Model JAT810€¦ · TOYOTA AIR JET WEAVING MACHINE Towel Loom Model JAT810 (FIRST EDITION) Thank...

JUNE, 2010 Ver. 2.01 (Towel)

TOYOTA AIR JETWEAVING MACHINE

Towel Loom

Model JAT810(FIRST EDITION)

Thank you for purchasing the JAT810 Air Jet Weaving Machine.

This instruction manual describes the correct installation, operating principles, function, adjustment, andmaintenance of the JAT810 motions, all of which should be familiar to all personnel concerned.

Before operating, adjusting, or maintaining the JAT810, be sure to read this manual carefully to understandthe JAT810.

Specifications, operating instructions, and dimensions in this manual are subject to change for improvementswithout prior notice.

TOYOTA shall take no responsibility for loss, damage, expense or claims for bodily injury or property damagearising from incorrect usage which is not in accordance with the instructions given in this manual.

In no event will TOYOTA be liable for products resulting from the use of this machine.

Introduction:

This manual is edited separately to provide instructions for towel looms. It consists of Machine and Electrical Parts. For items not covered herein, refer to the “Instruction Man-ual” for the standard looms (hereafter called Standard Machine “Instruction Manual”.)

Especially for matters related to safety, please first read Section S of the Standard Machine “Instruction Manual”.

As to the contents of the items described in both of the two above-said manuals, give pri-ority to this towel manual.

M1. Preparation for Setting .......................................................................................... M1-1

1.1 Yarn Beam Installation1.2 Preparation of the Beam1.3 How to Run the Warps and Woven Fabric Through1.4 How to Remove/Reinstall the P-tension Shaft for

Easier New Fabric Weaving

M2. Shedding Motion ................................................................................................... M2-1

2.1 Dobby Shedding Specifications2.2 Jacquard Shedding Specifications

M3. Temple .................................................................................................................. M3-1

3.1 Longitudinal Position of the Temple3.2 Crosswise Position of the Temple3.3 Vertical Position of the Temple3.4 Standard Setting of the Temple Ring3.5 Vertical Position of the Temple Cover3.6 Adjustment of Fell Plate Position

M4. Selvaging Machine................................................................................................ M4-1

4.1 Leno Weave with Two Clockers4.2 Trimmed Selvage Motion4.3 Gripper

M5. Pile Let-Off ............................................................................................................ M5-1

5.1 Pile Let-off Mechanism5.2 Outline of Let-off Control5.3 Adjustment of Easing Roller5.4 Adjustment of Electronic Terry Motion Type Let-off Pile Beam Tube Diameter Sensor

M6. Torsion Back ......................................................................................................... M6-1

6.1 Advance Adjustment6.2 Adjustment at the Change of Gland Warp Tension6.3 Machine Stop or Disabled Operation due to Abnormal Tension6.4 Height Adjustment

M7. Warp Stop Device ................................................................................................. M7-1

7.1 Longitudinal Position7.2 Vertical Position

CONTENTS

Section 1 Mechanical

Section 2 Electrical

M8. Lubrication ............................................................................................................ M8-1

8.1 Lubrication Cycle and Applicable Fluids8.2 Oil Change of Terry Motion Cam Box8.3 Oil Change of Jacquard Bevel Gearbox

M9. Electronic Terry Motion......................................................................................... M9-1

9.1 Adjusting the Stoppers9.2 Zero-point Restoration Proximity Switch9.3 Reverse Current Absorber Cover9.4 Lubrication of Terry Motion Gear Box

E1. State of Indicator Lamps and Mode Display .......................................................... E1-1

E2. Setting of Towel Loom-related Function Panel...................................................... E2-1

2.1 Towel Screen Setting Method2.2 How to Set [ PILE ]2.3 Pattern Initialization

E3. Setting and Operation of Towel Loom Beam-related Function Panel.................... E3-1

E4. Electric Components / Let-off Motions for A Towel Loom...................................... E4-1

4.1 Electric Components

E5. Instrumentation and Electronic Jacquard for Towel Weaving Machine ................. E5-1

E6. Electronic Terry Motion.......................................................................................... E6-1



M1. Preparation for Setting

1.1 Yarn Beam Installation

[ 1 ] Gland beam installation

(1) [Installation on the yarn beam gear side]Mark the yarn beam 1 90 mm from side “a”with a felt-tipped pen, etc.

(2) Screw in a yarn beam flange 2 from directionA. Set the inside of the flange to the markedposition.• For the ease of screwing, apply grease or

oil to the threaded portion.

(3) Set a yarn beam gear 4 to the yarn beam 1 sothat the bolt holes (large, 8 holes) of the yarnbeam gear 4 match the bolt holes of the yarnbeam 1. Then turn the yarn beam flange 2 soas to have the bolt holes (small, 3 holes)match the bolt holes on the yarn beam flange2.

(4) Tighten the yarn beam 1 and yarn beam gear4 with 8 bolts 8. Then match the bolt hole posi-tion of the yarn beam gear 4 with the yarnbeam flange 2. Tighten 3 bolts 7 sequentiallyand equally.

M1 - 1


(5) [Flange installation on the side of the counter-yarn beam gear]Mark the yarn beam 1 at a point the reeddrawing width of L mm to the right of the mark-ing made in (1).

NOTE: A minimum effective drawing width toeach nominal reed width is a nominal reedwidth minus 70 cm.

(6) Screw in the yarn beam flange 3 from directionB. Match the marking made in (5) to the insideof yarn beam flange 3.• For the ease of screwing, apply grease or


(7) Screw in the flange ring 5 also from directionB. Match the bolt holes of the yarn beamflange 3 and flange ring 5 by providing a clear-ance of 3 to 5 mm between the end faces ofthe yarn beam flange 3 and flange ring 5 andtighten the bolts.

M1 - 2


[ 2 ] Pile beam installation(1) [Installation on the side of the yarn beam gear]

Mark the yarn beam 1 107.5 mm from the side “a” with a felt-tipped pen, etc.

(2) Screw in the yarn beam flange 2 from directionA. Set the inside of the flange to the markedposition.• For the ease of screwing, apply grease or


(3) Set the yarn beam gear 4 to yarn beam 1 sothat the bolt holes (large, 8 holes) of the yarnbeam gear 4 match the bolt holes of the yarnbeam 1. Then turn the yarn beam flange 2 soas to have the bolt holes (small, 3 holes)match the bolt holes on the yarn beam flange2.

(4) Tighten the yarn beam 1 and yarn beam gear4 with 8 bolts 8. Then match the bolt hole posi-tions of the yarn beam flange 2 and yarn beamgear 4. Tighten 3 bolts sequentially andequally.

M1 - 3


(5) [Flange installation on the side of the counter-yarn beam gear]Mark the yarn beam 1 at L mm [reed drawingwidth minus (2* selvage texture width) plus 0to 10 mm] to the right of the marking made in(1).

NOTE: A minimum effective drawing width toeach nominal reed width is a nominal reedwidth minus 70 cm.

(6) Screw in the yarn beam flange 3 from directionB. Match the marking made in (6) to the insideof yarn beam flange 3.• For the ease of screwing, apply grease or


(7) Screw in the flange ring 5 also from directionB. Match the bolt holes of the yarn beamflange 3 and flange ring 5 by providing a clear-ance of 3 to 5 mm between the end faces ofthe yarn beam flange 3 and flange ring 5 andtighten the bolts.

[ 3 ] Bearing installation

(1) Mark the point A below from inside a bearingshaft 9:

(2) Insert a bearing 10 to the bearing shaft 9.

(3) Insert a hoop 11 so as to have the inside of thebearing 10 matches the marking made in (1).Then tighten the bolt 12 to position the bearing10.

(4) Bearing shaft 9 is attached to the machine.Remove bolt 13 and bearing shaft 9 from theempty yarn beam when replacing the beams.

Gland beamBeam gear side 25.5mm

Counter beam gear side 28.0mm

Pile beamBeam gear side 92.5mm

Counter beam gear side 65.0mm

M1 - 4


1.2 Preparation of the Beam[ 1 ] Preparation of gland beam

Wind the gland beam 1 counterclockwise from thebeam gear side A.

[ 2 ] Preparation of pile beam

Wind a pile beam 2 clockwise from the beam gearside A.

Care should be taken for the direction of wind-ing of the gland beam 1 and pile beam 2 whichrun counter to each other.

Care should be taken for the direction of wind-ing of the gland beam 1 and pile beam 2 whichrun counter to each other.

M1 - 5


1.3 How to Run the Warps and Woven Fabric Through(1) How to run the gland warps through

Run the warps to a gland warp dropper 2 via atorsion bar roller 1. Allow them to passbetween a pile warp dropper 3 to reach aheald 11 and a reed 12.

(2) How to run the pile warps throughRun the warps along a deflector roller 4 andvia a shock absorber bar 5 to a pile easingroller 6. Run them to the heald 11 and reed 12through the pile warp dropper 3.

(3) How to run woven fabricWind woven fabric on a surface roller 8 via anexpansion bar 7. Wind it on a cross roller 10by allowing it to pass over the press roller 9.

1) Surface roller

NOTE: Danger. Beware of a number of spikesembedded to the surface of the surface roller8. Care should be taken when working nearthe surface roller 8.

2) Cross rollerWind woven fabric on to a cross roller 10.Press it with apress roller 13 to insert the fabricto the groove.A : Gland beamB : Pile beama : Gland yarnb : Pile yarn

NOTE: During the setting, terry motion can bestopped by selecting texture weaving mode withthe function panel.

M1 - 6


1.4 How to Remove/Reinstall the P-tension Shaft for Easier New Fabric Weaving

At the new fabric weaving, removing top cross rail1, back roller 5, and P-tension shaft 6 makes it eas-ier to set the reed, heald frames, and droppers tothe weaving machine.

(1) Remove bolts 3 from right and left clamps 2 ontop cross rail 1.

NOTE: Do not loosen or remove bolts 4.

(2) Take out back roller 5.

(3) Make a note of the mounting angle of the leafspring, and then loosen bolts 8 on coupling 7.

(4) Slide the coupling 7 in the direction of arrow A.

(5) Remove bolts 10 from holder 9 and take off theholder.

(6) Remove P-tension shaft 6.

(7) Set the reed, heald frames, and droppers tothe weaving machine.

(8) Put P-tension shaft 6 on the bracket.

(9) Fit coupling 7 onto P-tension shaft 6 until cou-pling 7 comes into contact with the stop ring,while pressing shaft 6 in the direction of arrowA and sliding coupling 7 in the direction ofarrow B.

(10) Hold the leaf spring at an angle recorded in (3)and secure coupling 7 with bolts 8.

(11) Secure holder 9 with bolts 10.

(12) Place back roller 5.

(13) Put top cross rail 1 on the bracket.

(14) Tighten bolts 3.

(15) After start of new fabric weaving, set the pile ten-sion. Then loosen bolts 8 on coupling 7 andadjust the angle of the P-tension roller again sothat the warp sheet at section “C” becomesalmost horizontal.

(16) Check that bolts 3, 4, 8, and 10 are tightenedto the specified torques.

3

4

3

1

6, 7

5

3

4

3

21

7

6 9

10

10

B

A

8

The reed, heald frames and droppers are veryheavy, so take extra care when handling them.In (16), tighten bolts to the torque values spec-ified in the Standard Machine “Instruction Man-ual,” Chap. M, Subsect. M.1.9.

M1 - 7


Clean the pile yarn contact part on the boardpanel and the guide bar at every beamchange, and confirm that no foreign substanceis attached. (This is to avoid a thread beingadhered by a substance such as paste thatadversely affects and tension.)

M1 - 8


M2. Shedding Motion

2.1 Dobby Shedding SpecificationsFor basic handling method, please refer to Stäubli’s Instruction Manual.

2.1.1 Setting the Heald Frame Height and Shed Size

See “Appendix 6. Stäubli’s Positive Dobby (TypeS3220)” for the heald frame height and shed sizesetting procedures.

This section introduces the following reference val-ues for the towel looms.

Reference setting value list

NOTE (list specifications) :

1. Heald frame: C type riderless 330 MMCenter mail, Dimension H: 549 MM (Stavewidth standard)

2. Heald frame height A is the value at the closetiming (center shed).

3. If dimension H is different, add or subtract 1/2of the difference to or from dimension A. If theheald is 5 mm up, subtract 5 mm from thespecified dimension A.

4. The maximum shed size is 95 mm for theKlöcker half-leno device.

C

AH

Shedding lever Pile Leno weave Waste

selvage Ground

Frame No.

Dimen-sion C (mm)

Dimension A Frame height(mm)

Dimen-sion C (mm)


Dimen-sion C (mm)


Dimen-sion C (mm)


1 129 71

2 109 67

3 91 64

4 73 60

5 103 64

6 90 61

7 75 58

8 109 56

9 129 60

10 120 58

11 109 56

12 99 53

13 89 51

14 78 49

15 69 46

16 59 44

M2 - 1

M2. Shedding Motion

2.2 Jacquard Shedding SpecificationsRefer to the instruction manual of Jacquard shedding motion for the handling method.

2.2.1 Height of Top Rail Bracket(1) Loosen a nut 4.

(2) Loosen a bolt 2.

(3) Turn an adjust bolt 3 and adjust a height A of atop rail bracket 1.(Standard dimension of height A is 55 mm.)

(4) Tighten the bolt 2 to fasten top rail bracket 1.

(5) Tighten the nut 4.

2.2.2 Hanging of Draw Yarn1) The left end position of draw yarn is 200 mm

from the machined face inside the L.H. frame.

2) Determine the longitudinal position of drawyarn bysetting heald No. 1 to a point 43 mmfrom the rear face of the rocking shaft.

1

2

2

A 4

3

M2 - 2


M3. TempleMovable temple

A moving cloth fell produces pile.

NOTE: To make the temple movement smooth, a bearing 4 is installed to a temple base bracket 3. Accord-ingly, check that all thetemple guides 5 are constantly in contact with the bearing 4

3.1 Longitudinal Position of the Temple(1) Set the crank angle to 0° in fast pick.

(2) Lock the emergency stop push-button switch.

(3) Check clearance dimension “a” between thetemple and reed.3 to 4 mm when the warp tension is not applied2 to 3 mm when loaded with warp tension

(4) If the clearance is different between the leftand right, loosen expansion bar rod 1 fasten-ing nut 2 (two pieces each on the left and rightsides).Turn the extension bar rod nut left and right toadjust the longitudinal position of the temple toequalize the clearance.

NOTE: Pay attention to the intervals of thestoppers to the left and right of the cloth fell.(See M5.2 Stopper Adjustment) Adjust inter-val “a” correctly. The red may be damaged if in contact with theyarn guide plate during operation. Differenceof interval “a” in the longitudinal direction willresult in the difference of the pile length, addi-tionally causing fallen warp due to loose warp.

(5) If the clearance is the same on the left andright sides, turn turnbuckle 6 of the terrymotion lever for adjustment.

NOTE: Pay attention to the intervals of thestoppers to the left and right of the cloth fell.(See M5.2 Stopper Adjustment) Adjust inter-val “a” correctly.

(6) Release the emergency stop push-buttonswitch. Check by inching operation that theyarn guide plate is not in contact with the reed.

a

6

3

4

5

1 2

M3 - 1

M3. Temple

3.2 Crosswise Position of the Temple[ 1 ] Left-hand side of the loom(1) Loosen the bolts 2 (8 bolts) of a temple case 1.

(2) Move the temple case 1 so that a clearance“a” between the left-hand side A of a templering 3 and a gripper 4 becomes 0.5 mm.

(3) Tighten the bolts 2 to fix the temple case 1.

[ 2 ] Right-hand side of the loom

(1) Pull the warp drawn through the reed towardyou at a right angle to a reed 5.

(2) Set the temple 7 so as to have the right-handend of No. 1 ring 8 of the temple 7 aligned tothe right-hand end 6 of the warp.

(3) After the setting, check that the right-hand endof a fabric is held with the whole surface of No.1 ring 8.If not held with the whole surface, readjust.When readjusted, readjust a cutter lever.

(4) To change the drawing width of a reed, loosenthe fastening bolts 9 (6 bolts) to move the tem-ple 7 to a prescribed position, then tighten thebolts 9 to fix it.

M3 - 2


3.3 Vertical Position of the Temple(1) Adjust the height of the left- and right-hand

temples with the number of the shims 1between a temple bracket 2 and the templebase 3.Adjust the number of shims by loosening 8bolts on the left-hand side and 6 bolts on theright-hand side.The standard number of shim is one shim of 1mm.

(2) It is necessary to have a right-hand side cuttershaft bracket 4 at the same height with thetemple base 3. Insert the same number ofshims inserted between the cutter shaftbracket 4 and the temple base 3 in (1).To adjust, loosen the bolts 5 (2 bolts).The standard number of shim is one shim of 1mm.

3.4 Standard Setting of the Temple Ring(1) Loosen the bolt 2 to turn the temple ring 1 so

as to have a marked line x to the top. Tightenthe bolt 2 to fix the temple ring.• To provide the temple with a harder pull, set

the marked line x to the counter-reed side.

NOTE: Care should be taken, however, sinceloose warp will result if the end of the fabricfalls from the end of the temple.

• To weaken the temple pull, set the markedline x to the side of the reed.

M3 - 3

M3. Temple

3.5 Vertical Position of the Temple Cover(1) Loosen a bolt 3.

(2) Make the top face A of the temple cover 1flush with the top face B of the temple cover 2.

(3) Tighten the bolt 3 to fix the temple cover.

3.6 Adjustment of Fell Plate Position(1) Loosen a bolt 2 that fixes a fell plate 1.

(2) Set the height of a fell plate 1 (height differs by fabric).

[Tentative adjustment]Set the height of the fell plate 1 so that it willbe 6 mm vertically from the face A of a fellplate bracket 3. At this time, check that thelower face of the temple cover 4 and the topface of the fell plate 1 are at the same height.

[Fine adjustment]Set the upper jaw of reed 5 and the fabric sur-face 6 so that they will have a clearance of 1mm in the plain weaving state.

(3) Determine the left- and right-hand positions sothat the fell plate 1 will be 3 to 4 mm inside thecover than a face B of the temple cover 4 onboth the left-hand and right-hand sides of theloom.

(4) Fix the fell plate 1 by tightening the bolt 2.

NOTE: Decide the length of fell plate 1 accord-ing to the weaving width, and then cut andremove the rest. Finish the section smoothwith tools such as a file to prevent personsfrom injury or a yarn from getting stuck.

Never operate the loom during the above work.Otherwise, your hand may be caught betweenthe reed and temple cover 1.

1

2

3

56

M3 - 4


M4. Selvaging Machine

4.1 Leno Weave with Two ClockersInstall a leno weave selvage motion to two healdframes for dobby weave specification or connect itto a harness for jacquard weave specification.

With the up and down motion of the heald frames Aand B, cross yarns form the selvage texture bymoving to the left and right to a stationary yarn 3which is placed through the eye of a part 1.

For the texture of the leno weave selvaging motion,use a plain weave texture as shown in the figure tothe left.

4.1.1 Installation of Clocker(1) Lock the emergency stop pushbutton switch.

(2) Install the clockers 1 and 2 to the heald framesA and B.

NOTE: A maximum shedding amount of the clock-ers for a 330 mm center mail is 95 cm. Care shouldbe taken when setting the shedding.Dobby weave specification

Jacquard weave specification

M4 - 1


For multiple tucking jacquard

(1) Metal fitting number 1 is applied to stabilize theright and left position of leno weave with twoclockersModel number J5211-02010-00 PLATE,KLOCKER 4 pcs/place

4.1.2 How to Run the Selvage Yarns(1) Run a yarn from a bobbin 1 through a bobbin

stand 2 and then through the thread eye viatenser 3.

(2) Pass the yarn from the thread eye 4 throughthe eye of a tenser spring 5 then through agland dropper box A (put through the dropper).

(3) Pass the yarn between a pile dropper box B,through a yarn retainer device 6 then througha clocker device 7. (For how to run the yarnthrough the clocker, read M4.1 Leno Weavewith Two Clockers.)

Jacquard harness

1

1

2

3 4

3

4

M4 - 2


4.1.3 Yarns for Leno Weave Selvaging Motion

(1) Since leno weave has a number of yarn cross-ings, fine yarns of good quality and high tenac-ity with lesser fluffs and knots should be usedas principle.

(2) A cotton double (or triple) yarns of a highercount than the warps for plain weave is recom-mended.

(3) If the same yarn as the one for ground weav-ing may cause insufficient strength, selectanother yarn whose physical property is assimilar as possible. If a yarn different in qualityfrom the warp for ground weaving is to beused, perform preparatory check to cause notrouble in later processing.

4.2 Trimmed Selvage MotionLocated outside the right-hand end of the fabric, thetrimmed selvage motion entwines a weft 1 shuttledand several warps 2 for trimmed selvage (yarnsfrom the trimmed selvage stand) to provide the weftwith tension to form a fabric of normal woven tex-ture.

M4 - 3


4.2.1 Installation, Adjustment, and Preparatory Operation

Use a cheese on the trimmed selvage stand as theyarn for trimmed selvage. A total of six cheesesexcluding a cheese for the leno weave selvage willbe used for the trimmed selvage.

[ 1 ] How to run the trimmed selvage yarns through

(1) Hook a yarn from cheese 9 to rod 3 throughcheese spindle 2 then through a thread eye 4.• To run the yarn to cheese spindle 2, use a

tool (J8213-01010-00).

(3) Pass the yarn coming out of the thread eye 4to a gland drop box 6 (pass through the drop-per) through the eye of a tenser spring 5.

9

2

3 4

3

4

M4 - 4


(4) Guide the yarn coming out of the pile dropperbox through a heald 7 and a reed 8; entwine itwith a weft at the cloth fell. The yarn will runthrough a temple 9 and be cut with the RH cut-ter.

(5) The yarn is run through the guide rollers 10and 11, held by a weft band roller 12 andejected to a waste box 13.

[ 2 ] Trimmed selvage cheese specifica-tions

1) The standard yarn shall be EC23/2s.A cotton yarn may be applicable but strengthequivalent to or higher than 23/2s will berequired.

2) It is recommended that the shape of cheese isas illustrated at left.

M4 - 5


4.3 GripperThis is an auxiliary device for better solidifying the leno weave of selvage by holding the filled yarn ends (left-hand ends).

4.3.1 Installation Adjustment(1) [Positional relationship with the temple]

Determine a clearance “a” between the endface of a temple ring 1 and a gripper holder 2as 0.5 mm.

(2) [Relative position with the reed]Install a reed 3 so that a clearance “b”between the right-hand end of the gripper andthe left-hand end of No. 1 blade of the reed 3becomes 1 mm.

(3) [Vertical position]Set the crank angle to 0°. Adjust the gripperholder 2 so as to have a warp held with a yarnguide spring 4 and the gripper holder 2 bepositioned at the same height as the cloth fellheight C.

(4) [Contact pressure of yarn guide spring]Adjust the contact pressure of the yarn guidespring 4 by turning a nut 5 so as to have thewarps arranged on one line with the cloth fellheight C and firmly held.• Should a warp be pulled out of the holding

as the reed retreats after the beating,increase the contact pressure.

• Fluff will be produced if the contact pres-sure is excessive. Decrease the contactpressure.

• Care should be taken for the yarn guidespring 4 coming off the gripper holder 2 ifthe contact pressure is either excessivelystrong or weak.

M4 - 6


M5. Pile Let-Off Features of Towel Loom Pile Let-Off Mechanism

(1) Can control pile warps with tension.

(2) Can separately set the tension for the pile weave and plain weave.This prevents the pile yarns from floating in the plain weave.

(3) Changes tension for the pile or plain weave within a fraction of time. This largely prevents tight pile fromoccurring at a portion where tension changed or pile yarn from floating in the plain weave.

5.1 Pile Let-off Mechanism(1) An easing roller 3 follows the piling motion and

thusprevents the fluctuation of tension causedby the piling motion.

(2) A let-off controller L rotates the beam byobtaining information from the loom main con-trol M and a load cell 4. It feeds a tension value, etc. of the load cell 4to the loom main control M.

(3) A spring mechanism is designed to sharplychange the spring constant according to thepile or plain weaving.

1) Pile tenser plate 1 has a spring constant that issuitable for pile weaving.

2) Because pile tenser plate 1 overlaps withguide plate 2 at plain weaving such as borderweaving, a spring constant becomes higher tocope with the high tension.

12

M5 - 1

M5. Pile Let-Off

5.2 Outline of Let-off Control (1) Plain weave “a”

The beam rotates according to the densitydata forwarded from the loom’s main controllerM. In addition, difference between the set andactual tensions is used for regulating the beamrotation.

(2) Pile weave “b”The beam rotates according to the densitydata (including the pile length) forwarded fromthe loom’s main controller M. In addition, differ-ence between the set and actual tensions isused for regulating the beam rotation.

(3) Shift from the plain to pile weave “C”The beam rotates to deliver yarns to attain apiling tension when the woven texture isswitched.

(4) Stop pile weaving “d”Immediately upon the loom stopping, thebeam rotates to deliver yarns for easing ten-sion to a level appropriate for non-pile weavingstate.

M5 - 2


5.3 Adjustment of Easing Roller(1) Set the crank angle to 0° in the fast pick.

(2) Lock the emergency stop pushbutton switch

(3) Check that a dimension A is 104 mm (stan-dard set dimension).To adjust the dimension A, loosen a bolt 5.

NOTE: Should uneven pile be generated,Make the dimension A longer evenly.If overlengthened, pile yarns may be entan-gled during easing.

(4) Make adjustment in fast pick or plain weavestate so that a pipe holder arm 2 will becomevertical.When making individual adjustment, loosen abolt 3.When making overall adjustment, loosen abolt 4.

(5) Check that the easing roller 1 can be turnedsmoothly by hand.If not, it may cause uneven piling.

5.4 Adjustment of Electronic Terry Motion Type Let-off Pile Beam Tube Diameter Sensor

(1) Move a deflection roller 1 to the L.H. side (inthe direction of an arrow).

(2) Fix the bolt 3 so as to have the side A of a sen-sor stay 2 becomes flush with the end face ofthe deflection roller 1.

(3) Determine the height of the sensor stay byretaining a clearance of 1.0 mm between thedeflection roller 1 and a sensor 4.

M5 - 3

M6. Torsion Back

M6. Torsion Back Terry motion follows positively helped by the easing rod.

A passive method is adopted to absorb variation in the yarn path length caused by the shedding with the tor-sion bar.

Warp tension is absolutely controlled with a load cell.

6.1 Advance Adjustment

6.1.1 Tentative Adjustment(1) Slacken the warp tension on the gland beam

(to 0 kg).

NOTE: 0 kg cannot be attained depending onthe conditions.

(2) Loosen a bolt 2 (without removing it).

(3) Turn a warm 4 to release the torsion of a tor-sion bar 6.While releasing the torsion of the torsion bar 6,the tension roller bracket 7 moves in the direc-tion of X.

(4) Turn the warm 4 while rocking the tensionroller with hand until the tension roller bracket7 reaches a right angle to the warp line (glandwarp path).

(5) Check that a notch 5 points at 0 in a scale 1.If not pointing at the scale 0, loosen a screw 3and adjust the position of scale 1.

1

2

3 4

5

6

7

8

910

11

12

X

Ensure to follow the procedures below to pre-vent the warm from any damage.• Shake the tension roller by hand• Turn warm 4 by hand*Do not turn it with a tool forcibly.

M6 - 1


(6) Match to the shedding timing in the plainweave state. (Standard is 310°.)In the pile weave state, produce a state wherea temple 12 is closest to a reed 13.

(7) Rewind the beam from the function panel andtighten the warp tension to a set value. Makeadjustment by turning the warm 4 so as tohave an indicator 9 to point at between 0 and 5of the scale 10.

NOTE: When the warm 4 is adjusted, the warptension changes.Therefore, repeat the adjustment of the warptension and the warm 4.

(8) Tighten the bolt 2 to fix the warm 4.

NOTE: If the bolt 2 is loose, the warm 4 mayrotate during operation to change the setting.Be sure to tighten it correctly.

12

13

M6 - 2

M6. Torsion Back

(9) Check that the indicator 9 points at between–5 and +15 of the scale 10 during operation(including pile weaving).If the indicator 9 points at elsewhere, loosenthe bolt 2 and turn the warm 4 to make adjust-ment.

NOTE: Don’t adjust the warm 4 during opera-tion, or the warm starts oscillating when theplain weaving is switched to the pile weaving,which is quite dangerous.

6.2 Adjustment at the Change of Gland Warp Tension(1) Loosen the bolt 2.

(2) Turn the warm 4.For standard, turn the warm by 5° on the scaleto a tension of 50 kg.

(3) Tighten the bolt 2.

(4) Enter a desired set tension from the functionpanel and press the gland warp tension returnswitch.

(5) Start the loom operation.

(6) Check that the indicator 9 points at between–5 and +15 of the scale 10 during operation(including pile weaving).If the indicator 9 points at other than between–5 and +15 of the scale 10, loosen the bolt 2and turn the warm 4 to make adjustment.

NOTE: Don’t adjust the warm 4 during opera-tion, or the warm starts oscillating when theplain weaving is switched to the pile weaving,which is quite dangerous.

6.3 Machine Stop or Disabled Operation due to Abnormal Tension1) A proximity switch 11 is provided for preventing machine damages. Operation will not start if the proxim-

ity switch 11 is OFF. If the function panel indicates an “Abnormal tension” message, readjust the warm 2.

2) When the plain weave tension is HIGH, an apparent tension rises during an inching or pick finder periodif the pile length is increased.In such a case, readjust the warm 2.

1

2

3 4

5

6

7

8

910

11

12

X

Proximity switch 11 LED12

ON Lighted

OFF Off

M6 - 3


6.4 Height AdjustmentIf the height of torsion back is changed, the height of dropper box also changes.

(1) Loosen a bolt 9 of a dropper box bracket 8 anda nut 11 of an adjust bolt 10.To lower the height, loosen the adjust bolt 10and widen the clearance between the frame.

(2) Loosen a bolt 2.

(3) Loosen a nut 7, and turn an adjust bolt 6 toadjust the height.

(4) Check that the side A of the back bracket isflush with the flame 4.


(6) Tighten the nut 7.

(7) Tighten the bolt 9 so as to allow the dropperbox bracket 8 to have the same inclination asbefore the adjustment.

(8) Tighten the nut 11 so as to have the adjust bolt10 make a light contact with the frame 4.

M6 - 4

M7. Warp Stop Device

M7. Warp Stop Device Warp stop device (dropper box)

The dropper box is located above the warp line inthe rear of a loom. If a warp is cut, the dropperdrops to energize a contact bar 3. The signal istransmitted to the loom control box via a contactplate 4 and cable 5 to stop the loom operation. Inaddition, a towel weaving loom is provided with thedropper boxes for the gland 6 and the pile 7 so asto indicate which side of the yarn is broken.

7.1 Longitudinal Position(1) Lock the emergency stop pushbutton switch.

(2) Loosen the bolts 3 and 4 (each 4 bolts) that fixthe main units 1 and 2 of respective dropperboxes.

(3) Remove a fixing bolt 6 of a pile easing support5 inside the loom.

NOTE: The number of the fixing bolt 6 of thepile easing support 5 differs by the width of thereeds.

(4) Set respective dropper boxes to the positionsindicated below:

NOTE: The above is the positions for standardinstallation, which may be different dependingon the type of fabric.

(5) Tighten the bolts 3, 4, and 6 loosened in (2)and (3).

Gland dropper box A=28mm

Pile dropper box B=36mm

M7 - 1


7.2 Vertical Position The standard vertical position shall be 1 to 2 mmbetween the gland yarn and the oval tube and 4 to5 mm between the pile yarn and the oval tube.

Adjustment may be made with the number of shim14 or by making vertical adjustment of a dropperbox bracket 8. In the beginning, adjust with thenumber of shim 14.

If adjustment is insufficient with the method ofchanging the number of shim 14 only, make verticaladjustment of a dropper box bracket 13.

[ 1 ] Change of the number of shim

(1) Lock the emergency stop pushbutton switch.

(2) Loosen the bolts 3 and 4 (each 4 bolts) that fixthe main units 1 and 2 of respective dropperboxes.

(3) Remove a fixing bolt 6 of a pile easing shaftlever 5 inside the loom.

NOTE: The number of the pile easing shaftlever 5 may vary depending on the reed width.

(4) Adjust the number of the shim 14. (Standard number is 2 shims of 3.2 mm.)

(5) Tighten the bolts 3, 4 and 6 loosened in (2)and (3).

NOTE: If the groove of the pile easing shaftlever 5 and the bolt hole of a joint plate 7 donot match, loosen a bolt 8 to match the bolthole.

[ 2 ] Adjustment of vertical position of dropper box bracket

(1) Lock the emergency stop pushbutton switch.

(2) Loosen the fixing bolts 9 and 10.

(3) Remove a bolt 6.

(4) Loosen a nut 12 and adjust the height with anadjust bolt 11.

NOTE: Since the only contact point is theadjust bolt 11, overall inclination may bechanged.

(5) Tighten the bolts 6, 9, and 10 loosened in (2)and (3) for the height and inclination adjust-ment to fix the dropper box bracket 13.

NOTE: If the groove of the pile easing shaftlever 5 does not match the bolt hole of the jointplate 7, loosen the bolt 8 to match the hole.

(6) Tighten a nut 12 of the adjust bolt 11.

M7 - 2

M8. Lubrication

M8. Lubrication NOTE: This section describes the lubrication points specific to the towel loom.The descriptions do not include those points lubricated by a one-point lubrication device.Lubricate the points described here in addition to those described in the Standard Machine “Instruction Man-ual.”

8.1 Lubrication Cycle and Applicable Fluids(1) Grease lubrication

Always use lubricant recommended by this company. (Read M3.1 [2] of the Standard Machine “Instruc-

tion Manual.”)

10 hours Every 10 days Every 1.5 to 2.0 months at warp beam change

Electric centrallzed lubrication system

Grease gun Oiler Brush Grease

gun Oiler Brush

Gland yarn beam gear (left-hand side)

Lower beam pinion (left-hand side)

Lubricating intervals

Lubricating points

D

D

M8 - 1


Pile yarn beam gear (left-hand side)

Upper beam pinion (left-hand side)

RH cutter (mechanical) cutter bracket mid point

Electric winding gear




gun Oiler Brush


Lubricating points

D

D

D

D

M8 - 2

M8. Lubrication

(2) DobbyFor the lubrication points, type of fluid and lubrication cycle, follow the instruction manual for the dobbyloom.

(3) JacquardFor the lubrication points, type of fluid and lubrication cycle, follow the instruction manual for the jacquardloom.

Movable temple, bearing

Torsion bar guide voller

Pile easing shaft BKT




gun Oiler Brush


Lubricating points

A

D

D

M8 - 3


8.2 Oil Change of Terry Motion Cam Box(1) Oil type and replacement period are as fol-

lows:(Standard lubrication quantity is 8 liters.)

Reference: Type:Oil B#150 (Mobil 629, etc.)Replacement period:Once a year after the initialreplacement

(2) Drain used oil by inserting a drain tool into thedrain port.

(3) Fill oil until the oil level reaches the center ofthe level gauge 1.

NOTE: Refer to “M.3 Lubrication” in the StandardMachine “Instruction Manual.”

8.3 Oil Change of Jacquard Bevel Gearbox(1) Oil change period is as follows:

(Standard lubrication quantity is 2 liters.)

Reference: Type:Oil B#150 (Mobil 629, etc.)Replacement period:(Initial: after 15 million picks) Every 6 months after the initialreplacement.

(2) Drain used oil by inserting a drain tool into thedrain port.

(3) Fill oil until the oil level reaches the center ofthe level gauge 1.

(4) Check oil level monthly. Replenish oil if belowthe required level.


1

M8 - 4

M9. Electronic Terry Motion

M9. Electronic Terry MotionThis section describes the mechanical points of the electronic terry motion. The related electrical details aregiven in Section E6.

For the Mechanical Terry Motion, refer to Section M5.

9.1 Adjusting the StoppersAdjust the stoppers (there is once each at the RH and LH sides) according to the steps below.

(The same stoppers are used in the mechanical terry motion.)

(1) Set the crank angle at 0° on the first pick orground weaving.

(2) Press and lock the emergency stop button.

(3) Loosen nut 2 of stopper 1.

(4) Turn stopper 1 by hand until it lightly touchesthe expansion bar lever 3.Make sure that both the RH and LH stoppersare in contact with the expansion bar lever.

(5) Tighten nut 2 to secure stopper 1.

(6) NOTE: Check stopper 1 and lever 3 again dur-ing operation for excessively strong contactwith each other, and adjust for light contact.

1

2 3

M9 - 1


9.2 Zero-point Restoration Proximity SwitchDo not disturb the zero-point restoration proximity switch which has been adjusted in TOYOTA.

If the proximity switch setting is changed, adjust the switch according to the steps below.

(1) Set the MANUAL–AUTO switch in the inverterservo amplifier box to the MANUAL position.

(2) Move the terry motion lever with the FWD-REV switch until lever ’s hole A becomesaligned with hole B provided in the sub frame.

(3) Check the alignment by inserting a straight pinor bolt (ø8 mm) into holes A and B.

(4) Press and lock the emergency stop button.

(5) Install the terry motion lever flag and the prox-imity switch according to the dimensionsshown at left.Turn the machine power on and check that theproximity switch LED is OFF.

Hole AHole B

Proximity switchFlag

0 to 1

Flag2.5 to 3.5

Proximity switch

M9 - 2

M9. Electronic Terry Motion

9.3 Reverse Current Absorber CoverNEVER touch the reverse current absorber cover(located between the control box and the RHframe) when the machine is in operation or shortlyafter the machine comes to a stop. The cover isHOT!

9.4 Lubrication of Terry Motion Gear BoxThe oil type and oil change interval are the same asfor the main gearing box. (Typical oil volume to befed: 4.5 liters)

Reference: Type:Oil B#150 (Mobil 629) or equivalentChange interval:Once every year after the first oilchange.

(1) Insert the oil drain tool into the drainage port ofthe terry motion gear box and then drain thegear box.

(2) Supply oil until the oil level reaches above thecenter line of the oil sight glass when themachine is on halt.


M9 - 3



E1. State of Indicator Lamps and Mode DisplayThe following table outlines the comparative indication of the color of the indicator lamps, their lighted or blink-ing state and the mode display of the function panel.

(The colors of the indicator lamps are the standard colors set forth by Toyota.)

Towel

Indicator lampMode display

Remarks

Color State Control section

Red Lighted Normal stop WARP STOP (TOP) Main control

WARP STOP (BOTTOM)

Blinking Abnormal MAIN CONTROL: ABNORMAL TENSIONSIGNAL INPUT (TEXTURE YARN)

Main control

MAIN CONTROL: STOP SIGNAL FROM UPPER LET-OFF

MAIN CONTROL: SEND TIME-OUT, WITH UPPER LET-OFF

MAIN CONTROL: SEND ERROR, WITH UPPER LET-OFF

MAIN CONTROL: NEGATIVE RESPONSE FROM UPPER LET-OFF

MAIN CONTROL: TIME-OUT ERROR, WITH UPPER LET-OFF

MAIN CONTROL: FAILURE TO UPPER LET-OFF FOR END OF OPERATION

Warning MAIN CONTROL: EMERGENCY STOP SIGNAL FROM UPPER LET-OFF

Abnormal LET-OFF(UPPER): TOO HIGH WARP TENSION Upper let-off controlLET-OFF(UPPER): LAW WARP TENSION

LET-OFF(UPPER): ENCODER SIGNAL TROUBLE (IMMEDIATELY UPON STARTING OPERATION)

LET-OFF(UPPER): ENCORDER SIGNAL TROUBLE (DURING OPERATION)

LET-OFF(UPPER): ENCORDER SIGNAL REVERSED

LET-OFF(UPPER): SERVO COUNTER OVERFLOW

LET-OFF(UPPER): INITIALIZATION OF A SET VALUE

LET-OFF(UPPER): TENSION RETURN INTERRUPTED

LET-OFF(UPPER): MALFUNCTION OF SERVO AMPLIFIER EMERGENCY STOP

LET-OFF(UPPER): SERVO AMPLIFIER RETURN ABNORMAL

LET-OFF(UPPER): CONTROL SUBSTRATE-SERVO AMPLIFIER CONNECTION ABNORMAL

LET-OFF(UPPER): COMMAND ERROR TO SERVO AMPLIFIER

LET-OFF(UPPER): MES/L/H SWITCH POSITION ABNORMAL→ [ MES ]

LET-OFF(UPPER): TENSION CALIBRATION REQUIRED

State LET-OFF(UPPER): TENSION BEING RECOVERED

LET-OFF(UPPER): EMERGENCY STOP ON

Caution LET-OFF(UPPER): COMMAND NOT EXECUTABLE

LET-OFF(UPPER): SERVO AMPLIFIER ERROR CLEAR

LET-OFF(UPPER): SERVO AMPLIFIER EMERGENCY STP RESETTING

Warning LET-OFF(UPPER): BATTERY VOLTAGE DROP

Failure LET-OFF(UPPER): LOAD CELL ABNORMAL DETECTION

LET-OFF(UPPER): SERVO AMPLIFIER ABNORMAL DETECTION

LET-OFF(UPPER): SUBSTRATE ABNORMAL DETECTION

E1 - 1

E1. State of Indicator Lamps and Mode Display

Red Blinking Failure LET-OFF(UPPER): SERVO AMPLIFIER EXCESS SPEED ABNORMAL

Upper let-off control

LET-OFF(UPPER): SERVO AMPLIFIER RESOLVER ERROR

LET-OFF(UPPER): SERVO AMPLIFIER SHORT TIME OVERLOAD

LET-OFF(UPPER): SERVO MOTOR OVERHEAT (SOFT)

LET-OFF(UPPER): SERVO AMPLIFIER SPEED AMPLIFIER SATURATION

LET-OFF(UPPER): SERVO AMPLIFIER OVERCURRENT DETECTION (SOFT)

LET-OFF(UPPER): SERVO AMPLIFIER MAIN CIRCUIT CONTACTORABNORMAL

LET-OFF(UPPER): SERVO AMPLIFIER RESOLVER CABLE DISCONNECTION

LET-OFF(UPPER): SERVO AMPLIFIER MAIN CIRCUIT AC VOLTAGE DROP

LET-OFF(UPPER): SERVO AMPLIFIER OVERVOLTAGE DETECTION

LET-OFF(UPPER): SERVO AMPLIFIER IPM ABNORMAL DETECTION

LET-OFF(UPPER): TENSION CALIBRATION ABNORMAL

White Blinking Nomal stop NUMBER STOP Main control

PRELIMINARY WEAVE STOP

CUT STOP

Warning OPERATE FROM PILE NO.1 PICK,

MAIN CONTROL: STOP SIGNAL INPUT FROM THE SHEDDING

MAIN CONTROL: NORMAL TURN INHIBIT SIGNAL INPUT FROM THE SHEDDING MOTION

MAIN CONTROL: REVERSE INHIBIT SIGNAL INPUT FROM THE SHEDDING MOTION

Yellow Blinking Abnormal MAIN CONTROL: NO REQUEST RESPONSE SIGNAL FROM THE SHEDDING MOTION

Main control

MAIN CONTROL: COLOR SELECT SIGNAL FROM THE SHEDDING MOTION ABNORMAL

MAIN CONTROL: PATTERN ABNORMAL

MAIN CONTROL: REQUEST RESPONSE SIGNAL FROM THE SHEDDING MOTION ABNORMAL

MAIN CONTROL: PILE PICK SELECT ABNORMAL

Turned off Warning INITIALIZED PATTERN START Main control

State MAIN CONTROL: CHECKING PATTERN WITH THE SHEDDING MOTION

PROCEEDING WITH PRELIMINARY WEAVING

PROCEEDING WITH THE CUTTING

Caution MAIN CONTROL: PATTERN CHANGE SIGNAL INPUT FROM THE SHEDDING MOTION

MAIN CONTROL: PRELIMINARY WEAVE SIGNAL INPUT FROM THE SHEDDING MOTION

Indicator lampMode display

Remarks

Color State Control section

E1 - 2


E2. Setting of Towel Loom-related Function PanelRefer to “0.3 Detailed Explanation of Function Panel” of the Standard Machine “Instruction Manual” for thebasic handling procedure of the function panel.

2.1 Towel Screen Setting MethodTouch the [ Map ] – [ Towel ] icon to display thescreen shown in the bottom at left.

[ 1 ] Operation for ground weaving only

Use this mode when not using the terry motion forgaiting.

[ OFF ] Normal operation

[ ON ] No terry motion starts even for a pile pat-tern.

[ 2 ] Wrong warp path (border only)

Normally set to [ OFF ].

[ OFF ] Normal wrong warp stop

[ ON ] Stops for wrong warp if wrong warp isdetected in the same color with two picksin succession during boarder weaving.

[ 3 ] Select the cutting, preliminary weave pick, cutting pick and the type of cut-ting operation.

(1) Cutting when [ NUMBER STOP ] is selected.The loom stops operation when the number forthe cutting is reached.

NOTE: Set the number for the cutting on the[ MANAGER ] – [ COUNTER ] screen.

NOTE: Preliminary weaving pick or cuttingpick is not used.

E2 - 1

E2. Setting of Towel Loom-related Function Panel

(2) Cutting when [ PRELIMINARY WEAVE STOP ]is selected.The following cutting operation will be made:

NOTE: Set the number of picks for the cutting on

the [ Operator ] – [ CUTTING ] screen .

Operator Loom

1) When the cutting number reaches the set cuttingnumber, extra weaving operation starts.• Extra weaving operation

[In case of Jacquard]• Density is as per the set value in (7).• No terry operation[In case of electronic dobby]• Weaving in the pattern selected for extra

weaving• No terry operation

2) After weaving for the set number of picks forextra length, the loom stops operation.

3) Changes the pattern to a new start from No. 1pick.

4) Turn the loom start pushbutton ON.

5) The loom starts operation and weaves a towelpattern. Clear the number counter.

6) The loom stops after weaving for a set number ofpicks for the cutting. (Set the number of picks forthe cutting so as to have the extra length ofweaving reaches a position for cutting with easewhen the loom stops.

7) Cut the cloth.

8) Turn the loom start button ON.

Note that the loom stops once and restartsautomatically if the selected pattern for extraweaving is not a weaving pattern.

E2 - 2


(3) Cutting [ Cut stop ]The following cutting operation will be made:

Operator Loom

1) Weaves a piece of extra woven pattern afterweaving a number of cutting pieces in a towelpattern.[In case of Jacquard]Weaves according to the extra weaving patternfrom Jacquard.[In case of electronic dobby]The pattern selected for extra weaving is wovenas many as the number of extra weaving picks.

2) Upon completion of the weaving of extra wovenpattern, clears the piece number counter andstarts weaving a towel pattern.

3) After weaving a number of set picks for the cut-ting, the loom stops operation. (Set the numberof picks for the cutting so as to have the extralength of weaving reaches a position for cuttingwith ease when the loom stops.

4) Cut the cloth.

5) Turn the loom start button ON.

Note that the loom stops once and restartsautomatically if the selected pattern for extraweaving is not a weaving pattern.

Note that the loom stops once and restartsautomatically.

E2 - 3


[ 4 ] Setting the warp manual stop position

Select the warp manual stop position during pileweaving.

In the initial setting, the loom stops at L2 pick.Change the setting if any alteration in organizationis desired.

NOTE: Be careful since the machine does not stopfor 8 picks if L4 for 3-pile, which does not exist inthe pattern, is selected.

E2 - 4


2.2 How to Set [ PILE ][ 1 ] Electronic dobby specification

Touch the [ Map ] – [ Pattern ] icon to display thescreen shown at left.

Se the pile, border and take-up stop required forweaving on this screen.

Touch the [ SETTING START ] switch and the set-ting box to display the setting keys.

Pile: Select the pile, ground or border.GD : Ground weaveBD : BorderP3 - P7 : 3-pick pile - 7-pick pile

Pick: Select the pick type for pile weaving.S1 : Start pick (first pick when weaving long &

short piles)F1 : 1st pick of fast picksF2 : 2nd pick of fast picksF3 : 3rd pick of fast picksL1 : 1st pick of loose picksL2 : 2nd pick of loose picksL3 : 3rd pick of loose picksL4 : 4th pick of loose picks

E2 - 5


Pile-Length: Input the pile length.Input the terry motion operating length for thepick.The screen at left shows an example of 10.0mm pile with a gap of 2.0 mm for 3-pick pile.

Take-Stop: Select take-up or stop.OFF: No take-up stop (density selection valid)ON: With take-up stop (density selection

invalid)

Speed: Select the loom speed.H: High-speed rotationL: Low-speed rotation(to be selected mainly for border weaving)Refer to Chapter E2 2.6 Setting an Inverterfor the desired rpm.

2.3 Pattern Initialization

Touch [ Pattern 1st pick ] at left on the

[ Operator ] screen to start the pattern from the firststep.

E2 - 6


E3. Setting and Operation of Towel Loom Beam-related Function Panel

Touch the [ Map ] – [ Letoff ] icon.

[ 1 ] Setting for bottom beam controlIn the two-stage tension specifications, set the ten-sion for border weaving higher than that of pileweaving. When two-stage tension is not applied, set themwith the same numerical value. (Or, when 0 kg is set as the tension for borderweaving, the tension applied for pile weaving isapplied for border weaving as well.)

The items regarding pile → border adjustment iseffective at the time of two-stage tension change isapplied.The kilogram value shown at left indicates a numer-ical value to adjust the high tension at the time ofthe tension change.This numerical value is the one to correct the differ-ence that may occur by machine when fixing a cyl-inder while tension is high, though the inclinationthat is applied to the load cell changes accordingly.

When the tension is lower than the actual one,increase the numerical value within the range ofapproximately 20-35.

The setting value of the pick for pile → borderadjustment or border → pile adjustment is to makethe speed of the tension change faster at the timeof switching.Setting the number of pick continuously controlsthe motion to strain or loosen the let-off during thedesignated number of picks.Set it within the range of approximately 0-5.

[ 2 ] Setting for top beam control

(1) Warp tension (At boarder weaving)Input the tension for plain and border weaving.

(2) Warp tension (Pile)Input the tension for pile weaving.

(3) Warp tension (Stop)Input the tension upon loom stop during pileweaving.

NOTE: Always set it lower than the tension for(Pile).

(4) Beam diameterInput the top beam diameter.

(5) Tension adjustment (border → pile)This setting corrects the pile yarn let-offamount upon switching weaving from borderto pile.

E3 - 1


The value should be around 0.4.If pile defects occur in the 1st to 5th rows afterswitching to pile weaving, increase the valueat intervals of 0.1.If pile is normally produced at first but piledefects occur in any rows from the 3rd, 4th or5th, decrease the value at intervals of 0.1.

(6) Tension adjustment (pile → border)This setting corrects the pile yarn let-offamount upon switching pile → border weaving.Set the value to around 0.4.When the final pile becomes smaller uponswitching into the border weaving, increasethe value by 0.1.Conversely, when the final pile becomeslarger, decrease the value by 0.1.

(7) Tention adjustment (run → stop)This setting corrects the pile yarn let-offamount upon loom stop during pile weaving.The value should be around 0.2.If the actual tension is constantly higher thanthe Warp tension (Stop: S) in [2] (3) above,increase the value to above 0.2.Conversely, if the tension is constantly lower,decrease the value to below 0.2.

(8) Pile Forward (WARP STOP)At the time of warp stop, the upper (pile) beamis rotated forward for the set amount (unit: cm).Press the full running switch. Full operationrestarts after the upper beam rotates in thereverse direction.If upper beam tension reset, individual forwardrotation or individual reverse rotation is triedbetween warp stop and full running switchoperation, the upper beam is not rotated in thereverse direction.

(9) Beam diameter proximity switch errorThis is to set whether the loom stops or justissues an alarm when the input of the beamdiameter proximity switch has an error.Select the alarm for continuous operationwhen an auxiliary beam diameter proximityswitch is not available.The operation can be continuous with a fea-ture of let-off correction, however, you stillneed to confirm whether or not the pile lengthhas an error.

(10) Use / Not use of top beamSet the top beam as not used for weavingother than towel that does not require the topbeam.

E3 - 2


[ 3 ] Setting for beam changeTouch the [ Operator ] – [ Beam Change ] icon todisplay the screen shown at left.

(1) [ BOTTOM BEAM ] switchPress this switch for setting upon bottom beamreplacement.Refer to 3.2 [4] b [ BEAMSET ] Switch in “0.3Detailed Explanation of Function Panel” of theStandard Machine “Instruction Manual” for theoperation method.

(2) [ TOP BEAM ] switchPress this switch for setting upon top beamreplacement.Refer to 3.2 [4] b [ BEAMSET ] Switch in “0.3Detailed Explanation of Function Panel” of theStandard Machine “Instruction Manual” for theoperation method.

(3) Style name and Beam name• The style name and beam name are regis-

tered as the host data in the TMS or TTCSspecification for use as management data.

• In case of a non-networked loom, these areused only for reference on this screen.

NOTE: If the top (pile) beam is replaced in themechanical terry motion specification, checkthe “convergence status” described in “2.2 [ 1 ]Mechanical terry motion”Also correct the pile length as required.

E3 - 3


[ 4 ] Yarn beam operation from function panelTouch the Manual page through [ Map ] – [ Lefoff ]to display the screen shown at left.

The top and bottom beams and the take-up motioncan be operated manually.

Function

Rotates the upper (pile) and lower beams and the winder simultaneously in forward direction.

The beams rotate slowly for the first three seconds, then rotate faster.

Rotates the upper (pile) and lower beams and the winder simultaneously in reverse direction.

Rotates the upper (pile) beam in forward direction.

Rotates the upper (pile) beam in reverse direction.

Rotates the lower beam in forward direction.

Rotates the lower beam in reverse direction.

Rotates the winder in forward direction.

Rotates the wider in reverse direction.

Automatically restores the tension for the upper (pile) beam. (Weaving tension: G) *1

Automatically restores the tension for the upper (pile) beam. (Stop tension: S) *2

Automatically restores the tension for the lower beam.

Rotates the upper (pile) and lower beams simultaneously in forward direction.

Rotates the upper (pile) and lower beams simultaneously in reverse direction.

*1: Restoring the tension during the pile weaving activates the tension restoration twice.*2: Do not touch the stopper as the stopper for two-step tension switching operates for the two-step tension switching

specification.

Switch

E3 - 4


[ 5 ] Operation of Forward/Reverse Beam Rotation Switch on the L.H. Frame

Two switches are located on the upper beam frameon the L.H. frame as shown in the figure to the left.

When the switch is turned clockwise, the beamrotates in forward direction while the switch is beingturned.

Conversely, when the switch is turned counter-clockwise, the beam rotates in reverse directionwhile the switch is being turned. When the switchis released, the beam stops.

NOTE: These switches are not operable when theweaving machine is in operation.

NOTE: The beam rotates slowly for the first 0.5second and then rotates faster.

E3 - 5

E4. Electric Components / Let-off Motions for A Towel Loom


4.1 Electric Components Upper and lower let-off motions

The controllers of the bottom- and top-mounted let-off motions are integrated in main control box 1.

Servo amplifier board 2 controls the lower let-offmotion (ground let-off motion).

Servo amplifier board 3 controls the upper let-offmotion (pile let-off motion).

[ 1 ] Configuration of let-off control

2 : Take-up servo amplifier board

3 : Heat sink

4 : Connector (CN1) for DC power cable

5 : Connector (CN2) for signal cable in control box

6 : Connector (CN3) for load cell signal cable

7 : Connector (CN4) for communication cable

8 : Connector (CN5) for resolver cable

9 : Connector (CN7) for inspection (not used normally)

10 : Connector (CN9) for 200 VAC power cable

11 : Connector (CN10) for servo motor output cable

12 : DIP switch (SW1) for setting servo motormodel and machine spec.

13 : DIP switch (SW2) for let-off and take-up setting

14 : LED1 for main circuit monitor

15 : LED2 for control power (+5 V) monitor

16 : LED3 for CPU abnormality monitor

LET-OFF2

　12

3

Since the portions indicated by dash lines in take-up servo amplifier board 2, 3 are applied with high voltages, always turn the power off and wait until LED1 goes off before starting maintenance or replacement.

CN5 CN4 CN2

CN1

CN3

CN9 CN10

CN7

SW1SW2

8 7 5

1213

169

3

4

6

2

14

1110

15

High voltage: Be careful!

E4 - 1


[ 2 ] LED display and check pins

High voltage remains while LED1 is on. Before starting maintenance or replacement, always turn the poweroff and wait until LED1 goes off.

Since CK7 and CK8 are applied with a potential of approx. 200 V , carefully avoid electric shock.

LED No. Name Color Use Normal Error Major error cause

LED1 CHARGE Red Main circuit power monitor ON OFFError detection by servo amplifier board. Eliminate the error.

LED2 CON Green Control power (+5 V) monitor ON OFFControl power (DCPS10/+5 V) is 4.5 V or less

LED3 RDY Yellow CPU error monitor Blinking ON, OFF CPU defective or uncontrollable

Check pin No. Name Use

CK1 P5 +5V power supply

CK2 P15 +15V power supply

CK3 N15 –15V power supply

CK4 GND Power ground

CK7 CHP Main circuit DC power supply (+)

CK8 CHN Main circuit DC power supply (–)

CK9 TEN Load cell input signal

CK10 ZP Encoder Z-phase signal

CK1

LED2

CK10

LED3

CK4

CK8

CN5

CN1

CN3

CN4

IC26

IC5

IC6

IC1

C222

C263

C264

CN9 CN10

R301

R300

U2 V2 W2 A B C E FG

REC1

RY2

RY1

RY3

FU1

5A

FU2

5A

R311

RDY

CN7

SW

1S

W2

ON

ON

CN2

CON

CK3

CK2

CK9

LED1

CK7

C262

E4 - 2


[ 3 ] Setting the standard let-off tensionIn any of the following cases, set the basic let-offtension according to the let-off tension calibrationand zero adjustment procedure.

• When “WARP TENSION CALUBRATION NEC-ESSARY” or “INITIALIZE SET VALUES”appears on the function panel.

• When the RAM is cleared.

• When a new machine is installed.

• When the let-off servo amplifier board isreplaced with a new one.

• When the warp is loosened so that the actualtension becomes within the range from –2 to +2.

• When the warp beam is replaced.

[ 3.1 ] Tension calibration / zero adjustmentLower let-off (ground let-off)

(1) If warps have been loaded on the machine,slack them until no warp tension is appliedonto the tension roller.

(2) Touch “Calibration of the tension” on the Man-ual page of [ Map ] – [ Lefoff ] on the functionpanel.

(3) “Adjust the tension to 0?” appears. Touch“Yes”.Tension adjustment and zero adjustment arecompleted now. The display automaticallyreturns to the Manual page of [ Map ] –[ Lefoff ].

(4) Then check that the “Real Tension” shows –2to 2 kg on the function panel.If the “Real Tension” is outside of –2 to +2 kg,repeat from step (2).

1

3

TAKEUP

LET-OFF1

E4 - 3


(5) Measure the warp beam diameter at operationrestart and enter it on the [ FIXER ] – [ WARP ]screen.

(6) Start tension restoration.Touching the tension restoration switch 11starts the tension restoration.

[ 3.2 ] Tension calibration / zero adjustmentUpper let-off (pile let-off)

(1) Read the scale 1 of the torsion back andrecord it.

(2) Rotate the lower beam forward until the drop-per lowers to the end.

(3) Loosen the bolt 2.

(4) Turn the worm 4 and release the distortion ofthe torsion bar 6.

(5) Calibrate the tension on the function panel.(See steps (2) through (4) of tension calibra-tion / zero adjustment of ground let-off for ten-sion calibration.)

(6) Turn the worm 4 until the scale 1 reaches theprevious level.


(8) Measure the warp beam diameter at operationrestart and enter it on the [ FIXER ] – [ WARP ]screen.

(9) Start tension restoration.Touching the tension restoration switch 2starts the tension restoration.

1

2

3 4

5

6

7

8

910

11

12

X

E4 - 4


[ 4 ] RAM clear (data initialization)

Clear the RAM according to the procedure shown below.

“Clearing the RAM” is normally unnecessary.

After clearing the RAM, be sure to calibrate and restore the tension.

NOTE: Since all data set in the LET-OFF mode on the function panel are lost, save the data on the memorycard or take a memo before the following operation.

[ 4.1 ] RAM clearing procedure

(1) Turn the loom power off.

(2) Set all bits of DIP SW2 on the let-off servoamplifier board to ON. (See the figure at left.)

(3) Tuirn the loom power on.

(4) Turn the loon power off upon lapse of about 10seconds.

(5) Return all bits of DIP SW2 on the let-off servoamplifier baord.

(6) Turn the loom power on.(In this state, the indicator lamp is blinking inred, and the error message is being dis-played.)

[ 4.2 ] Operation after clearing the RAM

(1) Calibrate the tension.(See Section 2, “4.1 [ 3 ] Setting the standardlet-off tension” for the adjustment procedure.)

(2) Actually measure the warp beam diameterupon restarting operation, and input it on the[ FIXER ] – [ WARP ] screen.

(3) Restore the tension.(See Chapter 0. “Subsection 0.3.1 Displayconfiguration and switch operation method” ofthe Standard Machine “Instruction Manual” forthe adjustment procedure.)

(4) Restart operation.(After restarting operation, the rd-blinking indi-cator lamp goes off and the error message iscleared.)

CN 9 CN 10

SW 2

SW 1

SW

2

ON

4321

E4 - 5


[ 5 ] Method for setting DIP switches (SW1 and SW2)

Set the DIP switches (SW1 and SW2) on the servo amplifier according to the table below.

DIP switch (SW1): For setting the loom specification and servo motor capacity

DIP switch (SW2): For setting let-off and take-up

DIP switch (SW1) setting table

DIP switch (SW2) setting table Check the motor capacity on the servo motor nameplate.

Use Loom specificationMotor

capacityPin No.

8 7 6 5 4 3 2 1

Ground let-off Towel loom Standard density 500W

Pile let-off Towel loom (except ø1250) 600W ON ON ON

Pile let-off Towel loom (ø1250) 800W ON ON ON

Set “OFF” to a blank space.

Pin No.

4 3 2 1

Ground let-off ON ON ON

Pile let-off ON

Set “OFF” to a blank space.

Servo motor type Motor capacity

VLBST-05030T 500 W

VLBSE-06040T 600 W

VLBST-08030T 800 W

CN 9 CN 10

SW 2

SW 1

SW

1S

W 2

87654321ON

ON

4321

If a 500-W servomotor is used for double-beam lower let-off at worm box standard density, set as shown below.

Enlarged view

E4 - 6


[ 6 ] TroubleshootingFor the bottom- and top-mounted let-off motions

If LED3 (yellow) on the servo amplifier board is not blinking follow the flow shown below.

NO

YES

NO

YES

YES

NO

NO

YES

NO

NO

YES

YES

NO

LED3 is:

ON

OFF

Turn off and on the power.

Is 5VDC

for check pin CK1

normal?

Replace the servo amplifier board.

Repair the

wiring.

Fuse F6 is normal?

Is LED3 blinking?

Replace

fuse F6.

Replace the

DCPS10.

Check the

wiring

between the

TF1 and

DCPS10, and

the noise

filter.

Check the

three-phase

source and

the wiring

between the

CB1 and TF1.

Replace transformer TF1.

Is AC

input (100 VAC) fed

to pins 1 and 3 of the

DCPS10?

Is the primary input of trans-

former TF1 (voltage level between R1 and T1)

normal?

Is the wiring

between CN2 on the DCPS10

and CN1 on the let-off control

board normal?

Is there AC

input (100 VAC) between

pins 1 and 3 on connector

CN1 of the DCPS10?

E4 - 7


E5. Instrumentation and Electronic Jacquard for Towel Weaving Machine

[ 1 ] Jacquard Controller

Refer to the instruction manual issued by the manufacturer of the shedding motion.

[ 2 ] About the Electrical Signal to be used for Pattern Generation

Notes: 1 When a transistor is turned ON (energized), the interface circuit indicates “0”. Accordingly, it differsby the shedding manufacturer whether 0 or white in the screen display refers to either 0 or 1 for thefollowing data. This requires confirmation on the part of the shedding manufacturer.

2 It also depends on the shedding manufacturer which electrical signal does correspond to whichposition in the screen display. This too requires confirmation from the shedding manufacturer.

A-6) Color selection HA-7) Color selection MA-8) Color selection L

A-9) Density HA-10) Density MA-11) Density L

Usage Note: Set the same density to three picks or more in succession. Otherwise, the following error messages will display and the machine will not run:• “LET-OFF (or TAKE-UP): PATTERN ERROR”• “MAIN CONTROL: COMMUNICATIONS ERROR, WITH LET-OFF (or WITH TAKE-UP)”• “MAIN CONTROL: STOP SIGNAL FROM LET-OFF (or FROM TAKE-UP)”

A-6) A-7) A-8) Significance

0 0 0 Abnormal

0 0 1 Color 1

0 1 0 Color 2

0 1 1 Color 3

1 0 0 Color 4

1 0 1 Color 5

1 1 0 Color 6

1 1 1 Abnormal


0 0 0 Density (0)

0 0 1 Density (1)

0 1 0 Density (2)

0 1 1 Density (3)

1 0 0 Density (4)

1 0 1 Density (5)

1 1 0 Density (6)

1 1 1 Density (7)

E5 - 1

E5. Instrumentation and Electronic Jacquard for Towel Weaving Machine

A–12) Ground weave and pile HA–13) Ground weave and pile MA–14) Ground weave and pile L

A-15) Winding stop

Note on use: Make setting for 2 picks and over in succession.

A-16) Number counter

A-17) Border control

A-18) Single pileEffective for an electronic type terry motion specifications.

In the case of a 3-pick pile, enter a same value to each of the three picks.This applies to 4- and 5-pick piles.


0 0 0 3-pick pile

0 0 1 4-pick pile

0 1 0 5-pick pile

0 1 1 6-pick pile

1 0 0 Preliminary weave

1 0 1 No-load weave

1 1 0 Border

1 1 1 Ground weave

A-15) Significance

0 Winding stop (density selection invalid)

1 (density selection valid)

A-16) Significance

0 Number counter present

1 Number counter not present

A-17) Significance

0 Controlled

1 Not controlled

A-18) Significance

0 Single pile

1 Double pile

E5 - 2


A-19) Pile length HA-20) Pile length MA-21) Pile length L

Effective for an electronic type terry motion specifications.

In the case of a 3-pick pile, enter a same value to each of the three picks.This applies to 4- and 5-pick piles.

NOTE: Don’t turn the power OFF-ON while setting A+, A–, A*, B+, B– and B*, or pile length may fluctuateslightly.

A-22) Pick H in the pileA-23) Pick M in the pileA-24) Pick L in the pile

Make setting to each pick in the pile.For other than the pile, enter 2L to the pick you want to stop at warp breakage.

Example: If a warp breakage occurs during ground weaving and you want to stop 1/3: → Enter 2L once to three picks.If a warp breakage occurs during border weaving and you want to stop the pickimmediately:→ Enter 2L to all the picks of the boarder.


0 0 0 A : Pile length A

0 0 1 A+ : Step length is increased from the previous length.

0 1 0 A– : Step length is decreased from the previous length.

0 1 1 A* : The length remains unchanged from the previous one.

1 0 0 B : Pile length B

1 0 1 B+ : Step length is increased from the previous length.

1 1 0 B– : Step length is decreased from the previous length.

1 1 1 B* : The length remains unchanged from the previous one.


0 0 0 S1 : 1st pick of loose picks for long/short piles

0 0 1 1L : 1st pick of loose picks

0 1 0 2L : 2nd pick of loose picks

0 1 1 1F : 1st pick of fast picks

1 0 0 2F : 2nd pick of fast picks

1 0 1 3F : 3rd pick of fast picks

1 1 0 3L : 3rd pick of loose picks

1 1 1 4L : 4th pick of loose picks

E5 - 3

E6. Electronic Terry Motion

E6. Electronic Terry Motion[ 1 ] LEDs and Switches in the Inverter Box (See the drawing given on the next page)

PL1 ZERO POSITION LED ON when the terry motion is in the zero position.

PL2 ZERO POSITION ALARM LED ON when the servomotor zero position is lost, e.g., due to the discon-nected resolver line.

PL3 BATTERY ALARM LED ON when the servo amplifier battery level is low. Replace the batteryboard on the servo amplifier.

SS1 MANUAL-AUTO switch Should be set to the AUTO position for normal operation. To operatethe terry motion independently, set this switch to the MANUAL position.

NOTE: Be careful with sudden movement of the terry motion whichcould happen when you change this switch from the MANUAL toAUTO position.

SS2 FWD-REV switch Operational only when the MANUAL-AUTO switch is set to the MAN-UAL position.

Turning this switch in the FWD direction moves down the terry motionlever and the cloth fell shifts to the needle roller; turning it in the REVdirection moves it up and the cloth fell shifts to the beam.

BS1 ALARM RESET button If a terry motion error has occurred, press this button to clear the alarmstate.

NOTE: Be sure to take necessary actions referring to [ 5 ] Trouble-shooting.

BS2 ZERO POSITION button Operational only when the MANUAL-AUTO switch is set to the MAN-UAL position.

To return the terry motion only to the zero position (1st pick, 0°), pressthis swich.

TSW ZERO POINT PRESET Do not touch this switch. The zero point has been stored at the time ofshipment.

Servo amplifier Controls the terry motion servomotor. If a terry motion error hasoccurred, check the error codes on the servo amplifier display.

Inverter Controls the machine speed (rpm).

E6 - 1


Location of LEDs and Switches in the Inverter Box

PL1 ZERO POS.

PL2 ZERO POS. ALARM

PL3 BATTERY ALARM

SS1 MANUAL−AUTO

SS2 FWD−REV.

BS1 ALARM RESET

BS2 ZERO POS.

An inverter box has a high-voltage area and the voltage does not immediately decrease even if the power is turned off. When you open the door, turn off the power, wait at least 3 min-utes until the internal voltage decreases and open it.

G R R

SERVOAMP

BATTERY

BT SA

NC1NF1

NOISEFILTER

CNACNB

INVERTER

ACLTB1

PL1 PL3 PL2

SS1 SS2 BS2 BS1

TSW

1 2 3 4 5 6 7 8 9 10 11 12 13E CC BC AC JP1 PA E R1 S1 T1 O P Q

(Back of the inverter box cover)Normally: OFF

(turned downwards)

ZERO POS. RESET

E6 - 2


[ 2 ] Installation

Powering on the weaving machine after wiring between the machine and the inverter will turn on the ZEROPOSITION ALARM LED (PL2) located in the inverter box, as well as displaying alarm 23 or 32 on the servoamplifier 7-segment display. This is because the cable between the servomotor and servo amplifier was dis-connected at the time of shipment. Therefore, you need to register the zero point according to the procedurebelow.

Zero Point Registering Procedure

1) The ZERO POSITION ALARM LED comes on.

↓2) Alarm 23 appears on the servo amplifier display.

↓3) Press the ALARM RESET button.

↓4) Turn the machine power off. After at least 10 seconds, turn it on.

↓5) Alarm 32 appears on the servo amplifier display.

↓6) Press the ALARM RESET button.

↓7) Set the MANUAL-AUTO switch to the MANUAL position.

↓8) Turn the FWD-REV switch until the zero-point restoration proximity switch LED comes on.

First, turn the proximity switch in the FWD direction to shift the cloth fell forwards by approx. 10 mm.

Then, turn it in the REV direction until the zero-point restoration switch LED comes on.

↓9) Press the ZERO POSITION button. After a few seconds, check that the ZERO POSITION ALARM

LED goes off.

↓10) Turn the MANUAL-AUTO switch to the AUTO position.

↓11) Check that the ZERO POSITION LED is on and the zero-point restoration switch LED is off.

E6 - 3


[ 3 ] Adjustment(1) FWD-REV movement in manual operation

1) Set the MANUAL-AUTO switch to the MAN-UAL position.

2) Use the FWD-REV switch to move the clothfell only.

NOTE: If you move it excessively in the FWDor REV direction, the mechanical overrun pro-tector will work for safety, showing alarm 16 or18 on the servo amplifier display. If this hap-pens, press the ALARM RESET button.

(2) Zero-point restoration

1) Set the MANUAL-AUTO switch to the MAN-UAL position

2) Press the ZERO POSITION button, and thecloth fell will move to the zero-point.

[ 4 ] Safety Precautions

(1) Take care when doing any of the following since the cloth fell may move suddenly.

1) After approx. 10 seconds from when the weaving machine is turned ON.

2) When the MANUAL-AUTO switch is turned from the MANUAL to AUTO position.

3) When the weaving patterns or start pick is modified.

4) When the emergency stop switch is reset.

5) When the loom is started.The sudden movement is designed to correct the positional errors automatically; it should not be under-stood as abnormal.

(2) Before accessing the inside of the inverter box for maintenance, be sure to turn the machine power off.

R

RRG

Y

(Back of the inverter box cover)

TSW

Normally: OFF (turned downwards)

ZERO POS. RESET

PL1 PL3 PL2

SS1 SS2 BS2 BS1

PL1 ZERO POS.

PL2 ZERO POS. ALARM

PL3 BATTERY ALARM

SS1 MANUAL−AUTO

SS2 FWD−REV.

BS1 ALARM RESET

BS2 ZERO POS.

E6 - 4


[ 5 ] Troubleshooting

NOTE: Do not touch the SET button on the servo amplifier in the inverter box. Doing so may damage theinternal settings.

(1) If the “Terry motion Alarm” message appears on the function panel and the machine will not run (The yel-low lamp of the signal indicator flashes):

1) If the CHARGE LED (red) of the servo ampli-fier is off, it means that:• no 3-phase 200-V power is supplied to the

servo amplifier CN6 terminals R, S and T,or

• the servo amplifier is defective. (Replaceit.)

2) The wiring between the weaving machine andinverter box is broken.

SET

Any alarm code on the servo amplifier 7-segment display in the inverter box?

YES NO

Remove whatever caused error (referring tothe next page), press the ALARM RESETbutton, and then start the machine.

E6 - 5


Alarmlist

Alarm Alarm name Detecting method Cause and counter measures

AL01 Over-current (OC) IPM of the power supplydetected following troubles.(Model 035P or lower versions can detect 1 only.)1. Over-current2. Overheating3. Gate power supply low

1. Short circuit or grounding of armature wire (U, V, or W)

2. Ambient temperature is higher than 55 degrees Celsius.

Above problems are likely.If other causes are likely, contact the manufacturer.

AL02 Over voltage (OV) Main circuit DC power supply (PN voltage) is over 400 VDC.

1. The motor is running with a speed greater than the max. rotation rate.

2. Acceleration causes overshoot exceeding the max. rotation rate.

3. JP1 or JP2 is disconnected. Or the external counter current resistance is not connected or the connection line is broken.

AL03 Low PN voltage (PNLV)

Main circuit DC power supply (PN voltage) dropped below 170 VDC.

1. Low input power voltage.2. T phase is missing from input power supply. (In

case of 070 to 200P)3. If this alarm is issued during motor acceleration,

power supply capacity shortage is likely.

AL04 Main power supply input trouble (ACINF)

Low main power supply (AC) input voltage.

1. Electrolytic capacitor is properly charged during main power supply input.

2. Main power supply was disconnected during operation.

AL05 Function undefined

AL06 Resolver disconnected (RELV)

Resolver signal voltage between R1 and R2 dropped below 0.35 VAC.

Check that the resolver cable is not broken or disconnected.Test the voltage level between R1 and R2.(It should be over 0.35V in the AC range.)

AL07 Power status error (POWFAIL)

CPU cannot judge the amplifier type. 1. CPU’s software version is not consistent with the unit configuration.

2. The amplifier is out of order.Above problems are likely.Please contact the manufacturer.

AL08 Servo amplifier overheating (SOH)

The radiation fin is heated exceeding the range of 90 to 100 degrees Celsius.

1. Temperature rise inside the control panel.2. The cooling fan inside the amplifier is out of

order.

AL09 Counter current resistance overheating (RGOH)

Overheating of the amplifier integrated counter current absorption resistor is detected by software operation.

The frequency of acceleration or deceleration may be too high or continuous absorption (negative load) is likely.Calculate the counter current energy and install an exetrnal counter current resistor.

AL10 Reverse current absorption error (RGST)

The reverse current absorption transistor is ON over 50ms.

1. When an external resistor is not used, check if JP1 and JP2 are short-circuited or not.

2. When an exeternal resistor is used, turn OFF the machine and test the resistance between the terminal block PA and JP2. The normal range is between 6 and 30 ohms. If the value is over that range, a line break inside the resistor is likely. Replace the resistor.

AL11 Function undefined

AL12 DSP error (DSPERR) DSP stopped working. The amplifier is out of order.Please contact the manufacturer.

AL13 Resolver ABS battery low voltage (BLV)

The battery voltage is below 3.4V. Replace the battery.If AL24 has not been issued, the zero point setting is still saved.

E6 - 6


AL14 Brake error(BERR) 1. When the dynamic brake is used, brake output turning ON did not generate the brake confirmation signal input.3

2. When the holding brake is used, brake output turning ON kept the brake confirmation signal ON.

Read the descriptions on the dynamic and holding brake connections and check the wiring and used accessories.

AL15 Over-current detection (OCS)

The motor current exceeded 120% of the current limit setting.

1. The motor in rotation was locked mechanically.2. Short-circuit or grounding of the A, B, and C

phases of the motor.3. Parameter setting error. Please take contact with

us.

AL16 Speed amplifier saturation (VAS)

The speed amplifier was saturated and current exceeding the maximum level flew more than 3 seconds.

1. The motor is locked mechanically.2. The load inertia is too great to accelerate or

decelerate.3. Parameter setting error. Please take contact with

us.

AL17 Motor overload (MOL)

Motor temperature calculated from the actual load level rose exceeding 110% of the maximum temprature setting.

1. Load is too much for the motor output capacity.2. Operation cycles are too short for the motor

capacity.

AL18 Instant thermal (POL) This alarm is issued when output current is more than 120% of the motor rated current.

1. The motor is locked mechanically.2. Load is too much for the motor output capacity.3. Parameter setting error. Please take contact with

us.

AL19 Resolver error (RESERR)

The resolver feedback counter made erroneous counting.

1. Bad contact of the resolver cabling.2. The resolver cable is installed near the power

line and affected by noises. Check the resolver cable.

3. The ground line between the motor and the amplifier is broken or disconnected.

AL20 Overspeed (OSPD) The rotation rate exceeded 120% of the maximum rotation setting.

1. The servo adjustment value is overshooting. Couduct auto tuning.

2. A command value was too much.3. Bad contact of the resolver cabling.4. The resolver cable is installed near the power

line and affected by noises.5. The ground line between the motor and the

amplifier is broken or disconnected.

AL21 Deviation counter over (FULL)

Accumulated pulses in the deviation counter exceeded the following detection level.

1. Load is too much for the motor output capacity.2. The load inertia is too great to accelerate or

decelerate.3. The value for TP2 (Target loop gain) is set too

high.4. Current limit is set too low.

AL22 Resolver ABS phase error (ABSE)

The ABS sensor had phase shift. Adjust ABS sensor phases or replace the sensor.Please contact the manufacturer.

AL23 Resolver ABS broken line (ACN)

The ABS cable was disconnected or the +10 CTD signal line was disconnected.

Even when the power is turned OFF, disconnecting the ABS cable will trigger the alarm. Absolute position must be set again after the ABS cable was disconnected and reconnected for moving the machine or another purpose.

AL24 Resolver ABS battery alarm (BAL)

The ABS battery voltage dropped below 3.2V.

Replace the ABS battery immediately.The zero point setting is no longer saved.Reset the absolute position.


Motor maximum rotation rate Sensor split count ×10×60 TP2

Detection level

Example: Max.rpm 2000 rpm, Motor sensor: resolver

Target loop gain TP2 = 60

2000 2400 ×10 = 133000 pulses×60 TP2

Detection level

E6 - 7


NOTE: How to reset alarm codesPress the SET key of the display unit while an alarm code is displayed. Or turn ON the reset input signal toclear the alarm code and the flashing dot mark.If multiple alarms were issued, one alarm is cleared each time the SET key is pressed. All alarms are reset bythe reset input signal.

AL25 Option alarm (CPALM)

Option board alarm. The wiring between the machine and servo amplifier is broken or its connection is faulty.The zero-point restoration has failed. Try again.The jacquard power is off.

AL26 Parameter setting error (CERR)

No or incorrect parameter setting. This error occurs upon first power input. Please take contact with us.

AL27 Resolver ABS error (AEERR)

CHA and CHB signals are kept ON while the power is ON but were turned OFF perhaps by disconnection or line break.

1. ABS cable was disconnected.2. Bad contact of the connector. Check that CTD,

CHA and CHB signals are ON.

AL32 Zero point saving error (MZE)

When the resolver ABS is used, ABS setting is not completed with the ABS motor. Or this alarm is issued together with AL06, AL19, AL22, AL23, and AL27.When the encoder is used, the alarm is issued together with AL42, 43, and AL45.

In case of the ABS motor, AL32 is always issued with the factory setting.Set the ABS position int the following steps:

AL33 Resolver ABS invalid zero point (CLD)

The ABS position was not set following the steps on the right when AL06, AL19, AL22, AL23, or AL27 was issued.

AL36 Resolver ABS battery cable broken or disconnected (ABT)

The ABS battery went out of place when the power was turned OFF.

Check the battery cable connectors is not coming loose or the cable is not broken.


Turn ONthe power

AL23 andAL32 issued

Alarmresetting

Turn OFFthe power

Turn ONthe power

Confirm that onlyAL32 is issued.

Alarmresetting

SettingABS position

E6 - 8


(2) If the “Abnormal terry volume” message appears on the function panel (The yellow lamp of the signalindicator flashes), it means that:The pile length is too long, or so many entries of length (A)+ or (B)+ are made in pattern instructions.Correct the pattern.

(3) If the “Pile let-off: Proximity switch abnormal” message appears on the function panel (The red lamp ofthe signal indicator flashes), it means that:• The pile beam proximity switch is not positioned correctly,• The pile beam proximity switch is defective, or• The wiring between the pile beam proximity switch and the main control box is faulty.

(4) If the “Pile let-off: Cloth beam diameter abnormal” message appears on the function panel:• Set a new pile beam diameter.• If this error persists after changing the pile beam diameter, then the error cause may be the same as

for (3) above.

(5) If the BATTERY ALARM LED in the inverter box lights, it means that:• The battery life will expire soon. Replace the battery beside the servo amplifier, or• Press the ALARM RESET button and then run the machine. (Note that the BATTERY ALARM LED

remains ON.)• If the battery lift has expired completely, both the BATTERY ALARM LED and ZERO POSITION

ALARM LED come on every time the machine is powered up.

Follow the procedure below.

Press the ALARM RESET button.↓

Set the MANUAL-AUTO switch to the MANUAL position.↓

Turn the FWD-REV switch until the zero-point restoration proximity switch LEDcomes on.

↓Press the ZERO POSITION button.

↓Check to see that both the zero-point restoration proximity switch LED and theZERO POSITION ALARM LED are off, and then set the MANUAL-AUTO switchback to the AUTO position.

↓Ready for weaving operation

(6) If the cloth fell has not returned to the zero position for ground weave:

1) Set the MANUAL-AUTO switch to the AUTOposition.

2) Carry out the zero-point restoration.• If this operation has returned the cloth fell to

the zero point, check the wiring between theservo amplifier and the main control box.

• If this operation has failed to return it, turnoff the machine power, unplug and plug theresolver cable connector of the servoamplifier, and then turn on the machinepower.

Next, register the zero point (refer to [ 2 ]Installation).

3) Adjust the mounting position of the zero-pointrestoration proximity switch. (Refer to SectionM9.2.)

Zero-point restoration

Set the MANUAL-AUTO switch to MANUAL.

↓

Press the ZERO POSITION button.

E6 - 9


[ 6 ] Comparison with the Mechanical Terry Motion(1) The electronic terry motion has no terry proximity switch. Consequently, it is possible to initialize patterns

at any pick. (The crank angle is about 300°.)

(2) When the pile beam is replaced in the electronic terry motion, you do not need to check the pile beamcondition on the function panel or modify the pile length. Only the pile beam diameter setting should bemodified.

[ 7 ] Inverter Control Substrate

[ 7.1 ] Monitor LED

A monitor LED is located on the inverter substrateand indicates the state of the inverter by on/offstate. Refer to Subsection 1.1A.7 of the StandardMachine “Instruction Manual” for LED display.

[ 7.2 ] Rotary Switch

Rotary Switch 1 (SW1)

Set the power supply voltage. Set the voltage sup-plied to the loom. The output voltage to the motor iscalculated based on this value. Wrong setting maynot supply correct voltage to the motor.

Rotary Switch 2 (SW2)Not used. Always set to 0.

LED2

A high-voltage circuit is housed in the inverterbox and very dangerous.

Be sure to turn off the power and make surethat LED2 has gone out before carrying outmaintenance and setting SW.

Power supply voltage SW1 setting

AC 200 V SW1=1

220 V SW1=2

350 V SW1=3

380 V SW1=4

400 V SW1=5

415 V SW1=6

420 V SW1=7

440 V SW1=8

460 V SW1=9

E6 - 10


[ 7.3 ] DIP Switch

Use this to update programs for the substrate.

Normal mode (1: On, 2: Off)Keep this state under the normal condition.

Write mode (1: Off, 2: Off)Set 1 to Off to write a program from a memory card.Return it to the normal mode after finishing writing.

NOTE: Turn off the power to change the switch.

ON

OFF

1 2

ON

OFF

1 2

E6 - 11

Model JAT810€¦ · TOYOTA AIR JET WEAVING MACHINE Towel Loom Model JAT810 (FIRST EDITION) Thank...

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Transcript of Model JAT810€¦ · TOYOTA AIR JET WEAVING MACHINE Towel Loom Model JAT810 (FIRST EDITION) Thank...