Page 1 Notice: Specifications, operating instructions, and dimensions in this manual are subject to change for improvements without prior notice. TOYOTA shall take no responsibility for loss, damage, expense or claims for bodily injury or property damage arising from incorrect usage which is not in accordance with the instructions given in this manual.
Page 2 ATTENTION This manual uses the following symbols: WARNING, CAUTION, WARNING WARNING 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.
Page 3: Table Of Contents
CONTENTS OUTLINE OF INSTALLATION WORK................... 5 Chapter S. SAFETY 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 ......................15 S.1.4 Rules for Operating or Checking the Electrical Devices............17 Chapter 1.
Page 4 4.2.2 Network Connection Concept .................... 101 4.2.3 Network Design ......................... 103 4.2.4 Piping Work ........................111 4.2.5 Wiring Sample Diagram..................... 113 4.2.6 Network Cable Connector Installation Method ..............114 4.2.7 Network Cable Connection to JAT710 ................117 4.2.8 Connection with Customer’s Network................118...
Page 5 4.3 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) ..........122 4.3.1 TMS Scanner Overview ....................122 4.3.2 Features of TMS Scanner ....................123 4.3.3 Connection between Looms and Data Collection Boards (LTB3) ........126 4.3.4 Studying Loom Connection to TMS Scanner PC .............. 130 4.3.5 Works after Determining TMS Scanner Introduction ............
Page 6: Outline Of Installation Work
OUTLINE OF INSTALLATION WORK Items marked with a box are jobs which you should do. Use the list given below as a check list. 1. Preparations for Introducing the Machine Complete the following preparations: Building construction and floor work (Irregularity in the floor levelness: 5 mm or less, Surface irregularities of the floor where the legs of the machine are to be positioned: 1 mm or less) Foundation work, floor marking, and anchor bolt laying work* (* This job is not required if you select the gluing installation method.)
Page 7: Chapter S. Safety
Chapter S. SAFETY 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 ..........15 S.1.4 Rules for Operating or Checking the Electrical Devices ..17...
Page 8: Safe Work
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.
Page 9 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.
Page 10 S. SAFETY [ 2.2 ] Transport (1) Before bringing in machinery, always prepare well-maintained carriers. Carriers Q'ty Specifications Forklift 3.5 t (or wrecker) (Reed space:150-190 cm) Hand lift 3.0 t or more Small jack 1.5 t or more × × Wooden block Approx.
Page 11 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.
Page 12 S. SAFETY [ 3 ] Before Trial Run (1) Clear away bolts, nuts, tools and other unnec- essary 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.
Page 13: Rules For Safe Operation
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.
Page 14 2) If the signal indicator 1 flashes (in case of standard setting), warning lamp 2 lights and warning iron 3 is displayed: It means that the Toyota Automatic Pick Oper- ator (TAPO) is in operation. The machine is temporarily on halt and will restart running, so...
Page 15: Rules For Maintenance
S.1 Safe Work 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.
Page 16 S. SAFETY [ 3 ] During Maintenance Work For safety, be sure to turn off the machine before starting maintenance work. At the same time, be sure to put up the maintenance notice (specified by the plant) on the switches. [ 3.1 ] Basic maintenance procedure (1) Stop the machine by pressing the STOP switch.
Page 17: Rules For Operating Or Checking The Electrical Devices
S.1 Safe Work 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).
Page 19 Chapter 1. PREPARATIONS FOR INTRODUCING THE MACHINE Building ..................20 Foundation Work ..............22 1.2.1 Structure of Foundation ..........22 1.2.2 Laying the Foundation for Wiring and Piping....23 1.2.3 Floor Surface Conditions ..........23 1.2.4 Preparing Glue or Quick-hardening Cement ....23 1.2.5 Marking on the Floor .............
Page 20: Building
1. PREPARATIONS FOR INTRODUCING THE MACHINE Building (1) Make sure that the building has been com- pleted enough to protect the machines and related facilities from rain and wind. (2) Make sure that the width and height of the car- rying-in entrance are enough to carry in the machines laid on a forklift horizontally.
Page 21 1.1 Building Crank Shedding Motion (CS, CM) H (mm) D ( mm) Nominal Reed W(mm) Space (cm) φ 800F φ 930F φ 1000F φ 800F φ 930F φ 1000F R/S 150 3012 1265 1395 1465 1615 1727 1822 3412 1265 1395 1465 1615...
Page 22: Foundation Work
1. PREPARATIONS FOR INTRODUCING THE MACHINE Foundation Work Gluing Installation There are three types of installation methods for the weaving machines: • Gluing installation Steel packing • Bolting installation • On-the-floor installation Felt packing The bolting installation method may be divided into either straight-bolting or L-bolting installation.
Page 23: Laying The Foundation For Wiring And Piping
Required piping Air pipes (Other related piping, e.g., water piping) ATTENTION Conduits for network cabling is necessary in order to adopt the TMS (Toyota Monitoring System). Take it into consideration from the plant designing stage by referring to Appendix 4-2.
Page 24 1. PREPARATIONS FOR INTRODUCING THE MACHINE —— Reference —— If you are responsible for the preparation of the glue (for the gluing installation method) or quick-harden- ing cement (for the bolting installation method), refer to the recommended products given below. Glue for the gluing installation method Sikadur Product name:...
Page 25 1.2 Foundation Work 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 •...
Page 26: Marking On The Floor
1. PREPARATIONS FOR INTRODUCING THE MACHINE 1.2.5 Marking on the Floor (1) According to your floor plan specifying the lay- out 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).
Page 27 1.2 Foundation Work 2) Prepare quick-hardening cement (Poly-mortar). 3) Moisten the inside of the holes with water. Bolt support 55 mm (when no 4) While bleeding air, pour Polymortar into each frame feet are used) of the holes and put an anchor bolt into it so 60 mm (when frame that the distance from the top of the anchor feet are used)
Page 28 1. PREPARATIONS FOR INTRODUCING THE MACHINE EXAMPLE: Floor Plan for Negative Cam Shedding Motion (For details, refer to the submitted drawings.) 3745 2960 3945 3160 4145 3360 NOTE: This value does not denote the maximum width from the front to rear of the machine.
Page 29 1.2 Foundation Work EXAMPLE: Floor Plan for Crank Shedding Motion (For details, refer to the submitted drawings.) 3722 2937 3922 3137 4122 3337...
Page 30 1. PREPARATIONS FOR INTRODUCING THE MACHINE EXAMPLE: Floor Plan for Electronic Shedding Motion (For details, refer to the submitted drawings.) *B (MAX.) 4455 3670 1976 4655 3870 1976 4855 4070 1976...
Page 31 1.2 Foundation Work EXAMPLE: Floor Plan for Positive Cam Shedding Motion (For details, refer to the submitted drawings.) 4029 3244 4229 3444 4429 3644...
Page 32 1. PREPARATIONS FOR INTRODUCING THE MACHINE EXAMPLE: Floor Plan for Positive Dobby (For details, refer to the submitted drawings.) *B (MAX.) 4165 3380 1976 4365 3580 1976 4565 3780 1976...
Page 33: Wiring (For Looms Other Than Towel Weaving Machine)
1.3 Wiring (for looms other than towel weaving machine) Wiring (for looms other than towel weaving machine) 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 perfor- mances while maintaining safety.
Page 34 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 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.
Page 35: Circuit Breakers
1.3 Wiring (for looms other than towel weaving machine) 1.3.2 Circuit Breakers : Non-fuse circuit breaker(s) for inverter(s) 1: Plant switchboard 2: Group inverter : Non-fuse circuit breaker(s) for loom(s) 3: Loom line A ① : Cable between the switchboard breaker and the inverter 4: Loom line B ②...
Page 36 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 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.
Page 37: Cable Capacity
1.3 Wiring (for looms other than towel weaving 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 spe- cialists.
Page 38 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 2 ] Current in each loom operation state (In: Motor rated current) Current at delta starting Current at star mode starting High Current at slow operation Loom Loom operation 5 Hz operation by inverter Delta starting Star mode operation Slow operation...
Page 39 1.3 Wiring (for looms other than towel weaving machine) [ 4 ] Cable selection Select the cable according to steps [1], [2] and [3]. (1) Obtain the current flowing in cable ① between the circuit breaker on the switchboard and the inverter. Select the cable according to the value obtained by the equation below.
Page 40: Cable Capacity Calculation Examples (Reference Examples)
1. PREPARATIONS FOR INTRODUCING THE MACHINE 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 ①...
Page 41 1.3 Wiring (for looms other than towel weaving machine) • 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.
Page 42 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 2 ] Selection of cable ② between inverter and loom (Unit: mm Distance Power supply voltage Motor capacity 10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m 1.8 kW...
Page 43 1.3 Wiring (for looms other than towel weaving machine) [ 3 ] Selection of cable ③ between circuit breaker on switchboard and loom (Unit: mm Distance Power supply voltage Motor capacity 10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m...
Page 44 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 4 ] Selection of cable ① between circuit breaker on switchboard and electronic shedding loom (Unit: mm Distance Power supply No. of heald 10 m 20 m 30 m 40 m 50 m 60 m 70 m 80 m...
Page 45: Group Inverter
1.3 Wiring (for looms other than towel weaving 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 page 40 for the capacity of the cable between the inverter and loom.) [ 2 ] Major specifications, dimensions and weight of inverter Ventilation port RUN/STOP...
Page 46 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 3 ] Wiring method between inverter and loom Inverter For direct connection between Bus type wiring 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.
Page 47 1.3 Wiring (for looms other than towel weaving machine) [ 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 sat- isfied, install a transformer on the power supply side for regulation. (2) Is a distributor is required for wiring from the inverter to looms, it shall be provided by the customer.
Page 48: T Wiring (For Towel Weaving Machine)
1. PREPARATIONS FOR INTRODUCING THE MACHINE 1.3T Wiring (for towel weaving machine) NOTE: For the wiring of the looms other than the label weaving machine with separate inverter, refer to page 33. 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 perfor- mances while maintaining safety.
Page 49: Circuit Breakers
1.3T Wiring (for towel weaving machine) 1.3.2 Circuit Breakers 1: Plant switchboard : Non-fuse circuit breaker(s) for loom(s) 2: Loom A ① : Cables between breakers on switchboard and looms 3: Loom B 4: Loom C...
Page 50 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 1 ] 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.
Page 51: Cable Capacity
1.3T Wiring (for towel weaving 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 spe- cialists.
Page 52 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 2 ] Current in the loom operation state (Excluding the jacguard) (In: Motor rated current) Current at Current at delta starting star mode starting High Loom Loom operation Star mode operation Delta starting Full speed operation (Towel weaving machine) 5890...
Page 53: Cable Capacity Calculation Examples (Reference Examples)
1.3T Wiring (for towel weaving machine) 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 cable ①...
Page 54: Air Compressor
1. PREPARATIONS FOR INTRODUCING THE MACHINE Air Compressor 1.4.1 Compressed-air Requirements for Air Jet Weaving Machines and Precautions for Piping • Compressed air to be used for weft insertion should satisfy the following requirements in order to prevent weft miss and ensure fabric quality: •...
Page 55 1.4 Air Compressor [ 1 ] Calculating air volume required for weaving machines Q = Qo × (1 + Kz) × No (Nm /H) ..① Where Total air volume required (Nm /H) (*1) Air consumption per weaving machine (Nm Piping loss rate (0.2, taking into account air leakage from pipes) Number of weaving machines •...
Page 56 1. PREPARATIONS FOR INTRODUCING THE MACHINE [ 3 ] Calculating the approximate power consumption of compressor (1) For oil-free reciprocating compressors, oil-free screw compressors, and turbo compressors W = W1 × n × [a + b (1 – a)] (2) For oil injection screw compressors W = W1 ×...
Page 57: Layout Examples Of Air Compressors And Related Equipment
1.4 Air Compressor 1.4.3 Layout Examples of Air Compressors and Related Equipment [ 1 ] Oil-free reciprocating compressor If the dryer is a water-cooled type. Aftercooler & drain separator Differential pressure gauge Dry air Oil filter Carbon filte Dryer Air tank Oil-free reciprocating compressor Cooling tower...
Page 58: Piping
(3) Be sure to provide a drain port at a pipe rising portion. [ 2 ] Weaving room (1) The main pipe in the weaving room should be looped. Connect the main pipe and each weaving machine with a branch pipe. Layout and Piping Example for 48 JAT710 Looms...
Page 59 1.4 Air Compressor (2) Determine the pipe diameter according to the airflow rate. Criteria for determining the main pipe diameter • 240 m /H ....21/2 B (65A) or over • 480 m /H ....3B (80A) or over • 12,000 m /H ..5B (125A) or over Carbon steel pipe dimensions for piping Nominal diameter...
Page 60: Other Equipment
1. PREPARATIONS FOR INTRODUCING THE MACHINE 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. 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.
Page 61: Separate Take-Up Motion
1.5 Other Equipment 1.5.4 Separate Take-up Motion Connect the power supply to the separate take-up motion as shown below. Since this is a typical example, however, it is not always applicable to all separate take-up motions. [ 1 ] Power supply to separate take-up motion When operating the separate take-up motion using the plant power supply, it may be connected to the secondary side of the no-fuse circuit breaker (NF1) in the loom control box, but limit the power consumption by the separate take-up motion to within 500 W.
Page 63 Chapter 2. INSTALLATION WORK Preparations for Installation ............. 64 2.1.1 Arrangement of Workers ..........64 2.1.2 Setting-up of Unpacking and Carrying-in Tools ..... 64 2.1.3 Preparation of Piping ............. 64 Installation Work ..............65 2.2.1 Positioning of the Weaving Machine ......65 2.2.2 Jobs to be Done before Securing the Legs of the Weaving Machine ............
Page 64: Preparations For Installation
2. INSTALLATION WORK 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. Schedule Carrying-in and installa- Trial run...
Page 65: Installation Work
2.2 Installation Work 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.
Page 66 2. INSTALLATION WORK (2) If the machine is not level, make it level with packings. Listed below are packings available for weav- ing machines. Type Thickness Application To compensate for the sur- face irregularity of the floor. Felt 2 mm (This type should be used packing only for the gluing installation...
Page 67 2.2 Installation Work [ 2.2 ] Installation with anchor bolts As shown below, install the cheese stand base to the floor with anchor bolts according to your floor plan. 1 Drill from the top of the 2 Set an anchor bolt. 3 Drive in the pin with a 4 The anchor will be cheese stand base.
Page 68 It is very HEAVY. Using a cart will make this job easier. [ 3.1 ] Positioning the EDP stand Refer to JAT710 INSTRUCTION MANUAL, Chap- ter 5 Picking Motion. [ 3.2 ] Wiring and piping between the main...
Page 69 2.2 Installation Work [ 4 ] 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.
Page 70: Wiring And Piping To Weaving Machines
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.
Page 71 2.2 Installation Work —— Reference —— Air Piping Work to the Weaving Machine IMPORTANT Shown below are air pipes and related parts required before the start of the trial run. Parts A to E below are to be prepared by you for air piping. ③...
Page 73 Chapter 3. PREPARATIONS FOR WEAVING START-UP Warp-related Preparations............74 3.1.1 Mounting the Warp Beam(s) and Procuring Warp Yarn..74 3.1.2 Preparing the Droppers ..........78 3.1.3 Preparing the Healds............. 79 3.1.4 Preparing the Reed and Drawing in Warp ..... 81 3.1.5 Preparations for Selvage Construction......
Page 74: Warp-Related Preparations
3. PREPARATIONS FOR WEAVING START-UP Warp-related Preparations In the preparations described in this section, the following accessories should be prepared by either your company or Toyoda depending upon the specifications. Be sure to check which is responsible for those preparations. If you are responsible, prepare them before the weaving start-up. Warp beam(s) with flange and bearings Droppers Healds...
Page 75 3.1 Warp-related Preparations 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.
Page 76 NOTE: At the RH side of the let-off motion, install the RH beam in the same manner as for the LH beam. 1960 2240 DW : Drawing-in width 2310 LO : Genuine Toyota standard twin beam dimensions 2410 2560 Unit: mm (LO) Dimension A~R/S336 : 510-(R/S-DW)/2 DW/2–55...
Page 77 3.1 Warp-related Preparations [ 3 ] Winding warp onto a warp beam Warp beam gear Warp beam flange Warp letting-off direction Warp taking-up direction in sizing ATTENTION Be careful with the warp taking-up direction when sizing. [ 4 ] Preparing warp yarn When preparing warp yarn, be sure to observe the following: (1) Procure warp yarn and complete warp preparatory processes according to the schedule without any delay.
Page 78: Preparing The Droppers
3. PREPARATIONS FOR WEAVING START-UP 3.1.2 Preparing the Droppers IMPORTANT Check whether you are responsible for the preparation of the droppers. If you are responsible, prepare them before the start-up of weaving. –– Reference –– Choosing the Droppers The following data comes from the ISO and Grob catalogues. (1) Dropper types Type Closed type...
Page 79: Preparing The Healds
3.1 Warp-related Preparations 3.1.3 Preparing the Healds IMPORTANT Check whether you are responsible for the preparation of the healds. If you are responsible, prepare them before the start-up of weaving. –– Reference –– Steel Heald Specifications (1) Flat steel heald (reinforced type) Flat steel heald Overall length Max.
Page 80 3. PREPARATIONS FOR WEAVING START-UP (2) J-type riderless, flat steel heald (Uster auto drawing-in type) Max. Riderless, flat heald Overall length Yarn number count density Optimum yarn count English number Cross sec- count Mail size End-loop spacing (L mm) tion size Cotton Wool Linen (11”) (12”)
Page 81: Preparing The Reed And Drawing In Warp
3.1 Warp-related Preparations 3.1.4 Preparing the Reed and Drawing in Warp IMPORTANT Check whether you are responsible for the preparation of the reed. If you are responsible, prepare it before the start-up to weaving. NOTES ON REED HANDLING The reed plays a very important part in the machine operating efficiency and fabric quality. When handling the reed, observe the following precautions: –...
Page 82 3. PREPARATIONS FOR WEAVING START-UP [ 2 ] Drawing-in procedure Draw in warp from the left end of the reed (from the Reed 1st dent from the left main nozzle side) regardless of the drawing-in width. Drawing-in from the 2nd dent As shown at left, start drawing at the 2nd dent from the left.
Page 83: Preparations For Selvage Construction
3.1 Warp-related Preparations 3.1.5 Preparations for Selvage Con- struction [ 1 ] For Full-leno Selvage Device This device binds two leno yarns with every weft yarn at each side of the fabric to produce a firm sel- vage construction which will not become loose if weft yarns are cut.
Page 84 3. PREPARATIONS FOR WEAVING START-UP [ 2 ] For Half-leno Selvage Device (Klöcker) This device binds four leno yarns with every weft yarn at each side of the fabric to produce a firmer selvage construction than that produced by the full- leno selvage device, which will not become loose if weft yarns are cut.
Page 85 3.1 Warp-related Preparations [ 3 ] For warp-addition device This device generally feeds two additional warps into selvages in order to get cleaner warp separa- tion at the left end of fabrics (at the weft insertion side), thereby improving selvage firmness. Additional yarn (which you should procure) •...
Page 86: Preparations For Waste Selvage Device
3. PREPARATIONS FOR WEAVING START-UP 3.1.6 Preparations for Waste Selvage Device This device binds weft jetted up to the outside of the right edge of the woven fabric with several Waste-selvage yarn yarns fed from the waste-selvage cheeses (in the Waste-selvage bobbin stand-equipped type) or with several warps (in the stand...
Page 87 3.1 Warp-related Preparations [ 2 ] For non-stand type (which has no waste-selvage bobbin stand) This non-stand type uses ground warps of yarn Warp (ground yarn) number count 7’s to 40’s. (1) Number of waste-selvage yarns: 12 yarns as standard If a waste-selvage yarn break occurs fre- quently, use 16 yarns;...
Page 88: Weft-Related Preparations (Mainly Spun Yarn)
3. PREPARATIONS FOR WEAVING START-UP Weft-related Preparations (Mainly Spun Yarn) 3.2.1 Preparing Weft Yarn and Cheeses Air jet weaving machines whose weft insertion speed exceeds 1500 m per minute (Reed space: 190 cm, machine speed: 790 rpm) require not only high-quality weft yarn but also high-quality weft cones (cheeses).
Page 89: Lubricants, Cleaning Oil, And Sealant
3.3 Lubricants, Cleaning Oil, and Sealant Lubricants, Cleaning Oil, and Sealant 3.3.1 Lubricants [ 1 ] Lubricant Symbols and the Corresponding Products Commercially Available Type of Grease lubricants Symbol (For centralized lubrication) Manufacturer DTE Oil Mobil 600W Mobil Mobilgear 629 Mobilux EP-2 Mobilux EP-0 Extra Heavy...
Page 90: 2 ] Properties Of Lubricants
3. PREPARATIONS FOR WEAVING START-UP [ 2 ] Properties of Lubricants Types of lubricants Grease Symbol (For centralized Physical & chemical lubrication) properties 100°C 13–16 13–15 26–30 — — Kinematic viscosity 40°C 135–153 135–155 370–393 — — Viscosity index 95 or more 95 or more 97 or more —...
Page 91: 4 ] Lubricants Required After Production Weaving
3.3 Lubricants, Cleaning Oil, and Sealant [ 3.2 ] For positive tappet cam shedding motion Lubricant type Symbol Lubricating points Quantity per machine A little RH cutter and full-leno selvage device A little RH & LH tucker housings Grease Bearings and gears A little No oiling is required for the half-leno selvage device.
Page 92: 5 ] Lubricating Tools
3. PREPARATIONS FOR WEAVING START-UP [ 5 ] Lubricating Tools Oil drainer (Commercially available) NOTE: For the manufacturer names, refer to Chapter 4, Section 4.2. Oil drainer attachment (Tool No. 743) Grease gun (Tool No. 769-1) Oiler (Tool No. 695) Oiler (Commercially available) Oiler (Commercially available) Brush (Commercially available)
Page 93: Cleaning Oil And Sealant
3.3 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.
Page 95: Chapter 4. Appendix
4.2.3 Network Design ............103 4.2.4 Piping Work ..............111 4.2.5 Wiring Sample Diagram..........113 4.2.6 Network Cable Connector Installation Method .....114 4.2.7 Network Cable Connection to JAT710......117 4.2.8 Connection with Customer’s Network ......118 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) ....122 4.3.1 TMS Scanner Overview..........
Page 96: Jat710 Technical Information
4. APPENDIX JAT710 Technical Information 4.1.1 Nominal Reed Space and Effective Drawing-in Width [ 1 ] Nominal reed space 150, 170, 190, 210, 230, 250, 280, 336, 340, 360 and 390 cm [ 2 ] Effective drawing-in width Effective drawing-in width Max.
Page 97: Yarn Number Count Of Warp
4.1 JAT710 Technical Information 4.1.3 Yarn Number Count of Warp Reed space R/S(cm) Yarn type Spun yarn Ne5.5-100’s Ne9-60’s Ne14-60’s Ne14-50’s Filament yarn 30d-450d — — 40d-270d — — Glass fiber dtex 55-1340 — — — — — — —...
Page 98: Fabric Examples
4. APPENDIX 4.1.7 Fabric Examples Yarn type Fabrics Poolin (208) × ① PC45 PC45 ------------------------------------- × 1210 × 136 72 ② Calico C40 C40 × ---------------------------- - × 1840 × 78.9 63.5 Poolin (168) × ③ PC45 PC45 ------------------------------------- × 1687 ×...
Page 99: Tms (Toyota Monitoring System)
Toyota of these TMS options when determining the JAT710 specifications. • Network design based on JAT710 connection study diagram Study the JAT710 connection method by entering the wiring route in the plant layout drawing. Please prepare the network design appropriate for your plant by referring to 4.2.3 “Network Design”...
Page 100 • Straight connection is necessary. Note: Installation work materials such as metal conduits and power cables are also required. If you have any problem with 1) to 5) for TMS introduction, please consult with the Service or Sales Department of Toyota Industries Corporation.
Page 101: Network Connection Concept
4.2 TMS (TOYOTA MONITORING SYSTEM) 4.2.2 Network Connection Concept For networking in a plant, connect the network boards (optional) in respective loom control panels using switching hubs. • Key Points for Wiring Design • Maximum number of looms to be connected to a network should be about 200 units. If more than 200 units need to be connected, separate the network using a router.
Page 102 4. APPENDIX • 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. •...
Page 103: Network Design
4.2 TMS (TOYOTA MONITORING SYSTEM) 4.2.3 Network Design Network design is made for the following purposes: • To determine the laying routes of network cables and the power line. • To determine the lengths and quantities of necessary materials. • To determine the locations for installation of the computer, switching hubs and the router.
Page 104 4. APPENDIX 2) Dividing looms into groups as required • To network over 200 looms, divide the looms into groups, each consisting of within 200 looms. • If the row of looms is long, the network cable length may exceed 100 m. (The network cable must not be extended beyond 100 m.) Grouping of looms may make the wiring route study easier.
Page 105 4.2 TMS (TOYOTA MONITORING SYSTEM) Note: The computer is a precision electronic device. Select a location where it can be protected from fluffs and condensation. • If a router is necessary for networking over 200 looms, determine the place for router installation.
Page 106 4. APPENDIX • 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.
Page 107 4.2 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.
Page 108 4. APPENDIX • If there is no problem with the network wiring route, enter all routes in the plant layout drawing to complete the "network connection diagram". Network connection diagram example Note: Always connect each loom and switching hub, or between switching hubs using one indepen- dent cable in the form of star connection.
Page 109 4.2 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". Network device power cabling diagram example •...
Page 110 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)
Page 111: Piping Work
4.2 TMS (TOYOTA MONITORING SYSTEM) 4.2.4 Piping Work • The piping work for network wiring is described also in 4.2.2 Key Points for Design. Install exclu- sive metal conduits for noise prevention. (See the figure below.) Dia. 30 or above...
Page 112 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. •...
Page 113: Wiring Sample Diagram
4.2 TMS (TOYOTA MONITORING SYSTEM) 4.2.5 Wiring Sample Diagram Network wiring example 1 Power line (100 VAC) Switching-HUB To the computer (When a single piece of network cable within Network cable 100 m can be used) room Loom 1 Loom 2...
Page 114: Network Cable Connector Installation Method
4. APPENDIX 4.2.6 Network Cable Connector Installation Method (What must be prepared) • Network cable (*) • Connectors (*) • Nippers • Special network cable crimping tool Note: *The network cable is available in single core type and multiple core (stranded core) type. Pre- pare connectors that match the purchased cable type.
Page 115 4.2 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...
Page 116 4. APPENDIX 5) After checking if the inserted connectors are in the specified order, crimp them using the special crimping tool.
Page 117: Network Cable Connection To Jat710
4.2 TMS (TOYOTA MONITORING SYSTEM) 4.2.7 Network Cable Connection to JAT710 Connect the network cable on the loom side to the daughter board (network interface card) on the control board in the control box.
Page 118: Connection With Customer's Network
4. APPENDIX 4.2.8 Connection with Customer’s Network (1) Introduction For connection with the customer’s network, install a router to separate the loom TMS network from the customer's network. If directly connected, the data on the customer's network side may flow into the loom TMS network side to overload loom task processing, possibly causing temporary failure in loom network communication.
Page 119 4.2 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.
Page 120 4. APPENDIX 2) Computer setting The computer can basically communicate only with the computer belonging to the same network. For communication with a computer in a different network, it is necessary to send the data to the router once, from which it is to be sent to the computer in the different network. This router is called the default gate- way.
Page 121 4.2 TMS (TOYOTA MONITORING SYSTEM) 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...
Page 122: Tms Scanner (Toyota Monitoring System Scanner)
4.3.1 TMS Scanner Overview Use of the TMS (Toyota Monitoring System) scanner exclusively for the JAT710 loom will enable the operation data of other weaving machines (JAT610, LW600, and looms of other makes) to be col- lected 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.
Page 123: Features Of Tms Scanner
• 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 JAT710 looms connected to the TMS and other looms connected to the TMS scanner PC(s) is 1,000.
Page 124 JAT710 JAT610, etc. Edit data submenu Export to CSV file (2) Stop causes that can be collected from the looms other than JAT710 are as follows: Table 1. Stop Causes Collectable by TMS Scanner Stop cause JAT710 TMS scanner (JAT610, etc.)
Page 125 4.3 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) (3) TMS Scanner PC Configuration TMS scanner Dedicated computer (TMS scanner PC) Display Keyboard (with pointing device) Plant power supply (100 VAC, 50/60 Hz) (A transformer is necessary when the power supply voltage is different.) •...
Page 126: Connection Between Looms And Data Collection Boards (Ltb3)
4. APPENDIX 4.3.3 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.
Page 127 4.3 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...
Page 128 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...
Page 129 [ 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.
Page 130: Studying Loom Connection To Tms Scanner Pc
• 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 JAT710 and JAT610 are mixed, distinguish the models in different colors.
Page 131 4.3 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.
Page 132 • It is also possible to use two TMS scanner PCs (master and sub) for easier cable routing. • The total of JAT710 looms connected directly to the TMS and other looms like JAT610 connected via TMS scanner PCs must not exceed 1,000.
Page 133 4.3 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) • Underground conduit installation Connectors Loom Loom Floor surface Floor surface ← Junction box Conduit Conduit for cabling (diameter at 25 mm or more) installation • Overhead conduit installation Communication cable Ceiling Take the ceiling height and...
Page 134: Works After Determining Tms Scanner Introduction
• Aside from the scanner PC sent in [ 3 ], a computer installed with TMS is necessary. (This is unnecessary if the TMS for JAT710 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...
Page 135 4.3 TMS Scanner (TOYOTA MONITORING SYSTEM SCANNER) [ 5 ] Cable Installation, and TMS Scanner Setting and Connection (Customer’s Work) • Perform cabling as explained in 4.3.4 “Studying Loom Connection to TMS Scanner PC”. • Perform TMS scanner setting. • Check the connection between the TMS and TMS scanner.
Page 136: Manufacturers Of Weaving-Related Machines
4. APPENDIX Manufacturers of Weaving-related Machines Manufacturer name Address Machines • Leasing machine Todo, Ltd. 10th Hase Bldg. 2F, 391, +81 75 371 0715 Osaka-cho, Karasuma 5-jyo, +81 75 371 0665 • Reaching machine Simokyo-ku, Kyoto, • Drawing-in machine 600-8177 JAPAN •...

Toyota JAT710 Installation Manual

Chapter 1 . PREPARATIONS for INTRODUCING the MACHINE

Chapter 2 . INSTALLATION WORK

Chapter 3 . PREPARATIONS for WEAVING START-UP

Chapter 4. APPENDIX

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