] Earth Leakage Breaker...... 42 and Loom ...... 53 [ 3 ] Class D Grounding ...... 42 [ 4 ] Cautions for Wiring...... 53 [ 4 ] Capacities of Non-fuse Circuit Breakers 1.4 Water ...... 54 on Switch Board ...... 42 [ 5 ] Cable Capacity Selection ...... 42 1.4.1 Water Quality ...... 54 [ 6 ] Position for Installation of Phase 1.4.2 Water Quantity, Temperature and Compensation Capacitor for Slow Pressure ...... 56 ‘Inching Specification ...... 42 [ 1 ] Water Quantity...... 56 [ 7 ] When Wiring the Loom Power Cable to [ 2 ] Water Temperature...... 56 the Loom...... 43 [ 3 ] Water Supply Pressure...... 56 [ 8 ] Line Filter Installation to Counteract 1.4.3 Water Treatment ...... 57 Radio Noise ...... 43 1.5 Other Equipment...... 58 1.3.2 Circuit Breakers ...... 44 [ 1 ] Capacity of Non-fuse Circuit Breaker 1.5.1 Temperature Control and Air Conditioning .... 58 for Inverter ...... 44 1.5.2 Lighting ...... 58 [ 2 ] Capacity of Non-fuse Breaker 1.5.3 Separate Take-up Motion...... 59 for Loom ...... 45 [ 1 ] Power Supply to Separate Take-up 1.3.3 Cable Capacity...... 46 Motion...... 59 [ 1 ] Supply Voltage Fluctuation and [ 2 ] Running/Forward Signal...... 59 Line Voltage Drop ...... 46 [ 3 ] Loom Stop Signal from Separate [ 2 ] Current in Each Loom Operation State.... 47 Take-up Motion...... 59

19 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1. PREPARATIONS FOR INTRODUCING THE MACHINE 1.1 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. REFERENCE: Refer to the illustrations below and the dimensions given on the next page.

When carrying in the weaving machine, choose the capacity and number of forklifts and use them carefully to avoid fall-down and rollover.

Upper cam shedding motion (TP) Crank shedding motion (CS) Lower dobby shedding motion (DE)

Negative tappet cam shedding motion (TN)

REFERENCE: Dimensions (W, H, and D) are given on the next page.

20 1.1 Building

Crank shedding motion (CS)

Nominal Reed H (mm) D (mm) W (mm) Space (cm) ø800 ø914 ø1000 ø800 ø914 ø1000 R/S 150 2738 1275 1405 1475 1752 1807 1857 190 3138 1275 1405 1475 1752 1807 1857 230 3538 1275 1405 1475 1752 1807 1857 H: Upper face of heald frame

Negative tappet cam shedding motion (TN)

Nominal Reed H (mm) D (mm) W (mm) Space (cm) ø800 ø914 ø1000 ø800 ø914 ø1000 R/S 150 3007 1860 1990 2060 1752 1807 1857 190 3407 1860 1990 2060 1752 1807 1857 230 3807 1860 1990 2060 1752 1807 1857 H: Upper face of shedding stand

Upper dobby shedding motion (DE, DP), Upper positive cam shedding motion (TP)

Nominal Reed H (mm) D (mm) W (mm) Space (cm) ø800 ø914 ø1000 ø800 ø914 ø1000 R/S 150 2974 1229 1359 1429 1752 1807 1857 190 3374 1229 1359 1429 1752 1807 1857 230 3774 1229 1359 1429 1752 1807 1857 H: Upper face of control box

21 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.2 Foundation Work Out of the two types of installation methods for fix- Gluing Installation ing the weaving machine: Straight bolting method and L-shaped bolting method. The straight bolting method is explained here. Steel packing Felt packing CAUTION (In case of Araldite)

Concrete 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. Iron net

• The pressure-withstanding strength of concrete should be 26.5 MPa (270 kgf/cm2) or greater.

CAUTION Straight-bolting Installation

The compressive strength shall be measured Steel packing according to JIS A 1108 (Method of Test for Compressive Strength of Concrete). Polymortar If any other standard is applied, check satisfac- tion of the value specified in the JIS (Japanese Industrial Standard) by converting the measured value. Concrete

Foundation bolt

Iron net Straight bolt

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

Iron net

22 1.2 Foundation Work

1.2.1 Wiring for Electric Equipment Loom layout, foundation design and related construction works Mentioned in this chapter are items to be studied when laying the LW looms out, designing the foundation and carrying out the related construction works such as drains, water supply, power wiring, etc. The items are explained as to the standard weaving room and the standard looms. Fig. 2-1 shows the outline of this chapter. NOTE: In this chapter, loom dimensions of standard types are described. When designing the inside of the actual weaving room, be sure to check the dimensions by the Foundation Drawing of customer’s specifications which is supplied to each customer.

[ 1 ] “Layout of Looms” [ 1.1 ] “Passage Widths”

[ 1.2 ] “Loom Dimensions”

[ 2 ] “Loom Foundation”

[ 2.1 ] “Foundation Dimensions”

[ 2.3 ] “Erecting Position of Power Source”

[ 2.2 ] “Erecting Position of Water Source”

[ 2.4 ] “Drains”

Fig. 2-1

23 1. PREPARATIONS FOR INTRODUCING THE MACHINE

[ 1 ] Layout of Looms [ 1.1 ] Passage Widths The following shows items necessary for laying the LW looms out in the weaving room. • The looms are generally laid out with their fronts faced to one another. • On each passage in the weaving room, jobs mentioned in X1, X2 and Y1 to Y3 (Fig. 2-2) are carried out. Table 2-1 shows the passage widths required for the jobs mentioned in Fig. 2-2. • When designing the loom layout, examine the drain layout together.

CAUTION Regarding the antipollution measures against noise and vibration to the vicinity of the weaving factory, consult a specialty company sufficiently at the stage of examination on the foundation and construction works.

NOTE: X1-Passage between loom side and room wall In this chapter, loom This passage is used as a temporary storage dimensions of location for doffed cloth rolls and yarn beams. standard types are When conveying a yarn beam, the yarn beam described. When carrier has to turn around. designing the inside of the actual weaving room, be sure to check the dimensions by the Foundation Drawing of customer’s specifications which is supplied to each Y1-Passage between loom back and room wall customer. Attaching/detaching/conveying of the yarn beam and the tying machine, gating, and doffing are performed. (The yarn beam flange diameter is ø800 for standard and ø914, ø1000 for option.)

Y2-Passage between loom fronts Operation of the loom, attaching /detaching/ conveying of the cloth roller are performed. (The maximum cloth roll diameter is ø520.)

Y3-Passage between loom backs The same jobs as mentioned in Y1 are performed.

If...... • When the loom front faces to the room wall, refer to Y2. • When there are pillars in the weaving area, lay the looms out so that the jobs mentioned above can be done safely and easily, referring to the dimensions in Table 2-1.

24 1.2 Foundation Work

Table 2-1 Passage widths (machine with ø800 mm beam) (mm) X1 X2 X3 X4 Y1 Y2 Y3 Standard 3000 650 1500 2000 1500 700 1500 dimensions

X2-Passage between loom sides Jobs of operation, adjustment and maintenance are carried out for the control X3-Central passage between loom sides box (opening/closing of the door), motor This is provided when a lot of looms are pulley, dobby unit, cam unit, etc. on the RH installed. side of the loom, and the measuring device, filling inserting system, take-up motion, package stand, etc. on the LH side.

See [ 1.2 ] “Loom Dimensions” for detailed dimensions.

W1 : Loom width D : Loom depth

Drain ditch

Weaving room wall

U: Loom front

Fig. 2-2

25 1. PREPARATIONS FOR INTRODUCING THE MACHINE

[ 1.2 ] Loom Dimensions Example: Floor plan for 1C crank shedding motion

NOTE: In this chapter, loom dimensions of standard types are described. When designing the inside of the actual weaving room, be sure to check the dimensions by the Foundation Drawing of customer’s specifications which is supplied to each customer.

Fig. 2-3

(mm) R/S W0 W1 150 3030 1900 170 3230 2100 180 3330 2200 190 3430 2300 210 3630 2500 230 3830 2700

26 1.2 Foundation Work

Example: Floor plan for 1C cam shedding motion

Fig. 2-4

(mm) R/S W0 W1 W2 150 3299 1900 3030 170 3499 2100 3230 180 3599 2200 3330 190 3699 2300 3430 210 3899 2500 3630 230 4099 2700 3830

27 1. PREPARATIONS FOR INTRODUCING THE MACHINE

Example: Floor plan for 1C dobby shedding motion

Fig. 2-5

(mm) R/S W0 W1 W2 150 3266 1900 3030 170 3466 2100 3230 180 3566 2200 3330 190 3666 2300 3430 210 3866 2500 3630 230 4066 2700 3830

28 1.2 Foundation Work

Example: Floor plan for 2C crank shedding motion

Fig. 2-6

(mm) R/S W0 W1 150 3260 1900 170 3460 2100 180 3560 2200 190 3660 2300 210 3860 2500 230 4060 2700

29 1. PREPARATIONS FOR INTRODUCING THE MACHINE

Example: Floor plan for 2C cam shedding motion

Fig. 2-7

(mm) R/S W0 W1 W2 150 3529 1900 3260 170 3729 2100 3460 180 3829 2200 3560 190 3929 2300 3660 210 4129 2500 3860 230 4329 2700 4060

30 1.2 Foundation Work

Example: Floor plan for 2C dobby shedding motion

Fig. 2-8

(mm) R/S W0 W1 W2 150 3496 1900 3260 170 3696 2100 3460 180 3796 2200 3560 190 3896 2300 3660 210 4096 2500 3860 230 4296 2700 4060

31 1. PREPARATIONS FOR INTRODUCING THE MACHINE

[ 2 ] Loom Foundation [ 2.1 ] Foundation Dimensions

Fig. 2-9

Reed space W1 W2 W3 (cm) 150 2120 2000 1880 170 2220 2100 1980 180 2320 2200 2080 190 2520 2400 2280 210 2720 2600 2480 230 2920 2800 2680

32 1.2 Foundation Work

[ 2.2 ] Erecting Position of Water Source

CAUTION • Figs. 2-10 and 2-11 show examples of water supply pipe arranged along the drain ditch. • Fix the water supply pipe firmly to the foundation, otherwise piping parts may be damaged due to vibration during the loom operation. • Attach a stop vale (1/2") at the erecting position of the water supply pipe (Fig. 2-11). The stop valve should be prepared by the customer. Parts for connecting the stop valve and the loom (surrounded with a frame X, Fig. 2-11) are supplied together with the loom. • It is convenient to use the water supply pipe for cleaning the loom besides for supplying water to the loom itself. In this case, add a branch stop valve to the water supply pipe. A branch stop valve per several looms will be enough. • When performing the piping work, take care not to allow foreign matter to get into the pipe. After the piping work, open the drain cock of the piping and flush foreign matter out of the piping. Consult with a specialty company about the drain cock position. Also check that there is no leak from pipe joints.

NOTE: In this chapter, loom dimensions of standard types are described. When designing the inside of the actual weaving Branch pipe ø2" room, be sure to check the dimensions Main pipe ø3" by the Foundation Distributing pipe ø1" Drawing of customer’s specifications which is supplied to each customer.

Stop valve 1/2"

Fig. 2-10

33 1. PREPARATIONS FOR INTRODUCING THE MACHINE

Distributing pipe

205 (ø800)

230 W2 60 Loom front Erecting position of water source

150 (ø800)

The dimensions in ( ) are the yarn beam flange diameters. Select the dimensions according to Hose band the yarn beam specification. Stop valve hose

Nozzle Pump Float box

Stop valve 1/2"

Stop valve joint

View A

Fig. 2-11

34 1.2 Foundation Work

[ 2.3 ] Erecting Position of Power Source

CAUTION • Seal the end of the power source conduit tube to protect the thread part and prevent foreign matter from getting into the tube. • When carrying out the piping work, take care not to allow foreign matter to get into the conduit tube.

Fig. 2-12

35 1. PREPARATIONS FOR INTRODUCING THE MACHINE

[ 2.4 ] Drains Drain ditches are needed for the water jet looms. Fig. 2-13 shows an example where the main drain ditch is provided along the central passage. The branch ditch is located based on the position of the lower pan drain hole and generally graded to 1/200 to 1/500. See [ 2.1 ] “Foundation Dimensions”39 for detailed dimensions of the ditch.

NOTE: Cover In this chapter, loom Drain ditch dimensions of standard types are described. When designing the inside of the actual weaving room, be sure to check the dimensions by the Foundation Drawing of customer’s specifications which is supplied to each customer.

Loom View A

Position of lower pan drain hole

Rear of cloth 318

30 210 468 Position of lower pan drain hole (mm) L1 R/S(cm) L L1 L2 L2 150 1840 920 1720 170 2040 1020 1920 L Front of cloth 180 2140 1070 2020 190 2240 1120 2120 210 2440 1220 2320 230 2640 1320 2520 Fig. 2-13

36 1.2 Foundation Work

CAUTION • Grade the foundation surface under the loom as shown in Fig. 2-14 so that water can flow easily. • Finish the ditch surface smooth so that size waste or yarn waste may not stop to gather on the way. • When the concrete layer of the foundation and the ditch is thin, it will cause • cracks in the ditch due to loom vibration. • The ditch should be more than 70 mm deep at the shallowest part. Fig. 2-14

• Cover the ditch where it is open to the pas- Cover, checkered steel plate t = 6.0 mm sage section. Since the corner of the ditch breaks easily, reinforce it with an angle steel (Fig. 2-15). Especially the ditch and the cover should be strong enough where heavy items such as the yarn beam, etc. are conveyed.

Angle steel 50 × 50 × 4.5 Fig. 2-15

[ 2.5 ] Floor Finish Finish the floor after completing the foundation work.

CAUTION Provide crowning to the passage so that water may not gather on the passage, and finish the surface so as not to produce dust.

37 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.2.2 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.

5 mm or less

1 mm or less

38 1.2 Foundation Work

1.2.3 Ordering Quick-hardening Cement For the straight-bolting installation method

IMPORTANT

If you are responsible for the preparation of the quick-hardening cement (Polymortar) and straight bolts, prepare them before the start of installation work, as well as preparing M16 nuts and 6-class washers.

Quick-hardening cement for the bolting installation method

Polymortar

Product name : Polymortar P-1 Manufacturer : KOWA KASEI Co., Ltd. • Head office Address: 1st Miyuki Bldg., 1-15, Ginza 5-chome, Chuo-ku, Tokyo Tel : +81 3 3572 0421 Fax : +81 3 3572 0458 • Nagoya branch Address: 1706 Hatsuta-cho, Nakagawa-ku, Nagoya Tel : +81 52 365 3261 Fax : +81 52 365 3262 • Agents or Distributors in Asia: None (It is possible to send Polymortar to any country.)

Properties (according to the manufacturer’s manual) (1) Main ingredient : Polyester resin and special silica powder (2) Applications: 1) Jointing 2) Gluing of concrete or tiles 3) Laying of anchor bolts 4) Repair for broken concrete (3) Mechanical properties (after 2-hour hardening) • Compressive strength : 78.5 to 107.9 MPa (800 to 1100 kgf/cm2) (In accordance with the compression test in JIS A1183) • Modulus of elasticity against compression: 2942.0 to 4903.3 MPa (30000 to 50000 kgf/cm2) • Bending strength : 24.5 to 29.4 MPa (250 to 300 kgf/cm2) (In accordance with the bending test in JIS A1184) • Tensile strength : 9.8 to 14.7 MPa (100 to 150 kgf/cm2) (In accordance with the tensile test in JIS A1113) (4) Adhesive strength for concrete 4.4 MPa (45 kgf/cm2) or greater (In accordance with the bending test using butt-mortared concrete- blocks of 100 × 100 × 170 mm each)

If the glue or quick-hardening cement listed above is not available, then check the above tables to fine the properties (after hardening) necessary for an equivalent adhesive to be prepared instead.

39 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.2.4 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). REFERENCE: For the loom dimensions, refer to the drawing submitted from us.

1.2.5 Laying Anchor Bolts (Only for the 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. It is recommended that you use a gauge to eliminate any positioning irregularities between the weaving machines.

To obtain l3, use the following formula: 2 2 l3 = l1 + l2

(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.

40 1.2 Foundation Work

2) Prepare quick-hardening cement (Poly-mortar).

Bolt support 3) Moisten the inside of the holes with water. 55 mm (when no frame feet 4) While bleeding air, pour Polymortar into each are used) of the holes and put an anchor bolt into it so 60 mm (when frame feet are that the distance from the top of the anchor used) 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 Bolt prevent bolts from sinking into the Poly- mortar from their own weight before it hard- ens. • Pour Polymortar until it swells around bolts After 2 to 3 hours, by approx. 5 mm from the floor surface as scrape the Poly- shown at left. mortar swell. Poly-mortar

5) After 2 to 3 hours, remove the bolt support and scrape the Polymortar swell with a knife or something similar.

Bolt support

41 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.3 Wiring 1.3.1 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 power supply circuit to prevent hazards which may be caused by leakage current. Select the earth leakage breaker in consideration of the high frequency component generated by the inverter. Please consult with a specialized company.

[ 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.

42 1.3 Wiring

[ 7 ] When Wiring the Loom Power Cable to the Loom 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.

43 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.3.2 Circuit Breakers

LWT LWT LWT

1 : Plant switchboard : Non-fuse circuit breaker(s) for inverter(s) 2 : Group inverter : Non-fuse circuit breaker(s) for loom(s) 3 : Loom line A : Cable between the switchboard breaker and the inverter 4 : Loom line B : Cables between the inverter and looms 5 : Loom line C : Cables between switchboard breakers and looms *1 Group inverter 2 is not installed in case of individual inverter specification. The inverter, inverter breaker and related wiring shown here, therefore, are unnecessary.

[ 1 ] Capacity of Non-fuse Circuit Breaker for Inverter Provide one non-fuse circuit breaker on the inlet side for each inverter. (1) The capacity of the non-fuse circuit breaker on the inlet side of the 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 rating Power supply voltage Inverter model (kVA) 400 V or above 380 to 350 V 200/220 V 7P5L 11 30 A 30 A 50 A Rough calculation formula Inverter rating 011L 16 40 40 75 A ≥ ------× 1.5 018L 26 60 75 125 3× Power supply voltage 022L 32 75 100 150

44 1.3 Wiring

[ 2 ] Capacity of Non-fuse Breaker 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 according to the current flowing through the weaving machine (see Subsection 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.

Non-fuse breaker capacity (rated current A) Power supply voltage Motor capacity (kW) 350 V or more 200/220 V 2.6 30 A 45 A Rough calculation formula 3.0 30 60 A = Motor rated current × 4 (See 1.3.3 [ 3 ] “Motor Rated Current In” for the motor 3.5 50 100 rated current.) 4.0 50 100

45 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.3.3 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

Voltage drop by fluctuation Contracted voltage (supply voltage) Voltage received by loom Voltage drop by cable

Cable (between circuit breaker on switchboard and loom) Circuit breaker Plant Cable LWT loom switchboard (between circuit breaker on Cable switchboard and inverter) (between inverter and loom) Inverter Circuit breaker Voltage drop a by fluctuation c Contracted voltage (supply voltage)

Inverter input voltage Voltage drop b by cable

* Inverter output voltage (with voltage correction)

Inverter output voltage adjustment by torque boost (15 to 20% up) Inverter output voltage Voltage received by (without voltage correction) loom

Voltage drop on inverter input side (Total of voltage drops a and b ) Voltage drop c by cable

(1) The voltage received by the loom drops due to supply voltage fluctuation and the voltage drop at delta- starting 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 and can be cor- rected 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.

46 1.3 Wiring

[ 2 ] Current in Each Loom Operation State (In: Motor rated current)

U Current at delta starting Current at star mode starting High Current at slow operation

Loom rpm Loom Low operation

5 Hz operation by inverter U Delta starting Star mode operation

Slow operation Full speed operation

[ 3 ] Motor Rated Current In

Unit: (A) Motor Power supply voltage Frequency (kW) 200 V 220 V 350 V 380 V 400 V 440 V 500 V 550 V 575 V 1.8 8.3 7.5 4.8 4.4 4.2 3.8 3.3 3.0 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 50 Hz 3.5 16 15 9.2 8.4 8.0 7.3 6.4 5.8 5.6 4.0 18 18 10.4 9.5 9.0 8.2 7.2 6.5 6.3 5.02220131211108.88 7.7 1.8 8.3 7.5 4.8 4.3 4.1 3.8 3.3 3.0 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 5.02220131211108.88 7.7

47 1. PREPARATIONS FOR INTRODUCING THE MACHINE

[ 4 ] Cable Selection Select the cable according to steps [ 1 ], [ 2 ] and [ 3 ]. (1) Obtain the current flowing in cable between the circuit breaker on the switchboard and the 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]

Coefficient considering the loss by inverter high harmonic component, inverter input/output conversion coefficient and margin Inverter output voltage/motor rated voltage (Power supply voltage) Inverter short-time overload capacity

(2) Obtain the current flowing in the cable between the inverter and loom. Obtain the current 1 at slow operation (3.4 × In) in [ 2 ]. The value in [ 3 ] is used for In. Current value = 3.4 × In (3) Select cables and so that the total voltage drop by supply voltage fluctuation and by cables and is within 15 to 20%. (4) Obtain the current flowing in cable between the circuit breaker on the switchboard and loom. Obtain the current 2 at delta starting (20 × In) in [ 2 ]. Use the value in [ 3 ] for the In. Current value = 20 × In (5) Select cable so that the total voltage drop by supply voltage fluctuation and by cable becomes within 10%.

48 1.3 Wiring

1.3.4 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 and connecting the circuit breakers on the switchboard, inverter(s) and looms, calcula- tions are made on assumption of the voltage drop by supply voltage fluctuation as 5%, voltage drop by cable as 1% and voltage drop by cable as 9%. [ 2 ] The calculation for cable between the inverter and the loom is an example when the inverter and loom are directly connected. [ 3 ] The calculation for cable 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 . (For other than electronic shedding motion)

[ 1 ] Selection of Cable c between Circuit Breaker on Switchboard and Inverter

(Unit: mm2) Distance Power supply Inverter 10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m voltage model 7P5L 3.5 5.5 14 14 14 22 22 22 30 30 011L 5.5 8 14 22 22 22 30 30 38 38 200 V 018L8 142230383850506060 022L 14 22 30 38 50 50 60 80 80 80 7P5L3.55.58 14142222222230 011L 3.5 8 14 14 22 22 30 30 30 38 220 V 018L5.5142222303838505060 022L8 222230385060608080 7P5L 3.5 3.5 5.5 8 8 14 14 14 14 22 011L3.55.58 14141422222222 350 V 018L 3.5 8 14 14 22 22 30 30 38 38 022L5.5141422223038385050 7P5L 3.5 3.5 5.5 5.5 8 14 14 14 14 14 011L3.55.58 14141414222222 380 V 018L 3.5 8 14 14 22 22 22 30 30 38 022L5.5141422223030383850 7P5L 3.5 3.5 5.5 5.5 8 14 14 14 14 14 011L 3.5 5.5 5.5 8 14 14 14 22 22 22 400 V 018L 3.5 8 14 14 22 22 22 30 30 38 022L5.5141422223030383850 7P5L 3.5 3.5 5.5 5.5 8 8 14 14 14 14 011L 3.5 3.5 5.5 8 14 14 14 14 22 22 440 V 018L 3.5 5.5 14 14 14 22 22 22 30 30 022L 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.

49 1. PREPARATIONS FOR INTRODUCING THE MACHINE

[ 2 ] Selection of Cable d between Inverter and Loom

(Unit: mm2) Distance Power supply Motor 10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m voltage capacity 1.8 kW 3.5 5.5 8 14 14 22 22 22 30 30 2.65.58 1422222230303838 3.0 5.5 14 14 22 22 30 38 38 50 50 200 V 3.5 5.5 14 22 22 30 30 38 50 50 50 4.0 5.5 14 22 22 30 38 50 50 60 60 5.0 8 14 22 30 38 50 50 60 60 80 1.8 kW 3.5 5.5 8 14 14 14 22 22 22 22 2.63.58 1414222222303038 3.05.58 1422222230303838 220 V 3.5 5.5 14 14 22 22 30 30 38 38 50 4.0 5.5 14 22 22 30 38 38 50 50 60 5.0 5.5 14 22 22 30 38 50 50 60 60 1.8 kW 3.5 3.5 3.5 3.5 5.5 5.5 8 8 8 14 2.6 3.5 3.5 5.5 5.5 8 8 14 14 14 14 3.0 3.5 3.5 5.5 8 8 14 14 14 14 22 350 V 3.53.53.55.58 141414142222 4.03.55.55.58 141414222222 5.0 3.5 5.5 8 14 14 14 22 22 22 30 1.8 kW 3.5 3.5 3.5 3.5 3.5 5.5 5.5 8 8 8 2.6 3.5 3.5 3.5 5.5 5.5 8 8 14 14 14 3.0 3.5 3.5 5.5 5.5 8 8 14 14 14 14 380 V 3.5 3.5 3.5 5.5 5.5 8 14 14 14 14 14 4.03.53.55.58 141414141422 5.0 3.5 5.5 8 14 14 14 14 22 22 22 1.8 kW 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 5.5 5.5 5.5 8 8 14 14 3.0 3.5 3.5 3.5 5.5 5.5 8 14 14 14 14 400 V 3.5 3.5 3.5 5.5 5.5 8 8 14 14 14 14 4.0 3.5 3.5 5.5 5.5 8 14 14 14 14 14 5.03.53.55.58 141414142222 1.8 kW 3.5 3.5 3.5 3.5 3.5 3.5 5.5 5.5 5.5 5.5 2.6 3.5 3.5 3.5 3.5 5.5 5.5 5.5 8 8 14 3.0 3.5 3.5 3.5 5.5 5.5 5.5 8 8 14 14 440 V 3.5 3.5 3.5 3.5 5.5 5.5 8 8 14 14 14 4.0 3.5 3.5 3.5 5.5 8 8 14 14 14 14 5.0 3.5 3.5 5.5 5.5 8 14 14 14 14 14 • These values are calculated on assumption of the supply voltage fluctuation as 5% and voltage drop by cable as 9%. • In an area where supply voltage to the switchboard is unstable, please calculate by setting the voltage drop by cable separately.

50 1.3 Wiring

[ 3 ] Selection of Cable e between Circuit Breaker on Switchboard and Loom

(Unit: mm2) Distance Power supply Motor 10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m voltage capacity 2.6 kW 14 22 30 38 50 50 60 80 80 80 3.01422303850608080100100 200 V 3.5 14 22 38 50 60 80 80 100 100 100 4.0 14 30 38 50 60 80 100 100 125 125 5.0 14 30 50 60 80 100 100 125 150 150 2.6 kW8 142230385050606080 3.014223038385060608080 220 V 3.5142230385060808080100 4.0 14 22 38 50 60 80 80 100 100 125 5.0 14 30 38 50 60 80 100 100 125 125 2.6 kW 3.5 5.5 14 14 14 22 22 22 30 30 3.03.58 1414222222303038 350 V 3.53.58 1414222230303838 4.0 3.5 14 14 22 22 30 30 38 38 50 5.0 5.5 14 22 22 30 30 38 50 50 50 2.6 kW3.55.58 14141422222222 3.03.55.51414142222223030 380 V 3.53.58 1414142222303030 4.03.58 1414222222303038 5.0 5.5 14 14 22 22 30 30 38 38 50 2.6 kW3.55.58 14141414222222 3.0 3.5 5.5 8 14 14 14 22 22 22 30 400 V 3.53.55.51414142222223030 4.03.58 1414222222303030 5.03.58 1414222230303838 2.6 kW 3.5 3.5 5.5 8 14 14 14 14 22 22 3.0 3.5 5.5 8 14 14 14 14 22 22 22 440 V 3.5 3.5 5.5 8 14 14 14 22 22 22 22 4.0 3.5 5.5 8 14 14 22 22 22 22 30 5.03.58 1414222222303030 • These values are calculated on assumption of the supply voltage fluctuation as 5% and voltage drop by cable as 5%. • In an area where supply voltage to the switchboard is unstable, please calculate by setting the voltage drop by cable separately.

51 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.3.5 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 1.3.4 [ 2 ] “Selection of Cable d between Inverter and Loom” for the capacity of the cable between the inverter and loom.)

[ 2 ] Major Specifications, Dimensions and Weight of Inverter

Ventilation port D

RUN/STOP

RESET

Direct connection

Terminal H block Overall circuit diagram (affixed on back MCCB side of door) Right side surface (3-ø34) Left side surface(4-ø34) 50 50 (each with rubber bush)

3øT kVA PE 50 50 50 17.5 D

D-65 4-ø12

30 W-60 30 17.5

Inverter model 7P5L 011L 018L 022L Major Output current A 33 46 76 92 specifications RatingkVA11162632 Width W mm 500 500 600 600 Without Depth D mm 400 400 500 500 transformer *1 Height H mm 1000 1200 1300 1300 Dimensions and Weight kg 95 105 125 160 weight Width W mm 500 500 600 600 With Depth D mm 400 400 500 500 transformer Height H mm 1000 1200 1300 1300 Weight kg 120 150 170 220 *1 Inverters without a transformer are equipped with an AC reactor.

52 1.3 Wiring

[ 3 ] Wiring Method between Inverter and Loom

Inverter

LWT LWT LWT

Bus type wiring For direct connection between inverter and looms

• 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.

[ 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) No effective result can be obtained from the use of an earth leakage breaker for the inverter. (There is no need to install such breaker for inverters smaller than 300 V.) The earth leakage breaker is not necessary even if the power supply voltage exceeds 300 V. This is because the insulated transformer drops the voltage to 220 V. When installing an earth leakage breaker, select the one intended for use with the inverter. (3) Wiring shall be made to enable backup by another inverter when an inverter becomes faulty. (Changeover switch installation or connection change) (4) Is a distributor is required for wiring from the inverter to looms, it shall be provided by the customer. (5) Avoid connecting three or more cables to the inverter output terminals (TB).

53 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.4 Water 1.4.1 Water Quality The water quality exerts great influence on parts accuracies and stable weaving machine operations are maintained. Therefore, to maintain the expected loom performance and stable operation, it is important to check the water quality beforehand and determine the water treating method and equipment to obtain the proper water quality after consultation with a water treatment company. Since the water quality varies according to seasons, it is necessary to check the water quality several times a year. If any problems were found, consult a nearest specialist in water treatment. The table below shows the average water quality used for the LWT water jet looms.

Water quality Allowable water Main component Affect on weaving and loom analysis item quality standard Turbidity Below 2.0 ppm Organic inpurities: Scale, rust, corrosion, blocked filter, Particles of animal and vegitable; stained cloth mold, microbe Inorganic inpurities: Fine grains of clay, rock and soil; oxides of iron, manganese, etc. pH (25°C) 6.7 to 7.5 Water of thick acid or alkali causes rust and corrosion. Some sizing material comes off by alkali water. Total hardness Below 3 ppm Calcium ion Ca++, Lowered insulation of feeler head, poor filling insertion due to scale on nozzle magnesium ion Mg++ Total iron, Below 0.2 ppm Ion oxides Fe++, Mn++ Corrosion, coloration manganese

Free chlorine Below 0.3 ppm Cl2 Strong corrosiveness and oxidizability Chloride ion Below 20 ppm Greatest cause of corrosion – M alkalinity Below 60 ppm Bicarbonate ion (HCO3) In softened water (Na-type soft water), – – Na and HCO3 combines into NaHCO3 (salt bicarbonate). Therefore, water of high hardness and high M–alkalinity to same extent requires a dealkali treatment. Electric conductivity 140 to 200 µS/cm This is determined by electrolytic If too low, it causes false stops. matter dissolved in water. If too high because of a lot of inpurities in water, it causes erosion on feeler fingers. (when the current-carrying feeler is used) Consumption of Below 2.0 ppm This is related to existence of organic Corrosion, stained cloth, desizing, drop potassium matter. in size film strength permanganate Bacterior having chlorophyll, iron bacterior Evaporation residue Below 100 ppm Total amount of inpurities in water This causes various obstacles. Water temperature 14 to 20°C If too high, it increases desizing, letting bacterior breeds easily. If too low, it lowers strength of size or wax. Improper water temperature lowers filling inserting performance.

54 1.4 Water

REFERENCE: Actual water quality examples (Please analyze the water quality beforehand.) A research on rust was conducted. Since the data from the water treatment manufacturer and the information on already delivered looms are summarized briefly below, please analyze the water quality at the customer beforehand by referring to the following table. (1) Result of research

Poor water quality with respect to rust Good water quality with respect to rust (shaded portion) Allowable No. Item quality ABCDEFGH I J standard 7 6.7 6.7 to 8.1 6.5 to 9 7 6.5 6.3 6.3 7.2 7.6 1 pH 6.7 to 7.5 (22°C) (21°C) (25°C) (25°C) (24°C) (26°C) (26°C) (26°C) (17 to 20°C) (16 to 19°C) 2 Calcium ion (mg/l) Below 30 89 62 — — 45 3.5 6.3 7.4 6.7 2.4 89.5 to 3 Chloride ion (mg/ ) Below 20 53.1 74.8 600 38 6.6 17.4 15.9 6 to 7 8 to 9 l 270 4 Sulfate ion (mg/l) Below 20 69.1 83.1 78.5 400 84 8 11.2 31.6 0 0 M– alkalinity 5 Below 60 206 145 128 50 79 21.9 28.2 25 54.8 119.6 (CaCO3 mg/l) Soluble substance 6 Below 200 432 424 — 1500 352 55 81 99 150 — (mg/l) 7 Langelier index ' –1 to 0.5 –0.28 –0.91 — –1.5 –0.95 –3 –2.8 –2.8 0 — Residual chlorine Less than Below Below Below 8 Below 0.3 1.5 —0.10.05 0.5 — (mg/l) 0.05 0.05 0.05 0.05 Total hardness 9 Below 302853209.636————8.62.9 (mg/l)

Electric conductivity 10 Ω 140 to 200600700747754—————— µ/cm D: Changed to air jet introduction because of too bad water quality in this case. (2) Consideration 1) It is commonly seen that rust is likely to be generated if the chloride ion, sulfate ion, soluble substance or residual chlorine much exceeds its allowable quality standard. 2) Soluble substance much above the allowable standard is not desirable because corrosive substance increases. 3) 0.5% is the limit for residual chlorine as a result of research in addition to the above data. If control of this content is neglected, corrosive breakdown of the heald may arise. We have heard an example in which temporary abnormality of the heald occurred because of no change in control against the water temperature difference between summer and winter. 4) If the total hardness is high, electric conductivity rises and more scum accumulates at the nozzle. 5) Electric conductivity is determined by the electrolytic matter dissolved in water. If electric conductivity is low, false stops will arise in case of a current-carrying feeler. If electric conductivity is high because of much soluble substance, erosion of SUS material will arise. – 6) M alkalinity represents the content (mg/l) of CaCO3. It is little related to rust but is an important indicator for softening with lime. If the value is high, iron content is subject to hydrolysis to cause precipitation of hydroxide, which is likely to deposit on the reed, etc.

55 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.4.2 Water Quantity, Temperature and Pressure [ 1 ] Water Quantity Maximum water supply quantity by pump types

Unit Upper line : l / h / loom Lower line : t / 24h / loom Pumped Loom speed (rpm) Pump type water q’ty (cc/pick) 600 650 700 750 800 850 900 1000 83.3 90.2 97.2 104.1 111.1 118.0 124.9 138.8 16 2.41 2.00 2.17 2.33 2.50 2.67 2.83 3.00 3.33 105.4 114.2 123.0 131.8 140.5 149.3 158.1 175.7 18 3.05 2.53 2.74 2.95 3.16 3.37 3.58 3.79 4.21 130.3 141.2 152.0 162.9 173.7 184.6 195.4 217.1 20 3.77 3.13 3.39 3.65 3.91 4.17 4.43 4.69 5.21 157.6 170.7 183.9 197.0 210.1 223.3 236.4 262.7 22 4.56 3.78 4.10 4.41 4.73 5.04 5.36 5.67 6.30 187.7 203.3 218.9 234.6 250.2 265.9 281.5 312.8 24 5.43 4.50 4.88 5.25 5.63 6.01 6.38 6.76 7.51 219.8 238.1 256.4 274.8 293.1 311.4 329.7 366.2 26 6.36 5.28 5.71 6.15 6.59 7.03 7.47 7.91 8.79

REFERENCE: • Maximum pump stroke: 12mm • Operating efficiency: 96% • Calculation of water consumption per hour per loom 2 D × π × L Q = ------× Nk60× × (min) 4× 1000000 where D : Plunger diameter (mm) L : Plunger stroke (mm) N : Loom speed (rpm) k : Safety factor (1.0 to 1.2) k = 1.0 was used in the above table.

[ 2 ] Water Temperature Make every effort to supply water of 14 to 20°C. Generally speaking, as the water temperature increases, desizing becomes heavy, causing warp fluff or improper shedding and lowering the operating efficiency.

[ 3 ] Water Supply Pressure The water pressure supplied to the float box should be within 1.5 to 2.0 kg/cm2, because the float box is so designed as to work stably under that range of water pressure.

56 1.4 Water

1.4.3 Water Treatment There are various treating methods according to the source water quality. Determine the treating method and equipment after consultation with a specialist. Usually, the following water treatment process is adopted.

Pump Removal of Source water Removal of turbidity Fe and Mn Water tank

Pump Activated Softening Softening charcoal tank

Pump Pouring of Fine filtration LW looms chemicals

The purpose of each process is as follows.

Process Purpose Removal of turbidity, iron and To remove turbidity, iron ion, solid matter and manganese ion in the source water, and manganese prevent yellowish coloration. Activated charcoal To remove organic matter. Softening To replace Ca ion and Mg ion by Na ion to reduce the hardness. To add a certain rate of potassium hypochlorite to oxidize, sterilize, deodorize and Impregnation of chemicals breach the water. Fine filtration To remove fine solid particles, use a 5µ filter.

57 1. PREPARATIONS FOR INTRODUCING THE MACHINE

1.5 Other Equipment 1.5.1 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. Humidity control is important because especially low humidity will likely to cause warp fluffing or broken warp leading to decreased operation rate. 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.

Spun yarn Filament yarn Temperature (°C) 20 to 25°C Humidity (%RH) 65 to 80% Temperature, humidity, and air circulation Controllable Air circulation frequency (No. of times/hour) 12 to 15 • When the humidity drops below 65% RH, static electricity is generated to cause easy fluffing. • When the humidity rises to above 90% RH, condensation may arise to cause malfunctioning and failures of loom electric parts.

1.5.2 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

58 1.5 Other Equipment

1.5.3 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 sec- ondary 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.

Group inverter SC inverter Name Operation (magnet contactor) (relay)

MSL CRL Contactor or relay for commercial power supply ON during continuous running

ON during forward revolution MSF CRF Contactor or relay for forward revolution (normal running or slow inching) During reverse revolution MSR Note 1 Contactor for 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.

[ 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

Chapter 2. INSTALLATION WORK

2.1 Preparations for Installation ...... 62

2.1.1 Arrangement of Workers ...... 62

2.1.2 Setting-up of Unpacking and Carrying-in Tools ...... 62

2.2 Installation Work ...... 63

2.2.1 Positioning of the Weaving Machine ...... 63

2.2.2 Jobs to be Done before Securing the Legs of the Weaving Machine ...... 63

2.2.3 Installation ...... 63 [ 1 ] Levelling the Weaving Machine...... 63 [ 2 ] Cheese Stand (Package Stand) Base Installation on Foundation ...... 65 [ 3 ] How to Attach Direct Supply Parts ...... 66

2.2.4 Wiring and Piping to Weaving Machines ...... 70 [ 1 ] Wiring ...... 70 [ 2 ] EDP Wiring...... 71

61 2. INSTALLATION WORK

2. INSTALLATION WORK 2.1 Preparations for Installation 2.1.1 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.

Carrying-in and installation Schedule Trial run Weaving for inspection Worker’s of machines (April 7 and 8) (April 9 to 22) skill level* (April 1 to 6) Setting-up Trial run Adjustment A 2 workers Installation Preparation for test run Weaving start-up B 4 workers Carrying-in Cleaning and lubrication Warp beam setting C 4 workers Wiring Starting-up Electric 1 worker * 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.

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

Tools Quantity Tools Quantity

Hammer, 1 to 2 pound 2 Forklift, 3.5 t or more 1 min 1.4 m

Bar, 1.5 m × ø40 2 Hand lift, 3 t or more 2

Large pincers 2 Small jack, 1.5 t or more 2

Wooden bar, 120 mm square 4/machine

REFERENCE: The leveller will be prepared by TOYOTA service personnel.

62 2.2 Installation Work

2.2 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.

2.2.1 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.

2.2.2 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 cloth rollers, etc. from the weaving machine and carry them to the specified places. (3) Install the beam curtain, warp arrangement springs, and signal indicator to the specified positions. (4) Wipe off oil from the back roller, easing roller, dropper box, and side frames. (5) Check the quantity of the accessories according to the packing list.

2.2.3 Installation [ 1 ] Levelling the Weaving Machine

CAUTION

When a weaving machine exposed to cold out- • When two or more workers are to handle a door atmosphere is brought into a warm indoor job, they must always communicate through location, all machine parts will be covered with words or gestures before starting the job. condensed water droplets. This condensation • Whenever inserting or removing the pack- will cause immediate rust due to oxidation of ing under the weaving machine legs during the metal surfaces. leveling, never let fingers get between the Bring the machine indoors and leave it in its leg and floor surface. packed state for a while until it reaches room (1) Place levels 3 on side frames 1 and rocking temperature. 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. An irregularity of 0.5 mm/m in the levelness will register as one increment off in the level window. One increment

(Manufactured by OBISHI KEIKI. Grade A, Size 150)

63 2. INSTALLATION WORK

(2) If the machine is not level, make it level with packings. 5 Listed below are packings available for weaving machines.

4 Type Thickness Application Correct loom leveling Steel 1, 2, or 3 using a combination Stainless steel mm of three packing types (in thickness). Insert felt packings or steel packings under the bottom of the side frames' feet as shown at left. 4: Packing Packings 5: Side frame’s foot

P a c k Frame Frame in Frame g feet feet s feet

Packings

Insert the steel packing between the side frame’s and frame feet, and fix both feet by tightening the bolt. When inserting packings beneath the machine, lift up the weaving machine with small jacks 7 which should be applied to front cloth rail 8 and back cloth rail 9 as shown at left.

64 2.2 Installation Work

[ 2 ] Cheese Stand (Package Stand) Base Installation on Foundation

View

NOTE: The package stand varies with the customer specifications. Check the shape and dimensions of the stand with the relevant specifications. The above drawing shows the typical dimensions for installing the stand.

65 2. INSTALLATION WORK

[ 3 ] How to Attach Direct Supply Parts [ 3.1 ] Water Supply Hose Connect the float box and the water supply hose. (1) Wind a piece of seal tape around the hose joint A and screw it in the stop valve of the water supply pipe. NOTE: • Seal tape should be prepared by the user. • Securely connect the hose joint so as not to cause leaks. (2) Set the hose band to the end of the wired hose which comes from the float box . (3) Fit the hose to the hose joint and tighten the hose band .

[ 3.2 ] Blower Install the blower after tightening the anchor bolts. (If installed before tightening the anchor bolts, it may get harder to tighten anchor bolts. (1) Install bolts and nuts as illustrated to support blower . Adjust the height to match the floor surface condition to avoid blower shaking.

Part name Part number Quantity Bolt 81155-08040 4 Nut 84155-08000 4 (25)

66 2.2 Installation Work

(2) Remove the paper affixed on the inlet (IN) and outlet (OUT) sides of blower , and install blower flange and blower gasket on the IN and OUT sides of the blower using bolts and washers . NOTE: Do not install gasket on the out5let side in the case of blower model VFC308.

Blower motor model: VFC308 Part name Part number Quantity Flange W1515-01010-00 2 Gasket 61325-02000 1 82157-06016 4 Bolt & washer 84502-00600 4

Blower motor model: VFC408 Part name Part number Quantity Flange W1515-01030-00 2 Gasket 61325-02002 2 82157-08016 4 Bolt & washer 84502-00800 4 (3) Remove the terminal cover from blower , and connect the blower cables to the terminal block of blower . Since the cables are marked, be sure to connect them securely without an error.

Terminal E UVW block (Ground) E21 U21 V21 W21 Cable (Green/ (Red) (White) (Black) yellow) (4) Fit the hose on the suction side of the dehy- dration tank to the inlet (IN) side flange of blower , and fix it be fastening the hose band.

[ 3.3 ] Window Cover Mount the window covers by inserting the window bar into the groove insides the left window cover and the right window cover . NOTE: Attach the window cover to the loom after the warp mounting and adjustments.

67 2. INSTALLATION WORK

[ 3.4 ] Splash Sheet (1) Remove the splash plate from the loom. (2) Let the rib of the sheet fit into the groove of the splash plate .

[ 3.5 ] Reed Protector (1) Press in and down the reed protector to the LH member of the reed . (2) Place the reed on the adjusting pins of the reed holder, press it to the left against the stopper pin, and fix it with the reed clamps.

CAUTION The reed does not need mounting the reed protector if its side members are covered with ceramic coating.

Stopper pin Adjusting pin

68 2.2 Installation Work

[ 3.6 ] Heald Curtain Adjust the curtain length to the weaving width. (1) Place the cut-off position of the curtain at 5 to 10 mm from the CC yarn. In case of shedding specification by CC yarn, place it at 5 to 10 mm from the RH lever. (2) Cut the cover at the end of curtain bar bracket end face. (3) Do not scrap the cut off curtain for use upon weaving width change. (4) Install the curtain bat in the illustrated position. (80 cm from the bracket end) Adjust the curtain bar position when making the weaving width by –720 mm or more.

80 mm Cutting position O-ring Adjust to the curtain end face. (To prevent the curtain from Curtain bar displacement.) bracket

Leno

CC yarn Curtain cut-off portion

5 to 10 mm

[ 3.7 ] Insu-lock Untie the Insu-lock from the front cloth rail. Be sure that the lower pan is tilted toward the cloth front Insu-lock side.

Tilting Lower pan

[ 3.8 ] Individual Inverter Installation (In Case of Individual Inverter Specification) To fix the individual inverter while transporting each loom, they are connected using a support bar. Remove the support bar, and place the individual inverter directly on the floor.

69 2. INSTALLATION WORK

2.2.4 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 terminal board (TB3) 2 located inside the main control box. REFERENCE: This wiring work is not necessary for individual inverters (SC inverters) since it has been finished before delivery from the factory.

70 2.2 Installation Work

[ 2 ] EDP Wiring [ 2.1 ] Wiring from Weaving Machine to EDP Control Box (1) In case of 2-color specification 1) Remove the cable cover, and pass cables through inlet holes 1 and 2. (Table 1)

EDP control box

Arrow view Cover

Box exterior view Perspective in arrow direction

Table 1 No. Cable name Mark tube Destination 1 EI board power cable EDP.POWER Box internal connection (Notes 1 and 2) using ø60 bushing EI board power cable (option) EI-CNP LH board power cable LH1 CN2 Optical fiber LH1← LH1/LH2→ 2 LH actuator cable LH1 CN3 Box internal connection (Note 1) using ø34 bushing Note 1: Passing the connector through the bushing

a. Cross cutting the bushing with nippers as .

b. Pass the connector through the bushing before installation on the box. Install the bushing with the cable through it onto the cable inlet hole of the box.

Box

Wire harness Connector

Bushing (Insert the bushing.) (Fix the bushing onto the box.)

Note 2: Since the optical fiber cable is weak to bending, carefully avoid bending to an acute angle.

71 2. INSTALLATION WORK

2) After leading the cables in, install the cable cover. 3) Cabling to the inside of the EDP control box shabby be done as illustrated below.

EDP.POWER connector

LH1 Board

LH1 CN3

LH1 CN2 TX connector RX connector

EI - CNP

Connect the optical fiber with “LH1 ←” punched on the vinyl tube to TX on the LH1 board, and the one with “LH1/LH2 →” punched on the vinyl tube to RX on the LH1 board.

72 Chapter 3. PREPARATIONS FOR WEAVING START-UP

3.1 Warp-related Preparations...... 74 3.1.1 Mounting the Warp Beam(s) and Procuring Warp Yarn ..... 74 [ 1 ] Assembly of Yarn Beams Common with LW600 ...... 74 [ 2 ] Assembly of Yarn Beams Common with JAT ...... 78 [ 3 ] Warp Preparation ...... 80 [ 4 ] Warp Winding Direction...... 80 [ 5 ] Calculation of Maximum Warp Winding Length ...... 81 3.1.2 Ordering Heald Frames...... 83 3.1.3 Catch Cord (CC) Heald ...... 85 3.1.4 Ordering and Installing the Reeds ...... 86 [ 1 ] Types of Reed ...... 86 [ 2 ] How to Attach Reed ...... 86 [ 3 ] Outline of Reed ...... 87 3.1.5 Filling Preparation...... 89 3.1.6 Leno Yarn Preparation...... 89 3.1.7 Catch Cord Yarn ...... 90

3.2 Lubricants, Cleaning Oil, and Sealant ...... 91 3.2.1 Lubricants...... 91 [ 1 ] Lubricant Symbols and the Corresponding Products Commercially Available ...... 91 [ 2 ] Properties of Lubricants ...... 92 [ 3 ] Lubricants Required Before Trial Run ...... 92 [ 4 ] Lubricants Required after Production Weaving...... 93 [ 5 ] Lubricating Tools ...... 94 [ 6 ] Storage of Lubricants ...... 95 3.2.2 Cleaning Oil and Sealant...... 95 [ 1 ] Cleaning Oil...... 95 [ 2 ] Sealant Required at the Time of Oil Change...... 95

73 3. PREPARATIONS FOR WEAVING START-UP

3. PREPARATIONS FOR WEAVING START-UP 3.1 Warp-related Preparations In the preparations described in this section, the following accessories should be prepared by either your company or TOYOTA 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 • Healds • Heald frame • Reed • Winder for leno selvage yarn

3.1.1 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.

[ 1 ] Assembly of Yarn Beams Common with LW600 [ 1.1 ] Type of Yarn Beams Common with LW600

Yarn beam flange diameter Barrel diameter ø800 ø164 or ø176 ø914 ø214 ø1000 ø214 For details, refer to [ 1.3 ] “Assembly of Yarn Beams Common with LW600”.

[ 1.2 ] Adjustable Range of Weaving Width The table below shows the adjustable range of the beaming width.

(mm) Maximum winding Weaving width adjustable range Reed space (mm) width Standard (600) Option (800) 150 1510 c — 170 1710 c — 180 1810 c — 190 1910 cc 210 2110 cc 230 2310 cc

CAUTION • The beaming width is set to “Reed space + 10 mm” making the gear side flange as the basis. • When changing the beaming width by moving the anti-gear side flange, clean the barrel and thinly apply grease to the screw, then turn the flange gently so as not to damage the screw.

74 3.1 Warp-related Preparations

[ 1.3 ] Assembly of Yarn Beams Common with LW600 (1) To avoid serious damage to beam parts, remove any foreign material from the threads in barrel , flange and lock nut .

CAUTION If flange is assembled with barrel where dirt or foreign matter remains, the threaded portion may be damaged to become unusable. (2) Apply a thin coat of grease to the threads in barrel and flange . (3) Position and thread flange gently onto beam barrel from the gear side of yarn beam. Attach beam gear to barrel with the setting bolts.

CAUTION Since the barrel materials is aluminum, improper assembly can easily damage threads. (4) Leaving a clearance between the gear and the flange hub, insert the fixing bolts through the side of gear . Screw them into holes prepared in flange . Tighten them equally and alternately so that flange is evenly tensioned.

CAUTION • After tightening the bolts, the beam gear to flange clearance should be about 2 mm around the entire circumference. • The tightening torque of the gear and flange-boss binding bolt is 500 kg-cm. (5) Position and thread the opposite flange onto barrel . Rotate until it reaches the desired reeded width (beaming width). (6) Position and thread lock nut onto barrel , rotating it until it reaches a position leaving a slight clearance against the flange hub. Insert the setting bolts through lock nut and screw them into the prepared flange holes. Tighten them alternately and evenly.

CAUTION • After tightening the bolts, the clearance between the flange and nut should be about 2 mm around the entire circumference. • The tightening torque of the gear and flange-boss binding bolt is 500 kg-cm. (7) Wipe excess grease from the barrel and flange after assembling.

75 3. PREPARATIONS FOR WEAVING START-UP

About 2 mm (About 7 mm in case About 2 mm of Scholze product)

Assembly of yarn beam

76 3.1 Warp-related Preparations

Weaving width * * About 7 mm in adjustable range About case of Scholze About 2 mm product 2 mm (on gear side)

L (Effective length of square thread)

Beaming hole Beaming hole

106 100 (ø800 yarn beam) (ø800 100 168 yarn beam) (ø800 (ø914 or ø1000 yarn beam) 110 yarn beam) (ø914 or ø1000 110 yarn beam) (ø914 or ø1000 yarn beam) View B View A

(mm) Yarn beam flange diameter L1 L2 L3 L4 L5 L D1 D2 D3 D4 ø800 R/S+340 R/S+10 600 21 8 725 800 164 488 50 or 176 ø914 R/S+343 R/S+10 600 25 5.5 725 914 214 576 55 ø1000 R/S+343 R/S+10 600 25 5.5 725 1000 214 576 55

77 3. PREPARATIONS FOR WEAVING START-UP

[ 2 ] Assembly of Yarn Beams Common with JAT (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) Warp beam Warp beam dia. L1 (mm) flange dia. 2b 1b ø150 215 ø800 ø178 215 (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. (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.

Three bolts which secure gear 4 to flange 2 Eight bolts which secure gear 4 to beam 1

78 3.1 Warp-related Preparations

(6) Opposite to the warp beam gear side Make a mark on warp beam 1 “Drawing-in width” mm away from the mark made in step (2).

CAUTION Listed below are minimum effective drawing-in widths relative to the nominal reed spaces.

Nominal reed space Min. effective drawing-in R/S (cm) width (cm) 150 Nominal reed space – 60 cm 170 190 Nominal reed space – 70 cm 210 230 250 280 336 Nominal reed space – 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). REFERENCE: 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.

79 3. PREPARATIONS FOR WEAVING START-UP

[ 3 ] Warp Preparation Since the water jet loom operates at high speeds using the water, the quality of raw yarn or sizing exert great influence on the loom operating efficiency or the cloth quality. For instance, low quality of raw yarn or sizing causes improper shedding, that is, some warp ends are entangled and left in the shed. Therefore, the filling insertion is hindered by such yarns, resulting in a short pick or an endback and worsening the loom efficiency or the cloth quality. Accordingly, use extreme care in preparing the most suitable warp. It is important to prepare the warp “that was warped, sized and beamed under a uniform tension and does not have any fluff or broken filament”. When preparing the warp, pay attention to the following points. (1) Remove “burrs”, “scratches”, “size waste deposit”, etc. from every yarn contacting surface of preparatory machines such as the creel, warping machine, sizing machine, beaming machine, etc. (2) In each preparatory machine, the yarn tension should be thoroughly controlled with extreme care. (3) Prevent warp fluffing by thoroughly controlling the temperature and humidity or by using a static electricity remover. (4) Except special cases, the warp should be sized properly. When there is “fluff” or “broken filament” in the shed, it hinders filling insertion, lowering the loom operating efficiency. Therefore, it is important to remove the cause of “fluff” or “broken filament” and improve the smoothness and wear resistance of the warp. (5) Use a water resisting sizing agent that is of exclusive use for the water jet loom. Since the water jet loom uses water, the water soluble POVAL-base sizing agent for the shuttle loom use, if used, will be melted during operation and become unable to function properly. (6) Dry up the warp completely after sizing. (7) Handle the warp carefully. Note that the warp may fluff if it is shocked or touched by somebody. (8) Do not misdraw the warp ends. Misdraw can be the cause of “fluff” or “broken filament”. It can also be the cause cloth defects such as “warp streak”, “stretched warp” or “loose warp”. Misdraw is caused mostly by an artificial miswork in all processes after sizing. Take measures so as not to allow misdraw. (9) Since surplus ends not only waste the warp but also cause troubles in weaving, prepare the warp so as not to produce surplus ends.

[ 4 ] Warp Winding Direction Wind the warp around the yarn beam counterclock- wise when viewed from the yarn beam gear side. The wound warp shape should be flat without swell- Wrap Yarn beem gear ing near the flange. Beam the sized warp onto the loom beam after leaving the sized warp to shrink for more than two days. The diameter of the beamed warp should be less than the outside diameter of the yarn beam flange.

Winding Direction [Beamed warp diameter = Flange diameter – 15 mm]

Yarn beem flange

80 3.1 Warp-related Preparations

[ 5 ] Calculation of Maximum Warp Winding Length Calculation from apparent specific gravity of warp

2 2 π()D – D × W × ρ × 9000 Max. warp winding length L = ------1 2 (m) 4dN× ×

4LNd× × × 2 Warp winding diameter φ = ------+ D (cm) 9000× W × ρπ× 2 where D1 : Yarn beam flange dia. – 1.5 (cm) D2 : Yarn beam barrel dia. (cm) (ø800: 16.4 / ø1000: 21.4) d : Denier (d) (1 d = 1 g / 9000 m) ρ : Apparent specific gravity (g/cm3) N : Number of warp ends (ends) W : Warp winding width (cm)

Examples of apparent specific gravity by yarn types

Condition Warping beam Sizing beam Loom beam Yarn type Average Range Average Range Average Range Nylon yarn 0.90 0.80 to 0.92 0.76 0.70 to 0.82 0.81 0.80 to 0.82 Polyester yarn 1.00 0.98 to 1.10 0.93 0.85 to 1.00 0.90 0.80 to 0.95 Textured yarn 0.61 0.56 to 0.63 0.52 0.48 to 0.56 0.60 0.50 to 0.70 NOTE: The above values may change according to conditions.

81 3. PREPARATIONS FOR WEAVING START-UP

Warp winding length

Nylon 70d (end/in) Warp windingdiameter Warp

Warp winding length

Nylon 210d (end/in) Warp windingdiameter Warp

Warp winding length

Polyester 50d (end/in) Warp winding diameterWarp

Warp winding length

Polyester 75d (end/in) Warp winding diameter Warp

Warp winding length

82 3.1 Warp-related Preparations

3.1.2 Ordering Heald Frames

IMPORTANT

Make sure if you need ordering of heald frames. If you need ordering your self, be sure to purchase them before starting weaving.

The table below shows the healds of stainless steel set by our company. The healds on the market can also be used. In this case, use the stainless steel healds of the following dimensions.

5.5 × 1.2 mm IN CENTER

5.5 mm 15 mm L mm

0.3 mm

15.0 5.5 2.0 1.2

Flat reinforced heald Unit (mm) Sectional dimensions Eye dimensions End loop dimension (L) 5.5 × 0.3 5.5 × 1.2 280 302 330

NOTE: • Duplex flat heald • Carrier rod sectional dimensions are 9.5 × 1.5 mm.

83 3. PREPARATIONS FOR WEAVING START-UP

NOTE: • Let healds pass onto the heald bars so that their curved ends are arranged on the same bar. • Set the healds to the heald frame with their end curves held on the upper side as illustrated. • Set the duplex healds with their offset mails arranged alternately as illustrated left. • Since the mail part is weak, handle the heald carefully. • After a use, check the healds for scratches and wear and exclude the ones which became out of use. Clean the usable healds to remove size paste attached. • Keep the heald density less than about 25 pcs./inch. A too high density sticks the adja- cent healds together due to the surface tension of water, causing a warp streak or fluff.

84 3.1 Warp-related Preparations

3.1.3 Catch Cord (CC) Heald The following healds are available for the exclusive use of the CC yarn. Select the type when determining specifications. 3 2 L L 1 L L

View A A

L L1 L2 L3 278 139 240 120 328 164 290 145

85 3. PREPARATIONS FOR WEAVING START-UP

3.1.4 Ordering and Installing the Reeds [ 1 ] Types of Reed Since the reed is not included in the delivered loom, prepare the reed on user’s side. For the LWT710 looms, reed strokes are shortened for 2-color and 3-color specifications. When using reeds with dimension H exceeding 90 mm, the position of the curtain should be raised to prevent interference with reeds. Note that dimension H exceeding 102 mm cannot be used.

[ 2 ] How to Attach Reed (1) Place the reed , as illustrated below, on the two reed adjusting pins attached on both sides of the reed holder , then slide the reed to the left so that its side member fitted with the protector is pressed against the positioning pin knocked into the reed holder . (2) Apply the reed clamp to the reed and tighten the nuts to fix the reed. The tightening torque is 150 kgf-cm. (3) When the reed dents get worn due to rubbing with the warp ends, turn the reed adjusting pins , whose heads are eccentric, to change the setting height of the reed . In this case, set the punched marks of the right and left reed adjusting pins at the same angular position.

Reed adjusting pin

Punched mark

How to attach reed

86 3.1 Warp-related Preparations

[ 3 ] Outline of Reed [ 3.1 ] Reed for IR Feeler (Punched Dent Type)

2-R0.5 to 1 Section A-A (mm) Read stroke Standard Super-hard Reed dimension H 82 89 Front face of metallizing area side member (mm) Member thickness T 4.8 6.0 8.0 Reed thickness t 2.2 2.2 2.8 L (Reed drawing-in width + 112)

Reed drawing-in width

T Window

t *

Thick dent Side member Side member T Where dents are Rivet punched through Section B-B NOTE: • This reed is for the use of water jet looms. • Provide a 10 mm wide window and a 0.5 mm thick dent on either side of the reed as illustrated. • There should be no density dispersion. The reed dent should be perpendicular to the bottom member within 90° ± 30'. • DURAFLEX reed should be used. • “Overall length L × Density / Unit” should be punched on the frame face. • The two *-marked areas on the front and the back of the LH sidemember should be treated with super- hard metallizing (Praxair: LW-IN30). • Reed wire (SUS304) should be used. • When manufacturing 4.8 mm thick members (channel portions), use the stainless steel. • When a reversible reed is used, change the upper member height (channel portion) from 7 mm to 20 mm and add super-hard metallizing to the symmetrical portions at the top and bottom on the rear side. In case of the reversible reed, use by raising the reed curtain to prevent interference. Be also careful when using the reversible reed because water splashed to the rear side of the cloth increases to increase desizing of warp yarns. When operating the machine at high speeds, use the standard reed (7 mm). • The above dimension C should be 23 mm or under. If longer than 23 mm, the reed may interfere with the bottom surface of the feeler head.

87 3. PREPARATIONS FOR WEAVING START-UP

[ 3.2 ] Reed for IR Feeler (Dummy Reed Type)

2-R0.5 to 1 Section A-A (mm) Read stroke Standard Super-hard Reed dimension H 82 89 Front face of metallizing area side member (mm) Member thickness T 4.8 6.0 8.0 Reed thickness t 2.2 2.2 2.8

L (Reed drawing-in width + 25)

Reed drawing-in width

T Window

t *

Thick dent Side member T Rivet Section B-B

NOTE: • This reed is for the use of water jet looms. • Provide a 10 mm wide window and a 0.5 mm thick dent on the left side of the reed as illustrated. • There should be no density dispersion. The reed dent should be perpendicular to the bottom member within 90° ± 30'. • DURAFLEX reed should be used. • “Overall length L × Density / Unit” should be punched on the frame face. • The two *-marked areas on the front and the back of the LH side-member should be treated with super- hard metallizing (Praxair: LW-IN30). • Reed wire (SUS304) should be used. • When manufacturing 4.8 mm thick members (channel portions), use the stainless steel. • When a reversible reed is used, change the upper member height (channel portion) from 7 mm to 20 mm and add super-hard metallizing to the symmetrical portions at the top and bottom on the rear side. In case of the reversible reed, use by raising the reed curtain to prevent interference. Be also careful when using the reversible reed because water splashed to the rear side of the cloth increases to increase desizing of warp yarns. When operating the machine at high speeds, use the standard reed (7 mm). • The above dimension C should be 23 mm or under. If longer than 23 mm, the reed may interfere with the bottom surface of the feeler head.

88 3.1 Warp-related Preparations

3.1.5 Filling Preparation When preparing filling, pay close attention to the following points. (1) The filling should be would on a package (pirn, cheese, or cone) so that yarn unwinding tension is mini- mized. (2) Do not size filling yarn except in very special circumstances. Even for a lowtwist filling such as the stretch yarn, use only yarn lubricants. (3) Slub yarns and elastic yarns such as Lycra are difficult to weave. (4) Use yarns that have been torque-set to a factor of less than 3.0 Kringel (measured by Kringel Factor meter). (5) When winding filling onto jumbo bobbins, winding hardness should be within a range from 65° to 70°.

3.1.6 Leno Yarn Preparation Leno yarn Leno yarn can dramatically influence weaving efficiency, fabric quality and finishing processing. The following leno yarns are generally used. (1) Yarn of the same type as the warp. (2) Mono-filament yarns about half the size of the body yarn. (3) Two or three-ply 15 d to 20 d mono-filament yarns twisted to 40 to 60 T/m. (4) The high-stretch twisted yarns when a multi-filament yarns are required.

Preparation of leno bobbins (1) Wind yarn smoothly across the face of the leno bobbin, avoiding high selvages. Improper bobbin formation will cause tension fluctuations and result in broken leno yarn or loosened selvages. (2) Wind the leno yarn on the bobbin counter- clockwise when viewing the bobbin from the ratchet end. (3) Avoid excessive yarn tension. Excessive winding tension can deform or destroy the leno bobbin.

CAUTION Set the winding tension to 0.1 to 0.15 g per denier.

89 3. PREPARATIONS FOR WEAVING START-UP

Length of yarn on leno bobbin (1) Four leno bobbins are required per loom. (Four bobbins are supplied with each loom.) Spare bobbins should be purchased separately. (2) The leno yarn consumption per loom is calculated as follows: (Warp length) × 1.3 × 4. The following table shows examples of the yarn length when fully wound.

G: Weight in full bobbin state Grams of Yarn Actual Yarn Length in Theoretical Yarn Type Yarn (g/piece) Meters (m) Length in Meters (m) Nylon 70d-16F-100T/M 22 2968 2829 Polyester 150d-30F-640T/M 20 1098 1200

3.1.7 Catch Cord Yarn The catch cord (CC) holds the right end of the inserted filling to apply an appropriate tension to form a firm sal- vage. Therefore, use the CC yarn that is strong and knotless. A 100 to 150 d finished yarn is generally used. Use four packages of less than ø80(D) × 200 (H) per loom. The CC yarn consumption per loom is about “(Warp length) × (3.7 - 5.7) × 4 m”.

90 3.2 Lubricants, Cleaning Oil, and Sealant

3.2 Lubricants, Cleaning Oil, and Sealant 3.2.1 Lubricants [ 1 ] Lubricant Symbols and the Corresponding Products Commercially Available

Type of lubricants Oil Grease

Symbol E ABCD(For centralized Manufacturer lubrication) Mobil Gear Oil 600 Mobil 600W Mobil Vacuoline 528 Mobilux EP-2 Mobilux EP-0 XP150 Cylinder Oil Esso Teresstic 150 Spartan EP150 Beacon EP-2 Beacon EP-1 Sunlight Grease 0 Alvania EP Shell Tellus Oil C150 Omala Oil 150 Valvata Oil 460 Alvania EP Grease 2 Grease 0 NIPPON OIL Worm Gear Lube Epnoc Grease FBK Oil RO 150 Bonnoc M 150 Multinoc Grease 2 CORPORATION 380(N) AP (N) 0 JOMO JOMO JOMO Lisonix JOMO Lisonic JAPAN ENERGY JOMO Lathus 150 Reductus 150 Reductus 460 Grease EP No. 2 Grease EP No. 0 Daphne Daphne Daphne Eponex Daphne Eponex IDEMITSU KOSAN Super Gear Oil Mechanic Oil 150 EP No. 2 EP No. 0 150 Cosmo Oil Cosmo Gear Cosmo Grease Cosmo syuchu Cosmo Allpus 150 Lubricants SE150 Dynamax No. 2 Grease No. 0 Kyodo Oil Unilube No. 2 Unilube DL No. 0 Castrol British Petroleum BP Energol BP Energol BP Energol BP Energol Molub-Alloy (BP) HLP 150 GR-XP 150 MM-EP 2 MM-EP 0 G0140

Always use the recommended lubricants in the table above.

NOTE: (1) See the explanation on later pages for the portions corresponding to the use codes. (2) For lubrication of each of the dobby and positive cam shedding motion, refer to the instruction manual supplied from each manufacturer.

91 3. PREPARATIONS FOR WEAVING START-UP

[ 2 ] Properties of Lubricants

Types of lubricants Oil Grease Symbol E Physical & chemical ABCD(For centralized properties lubrication) Kinematic 100°C 13 to 16 13 to 15 26 to 30 — — viscosity Cst 40°C 135 to 153 135 to 155 370 to 393 — — Viscosity index 95 or more 95 or more 97 or more — — Flash point 216° or above 225° or above 236° or above — — Pour point –12.5° or below –10.0° or below 5° or below — — Total acid value mgKOH/g 0.85 or less 1.8 or less — — — Total base value mgKOH/g — 9.5 or less — — — Sulfated ash % — 12 or less — — — Soap base — — — Lithium Lithium Miscibility 25°C — — — 265 to 295 355 to 385 Dropping point — — — 175° or above 170° or above Oil percentage%————— MOS2 particle size ————— (average) µ

[ 3 ] Lubricants Required Before Trial Run [ 3.1 ] For Negative Tappet Cam Shedding Motion

Lubricant type Symbol Lubricating points Quantity per machine

A*1 Chain A little Oil B Tappet cam box*2 11.5 l Grease D Bearings, gears, and springs A little *1 : For applying oil A, use the oiler (Tool No. 695) provided with the machine. *2 : The oil in the tapped cam box is drained before shipment. Apply oil before the trial run.

[ 3.2 ] For Positive Tappet Cam Shedding Motion For the type and amount of oil to be used in the tappet cam (positive shedding) box, refer to the instruction manual of each manufacturer.

Lubricant type Symbol Lubricating points Quantity per machine Oil A Chain A little Grease D Bearings and gears A little

[ 3.3 ] For Crank Shedding Motion Prepare the same type of oil and grease as for the positive tappet cam shedding motion specified in [ 3.2 ].

[ 3.4 ] 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 for the positive tappet cam shedding motion specified in [3.2] above.

92 3.2 Lubricants, Cleaning Oil, and Sealant

[ 4 ] Lubricants Required after Production Weaving Prepare oil and grease by referring to the quantity listed below.

Lubricant type Symbol Lubricating points Quantity per machine RH & LH gearing boxes 4.4 (2.2 for each box) A l l Chain A little Oil B Tappet cam box (in negative shedding motion) 11.5 l Let-off drive box (single beam) 2.4 C l Electronically controlled take-up motion reduction gear 1 l D Bearings, gears, and springs A little Grease E Grease tank for the centralized lubrication system 400 g

CAUTION (1) After approx. 60 million picks (approx. 2.5 to 3 months) from the start of running for production, it is necessary to replace the oil for the gearing box, tappet cam box, let-off drive box, and electronically controlled take-up motion reduction gear. Be sure to order the specified oil according to the schedule. (2) Do not use the oil that has been mixed with water or any foreign matter. Otherwise, gears may be damaged. In such a case, replace the respective lubricant irrelevant to the replacement timing. (Oil mixed with water will be changed to yellowish color.)

93 3. PREPARATIONS FOR WEAVING START-UP

[ 5 ] Lubricating Tools 1: Oil drainer (Commercially available) REFERENCE: For the manufacturer names, refer to Chapter 4, Section 4.3 “Manufacturers of Weaving-related Machines”.

2: Oil drainer attachment (Tool No. 743)

3: Grease gun (Tool No. 769-1) 3 4: Oiler (Tool No. 695) 5: Oiler (Commercially available) 6: Oiler (Commercially available) 7: Brush (Commercially available) REFERENCE: • Tools numbered (such as Tool No. 743) are included in the tool kit provided with the machine. 54 7 6 • Commercially available tools should be set up by your company.

94 3.2 Lubricants, Cleaning Oil, and Sealant

[ 6 ] 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.

3.2.2 Cleaning Oil and Sealant [ 1 ] Cleaning Oil 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 When changing oil in the RH & LF gearing boxes and tappet cam box (in the negative shedding motion), it is necessary to remove the magnet plug for wiping off iron powder from the plug. After reinstalling the magnet plug, apply sealant (Three-bond 1215 or equivalent) to its screw section.

Chapter 4 APPENDIX

4.1 TMS (TOYOTA MONITORING SYSTEM)...... 98 [ 3 ] Loom Side Signal I/F Circuit Diagram.... 127 4.1.1 Scope of Your Work ...... 98 [ 4 ] Time Chart...... 128 4.1.2 Network Connection Concept ...... 101 [ 5 ] Checking Connection between Loom and LTB3 ...... 128 4.1.3 Network Design...... 103 [ 6 ] Management of Looms Connected to 4.1.4 Piping Work...... 111 TMS Scanner ...... 129 4.1.5 Wiring Sample Diagram ...... 113 4.2.4 Studying Loom Connection to 4.1.6 Network Cable Connector Installation TMS Scanner PC...... 130 Method ...... 114 [ 1 ] Prepare the Plant Layout Drawing...... 130 4.1.7 Network Cable Connection to LWT710.... 117 [ 2 ] Indicate the Computer Mounting Positions 4.1.8 Connection with Customer’s Network...... 118 in the Plant Layout Drawing ...... 130 [ 1 ] Introduction...... 118 [ 3 ] Study the Cabling Routes and Cable Lengths on the Layout Drawing...... 131 [ 2 ] Router Installation Example...... 118 [ 4 ] Cautions for TMS Scanner [ 3 ] Rough Description of Connection Communication ...... 131 Method...... 119 4.2.5 Works after Determining TMS Scanner 4.2 TMS Scanner Introduction ...... 134 (TOYOTA MONITORING SYSTEM SCANNER) ... 122 [ 1 ] Matters to be Checked upon Determining 4.2.1 TMS Scanner Overview ...... 122 Introduction (Discussion between the 4.2.2 Features of TMS Scanner...... 123 Customer and Us) ...... 134 [ 1 ] Restriction of TMS Functions by [ 2 ] Signal Conduit Installation Work Weaving Machine Model ...... 123 (Customer’s Work) ...... 134 [ 2 ] TMS Scanner PC Configuration ...... 125 [ 3 ] Sending The Cable and Scanner PC (Our Work)...... 134 4.2.3 Connection between Looms and Data Collection Boards (LTB3)...... 126 [ 4 ] Preparation of The TMS-PC (Customer’s Work) ...... 134 [ 1 ] Communication Method between LTB3 Boards and Computer ...... 126 [ 5 ] Cable Installation, and TMS Scanner Set- ting and Connection [ 2 ] Conditions for Connecting LTB3 to (Customer’s Work) ...... 135 the Loom...... 127 4.3 Manufacturers of Weaving-related Machines ... 136

97 4. APPENDIX

4. APPENDIX 4.1 TMS (TOYOTA MONITORING SYSTEM) Connecting the LWT710 Water Jet Weaving Machine to the network will allow use of TMS (Toyota Monitoring System) and other network applications (optional). You are requested to provide your own network piping, wiring-related equipment, computer arrangement and construction work on your account.

4.1.1 Scope of Your Work • Designation of TMS options of LWT710 Since the network board and software CD-ROM exclusively for LWT710 are necessary, lease inform TOYOTA of these TMS options when determining the LWT710 specifications. • Network design based on LWT710 connection study diagram Study the LWT710 connection method by entering the wiring route in the plant layout drawing. Please prepare the network design appropriate for your plant by referring to 4.1.3 “Network Design” and determine the required cable length as well as the quantities and installing 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 4.1.4 “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 4.1.3 (5) “Network equipment selection and ordering”. • In case of the Water Jet Weaving machine, carry out the above networking work with sufficient attention paid to the water quality and condensation.

(1) Computer Selection standards • PC/AT compatible machine preinstalled with Microsoft Windows 2000 or Microsoft Windows XP as the OS. • CPU : Frequency at or above 2.0 GHz • Memory : 512 MB or more • HDD : 2GB or more of HDD, C drive space • LAN : Ethernet port installed as network interface (compatible with 100BASE-TX or 10BASE-T) • Required peripherals: Display unit, keyboard, mouse, desk and chair • PC card drive: Type I or Type II × 1 slot (TMS can be operated by data collection from the memory card during network down. This is not mandatory.) (2) Software • Microsoft Internet Explorer version 5.5 or later • Microsoft Excel 2000 or 2003

98 4.1 TMS (TOYOTA MONITORING SYSTEM)

(3) Switching hubs Selection standards • All ports must be compatible with 100 BASE-TX/10BASE-T, full/half duplex communication. • 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 Caution:) Selection standards • All ports must be compatible with 100 BASE-TX/10BASE-T, full/half duplex communication. • 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:

Network 1

Router A

Network 2

Router B

Network 3

• Please contact us if you need further details of these units and their ordering information.

CAUTION When connecting looms to the customer's intracompany network, always use a router to separate the looms from the customer's intracompany network. (See 4.1.8 “Connection with Customer’s Network”.)

99 4. APPENDIX

(5) Network cable Selection standards • Must use 100BASE-TX (category 5 or above). • Straight connection is necessary.

CAUTION 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.

100 4.1 TMS (TOYOTA MONITORING SYSTEM)

4.1.2 Network Connection Concept For networking in a plant, connect the network boards (optional) in respective loom control panels using switching hubs.

Loom Loom Router Loom Loom Switching Switching Loom hub hub Loom Network 1 Network 2

Switching Switching hub hub Loom Loom

Loom Switching Switching Loom Loom hub hub Loom

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. • In case of a Water Jet machine, carefully prevent adverse influence from water and condensation.

101 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. • 100BASE-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.

102 4.1 TMS (TOYOTA MONITORING SYSTEM)

4.1.3 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.)

103 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.

Over 200 Units

• 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.

Over 100 m

104 4.1 TMS (TOYOTA MONITORING SYSTEM)

(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.

CAUTION 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.

105 4. APPENDIX

• Relaying switching hubs are necessary for connecting looms to the network. First determine their positions.

CAUTION The computer is a precision electronic device. Select a location where it can be protected from fluffs and condensation. If it is to be installed inside the plant, house it in a metal box for protection. • Determine the places for installing switching hubs for loom connection. • The number of looms to be connected to each switching hub depends on the number of its ports. (8, 16 or 24 ports are general.) • The total number of switching hubs will decrease if the number of ports in each switching hub is greater. Such problems as long wiring path and complicated wiring routes, however, may arise. • Determine the switching hub positions on the layout drawing in consideration of the wiring routes.

106 4.1 TMS (TOYOTA MONITORING SYSTEM)

(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.

Over 100 m

107 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

CAUTION 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.

108 4.1 TMS (TOYOTA MONITORING SYSTEM)

• 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”.

100 or 200 VAC

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.

109 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.

CAUTION • For selection standards, refer to 4.1.1 “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.

110 4.1 TMS (TOYOTA MONITORING SYSTEM)

4.1.4 Piping Work • The piping work for network wiring is described also in 4.1.2 “Network Connection Concept”. Install exclusive metal conduits for noise prevention. (See the figure below.)

Length from floor to connector 1.5 m

To network board To network board (within control panel) (within control panel)

Network cable Metal conduit To switching hub

Dia. 30 or above

To network board To network board (within control panel) (within control panel)

Metal conduit

Network cable To switching hub

(✽) 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.

CAUTION Install 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 (uninter- ruptible power supply) for stabilized power supply. (See 4.1.5 “Wiring Sample Diagram”.)

CAUTION The computer is a precision electronic device. Select a location where it can be protected from fluffs and condensation. In case of a Water Jet machine, install it so as to avoid adverse influenced of water. If it is to be installed inside the plant, house it in a metal box for protection.

111 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.

Weld hexagon nuts (M9) on the rear face of the outer box.

(Outer box dimensions) (Center plate dimensions) A = 445 D = 400 B = 495 E = 450 C = 195 (Center plate mounting position) F = 360 G = 410

• Drill holes at the top or bottom of the box for leading the power and network cables into the box. Determine the positions according to the plant wiring condition. • To protect the cables, cover the hole edges with rubber grommets. • Determine the hole diameters according to the number of switching hub ports by referring to the guideline below. For power cable Dia 20 For network cable (in case of 8 ports) Dia 30 For network cable (in case of 16 ports) Dia 30 × 2 For network cable (in case of 24 ports) Dia 40 × 2

Switching hub box manufacturing example

112 4.1 TMS (TOYOTA MONITORING SYSTEM)

4.1.5 Wiring Sample Diagram Network wiring example 1 (When a single piece of network cable within 100 m can be used)

Power line (100 VAC) Switching-HUB To the computer Network cable room

Loom 1 Loom 2 Loom 3 Switching-HUB

Switching-HUB

Network wiring example 2 (When a single piece of network cable over 100 m is required)

Power line (100 VAC) Switching-HUB To the computer Network cable room

Loom 1 Loom 2 Loom 3 Switching-HUB

Switching-HUB Switching-HUB Switching-HUB

Switching-HUB

Switching-HUB Switching-HUB Switching-HUB

113 4. APPENDIX

4.1.6 Network Cable Connector Installation Method

What must be prepared • Network cable (*) • Connectors (*) • Nippers • Special network cable crimping tool

CAUTION * 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.

114 4.1 TMS (TOYOTA MONITORING SYSTEM)

(2) Arrange the core conductors as illustrated below.

Order

Orange/white

Orange

Green/white

Blue

Blue/white

Green

Brown/white

Brown

(3) Cut the core conductors with nippers for neat arrangement.

(4) With the metal terminals of the connector facing upward, insert the arranged conductors into the connector.

115 4. APPENDIX

(5) After checking if the inserted connectors are in the specified order, crimp them using the special crimping tool.

116 4.1 TMS (TOYOTA MONITORING SYSTEM)

4.1.7 Network Cable Connection to LWT710 Connect the network cable on the loom side to the daughter board (network interface card) on the control board in the control box.

117 4. APPENDIX

4.1.8 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.

[ 2 ] Router Installation Example Example of connection with (1) Loom TMS network (172. 17. 1. ✽✽✽) (2) Customer’s company network (123. 456. 78. ✽✽✽)

Loom TMS network (172.17.1.✽✽✽) • IP address : 172.17.1.✽✽✽ • Subnet mask : 255.255.255.0 • Default gateway : 172.17.1.254 172.17.1.254

CISCOSYSTEMS Router

123.456.78.254

Customer’s intracompany network (123.456.78.✽✽✽) • IP address : 123.456.78.✽✽✽ • Subnet mask : 255.255.255.0 • Default gateway : 123.465.78.254

118 4.1 TMS (TOYOTA MONITORING SYSTEM)

[ 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.

Network 1 Network 2

Network: “172.17.1.✽” Network: “123.456.78.✽” Sub-net mask: “255.255.255.0” Sub-net mask: “255.255.255.0”

[ 3.1 ] 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.

Port A IP address: 172.17.1.254 Sub-net mask: 255.255.255.0

Router

Port B IP address: 123.456.78.254 Sub-net mask: 255.255.255.0

Connect the router set as shown above to two networks.

Network 1

Network: “172.17.1.✽” Sub-net mask: “255.255.255.0”

Port A

Router Connect to the switching hub of each network. Port B

Network 2

Network: “123.456.78.✽” Sub-net mask: “255.255.255.0”

119 4. APPENDIX

[ 3.2 ] 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.

For the computer in network 1

For the computer in network 2, input 123.456.78.254.

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.

120 4.1 TMS (TOYOTA MONITORING SYSTEM)

[ 3.3 ] 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.

121 4. APPENDIX

4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) 4.2.1 TMS Scanner Overview Use of the TMS (Toyota Monitoring System) scanner exclusively for the JAT/LWT710 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 (LTB3) 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 LTB3. The TMS can collect data from the TMS scanner PC, and summarize the operation data of the JAT/LWT710 and the TMS scanner PC into the same report and graph.

TMS TMS scanner PC

Switching hub Switching hub

Warp-out/Doffing switch

Use of the TMS scanner to connect looms other than JAT/LWT710 to the TMS.

LTB3

JAT/LWT710 network Network of looms other (Ethernet) Looms require parallel monitor than JAT/LWT710 outputs such as the production (Serial communication) pulse, stop signal, and stop cause signal.

Fig. 1 TMS Scanner Overview

122 4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)

4.2.2 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 JAT/LWT710 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 JAT/LWT710.

[ 1 ] Restriction of TMS Functions by Weaving Machine Model The TMS scanner is restricted in available functions depending on the connected loom type.

[ 1.1 ] Data by Shift

c: Not restricted U: Restricted °: Unusable JAT/LWT710 JAT610, etc. z Shift report c U(*1) z Style report c U(*1) z Production output graph cc z Operation rate graph cc z Stop cause graph c U(*1) z Looming list and forecast cc z Stop history c × *1 Display of the causes for the shift report, style report, and stop cause graph is partially restricted. See the table below.

c: Not restricted U: Restricted —: No output on machine Stop cause JAT710 LWT710 TMS scanner (JAT610, etc.) Warp miss (upper) ccU (Counted as warp miss) Warp miss ccc Selvage miss (left) — c U (Counted as selvage miss (right)) Selvage miss (right) ccc Leno miss (left) ccc Leno miss (right) ccU (Counted as leno miss (left)) Weft miss ccU (Wholly counted as WF1 miss) Warp out ccc Cloth doffing ccc Manual stop ccc Power OFF ccc Others ccc

123 4. APPENDIX

[ 1.2 ] Machine Data

JAT/LWT710 JAT610, etc. z Operation status display cc z Data collection (network) cc z Data reading (memory card) c° z Link to loom screen c° z Loom time setting c° z Cloth/beam list setting °c z Other list setting °c z Cloth/beam maintenance °c

[ 1.3 ] Data by Operator

JAT/LWT710 JAT610, etc. z Operator report c° z Production output graph c° z Operation rate graph c°

[ 1.4 ] Setting

JAT/LWT710 JAT610, etc. z Report setting cc z IP address setting cc z Password setting cc

[ 1.5 ] Scanner Setting

JAT/LWT710 JAT610, etc. z Style setting °c z Shift schedule setting °c z Unit setting °c z Loom name and specification setting °c z Password setting °c

[ 1.6 ] Data Editing

JAT/LWT710 JAT610, etc. z Edit data submenu cc z Export to CSV file cc

124 4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)

[ 2 ] TMS Scanner PC Configuration

TMS scanner Dedicated computer (TMS scanner PC) Display

Keyboard (with pointing device)

UPS

Plant power supply (100 VAC, 50/60 Hz) (A transformer is necessary when the power supply voltage is different.)

• 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.

CAUTION

• 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.

125 4. APPENDIX

4.2.3 Connection between Looms and Data Collection Boards (LTB3) To introduce the TMS scanner, it is necessary to connect looms to LTB3 boards. Check if the looms to be monitored allow connection with the LTB3 boards.

[ 1 ] Communication Method between LTB3 Boards and Computer The data collection board (LTB3) collects the loom parallel monitor signals such as the production pulse, stop signal and stop cause signal. LTB3 sends the collected data to the TMS scanner PC by serial communication (RS485).

Loom Parallel monitor signal

Parallel signal interface LTB3

Loom

Parallel signal interface LTB3

Loom Serial communication (RS485)

Parallel signal interface LTB3

Upstream Downstream

TMS scanner PC

CAUTION

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.

126 4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)

[ 2 ] Conditions for Connecting LTB3 to the Loom To connect LTB3 to each loom, the following power voltage and signals must be supplied from the loom:

Necessary power voltage • 12 VDC (LTB3 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)

Stop signal (run/stop)

Weft miss stop signal, etc. • • • • • •

Warp miss stop signal

Signal ground

Production pulse signal

Signal ground

127 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.

Loom running state

Production pulse (1 pick output)

Stop signal Stop cause signal

*1 Ta: Loom stop output delay time = 50 msec max.

[ 5 ] Checking Connection between Loom and LTB3 • 12-VDC power supply is mandatory • Production pulse and run/stop signals are mandatory. • If no other signal exists, LTB3 counts it as “other stop”. • Check if the signal I/F circuit on the LTB3 side is suitable for LTB3. • Contact us when connecting our JAT610 or LW600. • Consult with the loom manufacturer when connecting a loom of other make.

128 4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)

[ 6 ] Management of Looms Connected to TMS Scanner Summarize JAT710 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.

Manufacturer Power Mandatory Model name Quantity I/F circuit Remarks (lacking signal, etc.) name supply signals JAT710 TOYOTA cccConnected directly to TMS LWT710 TOYOTA cccConnected directly to TMS JAT610 TOYOTA cccConnected to TMS via TMS scanner LW600 TOYOTA cccConnected to TMS via TMS scanner

Total

CAUTION

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.

129 4. APPENDIX

4.2.4 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 JAT/LWT710 and JAT610 are mixed, distinguish the models in different col- ors.

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.

CAUTION

Computers are precise electronic devices. Select the positions that can be protected from flies and dew- ing.

130 4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)

[ 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.

Downstream

Upstream ..... 127 max.

Channel 1 (S1-01)

..... 127 max.

Channel 2 (S1-02)

..... 127 max.

Channel 3 (S1-03)

..... 127 max.

Channel 4 (S1-04)

131 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 LTB3. Each loom ID for identification is determined by combining the serial communication channel number and the LTB3 address. For example, the ID of the loom with 1 as its LTB3 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 JAT/LWT710 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.

Connection cable between loom and computer (First lay the material cable, and connect both ends via exclusive connectors later.)

Computer

Special-purpose connection cable between looms

• 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 which- ever one according to the situation in the customer’s plant.

132 4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)

Underground conduit installation

Connectors

Loom Loom Floor surface Floor surface

← Junction box

Conduit installation Conduit for cabling (diameter at 25 mm or more)

Overhead conduit installation

Communication cable

Ceiling

Take the ceiling height and loom length into consideration Conduit for cabling when studying the cable length. (diameter at 25 mm or more)

133 4. APPENDIX

4.2.5 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 REFERENCE: 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 4.2.4 “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. NOTE: 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 JAT/LWT710 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 2000” or “Microsoft Windows XP” CPU : Frequency at 800 MHz or above Memory : 256 MB or more HDD : Hard disk with an empty space of 2 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 2000 or Microsoft Windows XP Others : Display, keyboard, mouse, etc. The TMS requires application software: Microsoft Excel 2000 and Microsoft Internet Explorer.

134 4.2 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER)

[ 5 ] Cable Installation, and TMS Scanner Setting and Connection (Customer’s Work) • Perform cabling as explained in 4.2.4 “Studying Loom Connection to TMS Scanner PC”. • Perform TMS scanner setting. • Check the connection between the TMS and TMS scanner. NOTE: This work requires supervision by our service engineer. Please ask us to dispatch the service engineer according to your work execution schedule.

135 4. APPENDIX

4.3 Manufacturers of Weaving-related Machines

TEL Manufacturer name Address Machines FAX Todo, Ltd. 10th Hase Bldg. 2F, 391, Osaka- +81 75 371 0715 • Leasing machine cho, Karasuma 5-jyo, Simokyo-ku, +81 75 371 0665 • Reaching machine Kyoto, 600-8177 JAPAN • Drawing-in machine • Dropper pinning machine • Tying-in machine • Beam carrier • Beam stocker • Automatic reed washing machine Zellweger Uster Ltd. H-8610, Uster, SWITZERLAND +41 1 943 2211 • Drawing-in machine +41 1 943 3838 • Dropper pinning machine 6-3, Boushima 4-chome, Minoh-shi, +81 72 721 1481 • Tying-in machine Osaka, 562-0013 JAPAN +81 72 721 1538 • Leasing machine Osaka Taiyu Co., Ltd. 10-1, Ina 6-chome, Minoh-shi, +81 72 729 2121 • Beam carrier Osaka, 562-0015 JAPAN +81 72 728 3439 Teijin Seiki Co., Ltd. 1-9-1, Edobori, Nishi-ku, Osaka, +81 6 6448 6001 • Drawing-in machine 550-0002 JAPAN +81 6 6445 2004 Toyoda Seiki, Ltd. 1-8, Uchihata-cho, Hanazono, +81 75 802 5371 • Tying-in machine Ukyo-ku, Kyoto, 616-8045 JAPAN +81 75 821 4353 Kitamura, MFG. Ltd. 96-1, Senfukuji-machi, Matsutou, +81 76 276 3111 • Cloth inspection machine Ishikawa, 924-0802 JAPAN +81 76 276 1529 Toyoda Sangyo Co., Ltd. 57-5, Ochayashita, Ogakie-cho, +81 566 21 4565 • Weft cutter grinding machine Kariya, Aichi, 448-0813 JAPAN +81 566 21 5236 Kiji Reed Co., Ltd. 21, Asahigaoka 3-chome, +81 76 275 6656 • Automatic reed washing machine Matsutou, Ishikawa, 924-0004 +81 76 275 2268 JAPAN Takayama Reed Co., Ltd. 27-20, Jinguji 2-chome, Kanazawa, +81 76 252 2266 • Automatic reed washing machine Ishikawa, 920-0806 JAPAN +81 76 252 3134 Eito System Co., Ltd. 15-60, Yoshino-sakai, Matsuoka- +81 776 61 4500 • Beam stocker cho, Yoshida-gun, Fukui, 910-1127 +81 776 61 4545 • Beam setter JAPAN • Glass-fiber cloth inspection machine Ishihara Shoji K.K. 19-12, Shioiri-cho, Mizuho-ku, +81 52 811 2191 • Oil lubricator Nagoya +81 52 822 5415 • Oil drain

136