Toyota JAT810 Instruction Manual

TOYOTA AIR JET

WEAVING 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, and
maintenance 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 understand
the JAT810.

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 Man­ual” 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 pri­ority to this towel manual.

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.

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

JUNE, 2010 Ver. 2.01 (Towel)

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

CONTENTS

Section 1 Mechanical

Section 2 Electrical

1.1 Yarn Beam Installation

1.2 Preparation of the Beam

1.3 How to Run the Warps and Woven Fabric Through

1.4 How to Remove/Reinstall the P-tension Shaft for

Easier New Fabric Weaving

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

2.1 Dobby Shedding Specifications

2.2 Jacquard Shedding Specifications

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

3.1 Longitudinal Position of the Temple

3.2 Crosswise Position of the Temple

3.3 Vertical Position of the Temple

3.4 Standard Setting of the Temple Ring

3.5 Vertical Position of the Temple Cover

3.6 Adjustment of Fell Plate Position

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

4.1 Leno Weave with Two Clockers

4.2 Trimmed Selvage Motion

4.3 Gripper

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

5.1 Pile Let-off Mechanism

5.2 Outline of Let-off Control

5.3 Adjustment of Easing Roller

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

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

6.1 Advance Adjustment

6.2 Adjustment at the Change of Gland Warp Tension

6.3 Machine Stop or Disabled Operation due to Abnormal Tension

6.4 Height Adjustment

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

7.1 Longitudinal Position

7.2 Vertical Position

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

8.1 Lubrication Cycle and Applicable Fluids

8.2 Oil Change of Terry Motion Cam Box

8.3 Oil Change of Jacquard Bevel Gearbox

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

9.1 Adjusting the Stoppers

9.2 Zero-point Restoration Proximity Switch

9.3 Reverse Current Absorber Cover

9.4 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 Method

2.2 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

Section 1 Mechanical

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 direction

A. Set the inside of the flange to the marked
position.

• For the ease of screwing, apply grease or
oil to the threaded portion.

(3) Set a yarn beam gear 4 to the yarn beam 1 so

that the bolt holes (large, 8 holes) of the yarn
beam gear 4 match the bolt holes of the yarn
beam 1. Then turn the yarn beam flange 2 so
as to have the bolt holes (small, 3 holes)
match the bolt holes on the yarn beam flange

2.

(4) Tighten the yarn beam 1 and yarn beam gear

4 with 8 bolts 8. Then match the bolt hole posi­tion of the yarn beam gear 4 with the yarn
beam flange 2. Tighten 3 bolts 7 sequentially
and equally.

M1 - 1

M1. Preparation for Setting

(5) [Flange installation on the side of the counter-

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

NOTE: A minimum effective drawing width to
each nominal reed width is a nominal reed
width minus 70 cm.

(6) Screw in the yarn beam flange 3 from direction

B. Match the marking made in (5) to the inside
of yarn beam flange 3.

• For the ease of screwing, apply grease or
oil to the threaded portion.

(7) Screw in the flange ring 5 also from direction

B. Match the bolt holes of the yarn beam
flange 3 and flange ring 5 by providing a clear­ance of 3 to 5 mm between the end faces of
the yarn beam flange 3 and flange ring 5 and
tighten the bolts.

M1 - 2

Section 1 Mechanical

[ 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 direction

A. Set the inside of the flange to the marked
position.

• For the ease of screwing, apply grease or
oil to the threaded portion.

(3) Set the yarn beam gear 4 to yarn beam 1 so

that the bolt holes (large, 8 holes) of the yarn
beam gear 4 match the bolt holes of the yarn
beam 1. Then turn the yarn beam flange 2 so
as to have the bolt holes (small, 3 holes)
match the bolt holes on the yarn beam flange

2.

(4) Tighten the yarn beam 1 and yarn beam gear

4 with 8 bolts 8. Then match the bolt hole posi­tions of the yarn beam flange 2 and yarn beam
gear 4. Tighten 3 bolts sequentially and
equally.

M1 - 3

M1. Preparation for Setting

(5) [Flange installation on the side of the counter-

yarn beam gear]
Mark the yarn beam 1 at L mm [reed drawing
width minus (2* selvage texture width) plus 0
to 10 mm] to the right of the marking made in
(1).

NOTE: A minimum effective drawing width to
each nominal reed width is a nominal reed
width minus 70 cm.

(6) Screw in the yarn beam flange 3 from direction

B. Match the marking made in (6) to the inside
of yarn beam flange 3.

• For the ease of screwing, apply grease or
oil to the threaded portion.

(7) Screw in the flange ring 5 also from direction

B. Match the bolt holes of the yarn beam
flange 3 and flange ring 5 by providing a clear­ance of 3 to 5 mm between the end faces of
the yarn beam flange 3 and flange ring 5 and
tighten the bolts.

[ 3 ] Bearing installation

(1) Mark the point A below from inside a bearing

shaft 9:

Gland beam

Pile beam

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

(3) Insert a hoop 11 so as to have the inside of the

bearing 10 matches the marking made in (1).
Then tighten the bolt 12 to position the bearing

10.

(4) Bearing shaft 9 is attached to the machine.

Remove bolt 13 and bearing shaft 9 from the
empty yarn beam when replacing the beams.

Beam gear side 25.5mm

Counter beam gear side 28.0mm

Beam gear side 92.5mm

Counter beam gear side 65.0mm

M1 - 4

Section 1 Mechanical

1.2 Preparation of the Beam

[ 1 ] Preparation of gland beam

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

Care should be taken for the direction of wind­ing of the gland beam 1 and pile beam 2 which
run counter to each other.

[ 2 ] Preparation of pile beam

Wind a pile beam 2 clockwise from the beam gear
side A.

Care should be taken for the direction of wind­ing of the gland beam 1 and pile beam 2 which
run counter to each other.

M1 - 5

M1. Preparation for Setting

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 a
torsion bar roller 1. Allow them to pass
between a pile warp dropper 3 to reach a
heald 11 and a reed 12.

(2) How to run the pile warps through

Run the warps along a deflector roller 4 and
via a shock absorber bar 5 to a pile easing
roller 6. Run them to the heald 11 and reed 12
through the pile warp dropper 3.

(3) How to run woven fabric

Wind woven fabric on a surface roller 8 via an
expansion bar 7. Wind it on a cross roller 10
by allowing it to pass over the press roller 9.

1) Surface roller

NOTE: Danger. Beware of a number of spikes
embedded to the surface of the surface roller

8. Care should be taken when working near
the surface roller 8.

2) Cross roller
Wind woven fabric on to a cross roller 10.
Press it with apress roller 13 to insert the fabric
to the groove.

A : Gland beam
B : Pile beam
a : Gland yarn
b : Pile yarn

NOTE: During the setting, terry motion can be

stopped by selecting texture weaving mode with
the function panel.

M1 - 6

Section 1 Mechanical

3

4

3

1

6, 7

5

3

4

3

2

1

7

6

9

10

10

B

A

8

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

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

The reed, heald frames and droppers are very
heavy, so take extra care when handling them.
In (16), tighten bolts to the torque values spec­ified in the Standard Machine “Instruction Man­ual,” Chap. M, Subsect. M.1.9.

(1) Remove bolts 3 from right and left clamps 2 on

top 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 leaf

spring, 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 the

holder.

(6) Remove P-tension shaft 6.

(7) Set the reed, heald frames, and droppers to

the 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 arrow
A and sliding coupling 7 in the direction of
arrow 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 ten­sion. Then loosen bolts 8 on coupling 7 and
adjust the angle of the P-tension roller again so
that the warp sheet at section “

C”

becomes

almost horizontal.

(16) Check that bolts 3, 4, 8, and 10 are tightened

to the specified torques.

M1 - 7

M1. Preparation for Setting

Clean the pile yarn contact part on the board
panel and the guide bar at every beam
change, and confirm that no foreign substance
is attached. (This is to avoid a thread being
adhered by a substance such as paste that
adversely affects and tension.)

M1 - 8

Section 1 Mechanical

C

A

H

M2. Shedding Motion

2.1 Dobby Shedding Specifications

For 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 (Type
S3220)” for the heald frame height and shed size
setting procedures.

This section introduces the following reference val­ues for the towel looms.

Reference setting value list

Shedding

lever

Frame

No.

1 129 71

2 109 67

39164

47360

5 103 64

69061

77558

8 109 56

912960

10 120 58

11 10 9 56

12 99 53

13 89 51

14 78 49

15 69 46

16 59 44

Pile Leno weave

Dimen
sion A

Dimen-

C

sion

(mm)

Frame
height

(mm)

Dimen­sion

(mm)

C

Dimen
sion A
Frame
height

(mm)

Waste

selvage

Dimen-

C

sion

(mm)

Dimen
sion A
Frame
height

(mm)

Ground

Dimen-

C

sion

(mm)

Dimen
sion A
Frame
height

(mm)

NOTE (list specifications) :

1. Heald frame: C type riderless 330 MM
Center mail, Dimension H: 549 MM (Stave
width standard)

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

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

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

M2 - 1

2.2 Jacquard Shedding Specifications

1

2

2

A

4

3

Refer 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 a

top 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 Yarn

1) 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 draw
yarn bysetting heald No. 1 to a point 43 mm
from the rear face of the rocking shaft.

M2. Shedding Motion

M2 - 2

Section 1 Mechanical

a

6

3

4

5

1

2

M3. Temple

Movable 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 the

temple and reed.
3 to 4 mm when the warp tension is not applied
2 to 3 mm when loaded with warp tension

(4) If the clearance is different between the left

and right, loosen expansion bar rod 1 fasten­ing nut 2 (two pieces each on the left and right
sides).
Turn the extension bar rod nut left and right to
adjust the longitudinal position of the temple to
equalize the clearance.

NOTE:

stoppers to the left and right of the cloth fell.
(See M5.2 Stopper Adjustment) Adjust inter­val “a” correctly.
The red may be damaged if in contact with the
yarn guide plate during operation. Difference
of interval “a” in the longitudinal direction will
result in the difference of the pile length, addi­tionally causing fallen warp due to loose warp.

(5) If the clearance is the same on the left and

right sides, turn turnbuckle 6 of the terry
motion lever for adjustment.

NOTE:

stoppers to the left and right of the cloth fell.
(See M5.2 Stopper Adjustment) Adjust inter­val “a” correctly.

(6) Release the emergency stop push-button

switch. Check by inching operation that the
yarn guide plate is not in contact with the reed.

Pay attention to the intervals of the

Pay attention to the intervals of the

M3 - 1

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

(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 toward

(2) Set the temple 7 so as to have the right-hand

(3) After the setting, check that the right-hand end

(4) To change the drawing width of a reed, loosen

M3. Temple

“a” between the left-hand side A of a temple
ring 3 and a gripper 4 becomes 0.5 mm.

you at a right angle to a reed 5.

end of No. 1 ring 8 of the temple 7 aligned to
the right-hand end 6 of the warp.

of 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.

the fastening bolts 9 (6 bolts) to move the tem­ple 7 to a prescribed position, then tighten the
bolts 9 to fix it.

M3 - 2

Section 1 Mechanical

3.3 Vertical Position of the Temple

(1) Adjust the height of the left- and right-hand

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

(2) It is necessary to have a right-hand side cutter

4

shaft bracket
temple base 3. Insert the same number of
shims inserted between the cutter shaft
bracket 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 1
mm.

at the same height with the

1

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. Tighten
the 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:

loose warp will result if the end of the fabric
falls from the end of the temple.

•

Care should be taken, however, since

To weaken the temple pull, set the marked
line x to the side of the reed.

M3 - 3

3.5 Vertical Position of the Temple Cover

1

2

3

5

6

(1) Loosen a bolt 3.

(2) Make the top face A of the temple cover

flush with the top face B of the temple cover 2.

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

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

3.6 Adjustment of Fell Plate Position

M3. Temple

1

(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]

1

Set the height of the fell plate
be 6 mm vertically from the face A of a fell
plate bracket 3. At this time, check that the
lower face of the temple cover 4 and the top
face of the fell plate 1 are at the same height.

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

(3) Determine the left- and right-hand positions so

that the fell plate
cover than a face B of the temple cover 4 on
both the left-hand and right-hand sides of the
loom.

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

NOTE:

ing to the weaving width, and then cut and
remove the rest. Finish the section smooth
with tools such as a file to prevent persons
from injury or a yarn from getting stuck.

Decide the length of fell plate 1 accord-

1

will be 3 to 4 mm inside the

so that it will

5

and the fabric sur-

M3 - 4

Section 1 Mechanical

Dobby weave specification

Jacquard weave specification

M4. Selvaging Machine

4.1 Leno Weave with Two Clockers

Install a leno weave selvage motion to two heald
frames for dobby weave specification or connect it
to a harness for jacquard weave specification.

With the up and down motion of the heald frames
and B, cross yarns form the selvage texture by
moving to the left and right to a stationary yarn
which 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 to
the left.

4.1.1 Installation of Clocker

(1) Lock the emergency stop pushbutton switch.

(2) Install the clockers 1 and 2 to the heald frames

A

and B.

NOTE:

ers for a 330 mm center mail is 95 cm. Care should
be taken when setting the shedding.

A maximum shedding amount of the clock-

A

3

M4 - 1

M4. Selvaging Machine

Jacquard
harness

1

1

2

3

4

3

4

For multiple tucking jacquard

(1) Metal fitting number 1 is applied to stabilize the

right and left position of leno weave with two
clockers
Model 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 via
tenser 3.

(2) Pass the yarn from the thread eye 4 through

the eye of a tenser spring 5 then through a
gland dropper box A (put through the dropper).

(3) Pass the yarn between a pile dropper box B,

through a yarn retainer device 6 then through
a clocker device 7. (For how to run the yarn
through the clocker, read M4.1 Leno Weave
with Two Clockers.)

M4 - 2

Section 1 Mechanical

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 tenac­ity with lesser fluffs and knots should be used
as principle.

(2) A cotton double (or triple) yarns of a higher

count than the warps for plain weave is recom­mended.

(3) If the same yarn as the one for ground weav-

ing may cause insufficient strength, select
another yarn whose physical property is as
similar as possible. If a yarn different in quality
from the warp for ground weaving is to be
used, perform preparatory check to cause no
trouble in later processing.

4.2 Trimmed Selvage Motion

Located outside the right-hand end of the fabric, the
trimmed selvage motion entwines a weft 1 shuttled
and several warps 2 for trimmed selvage (yarns
from the trimmed selvage stand) to provide the weft
with tension to form a fabric of normal woven tex­ture.

M4 - 3

M4. Selvaging Machine

9

2

3

4

3

4

4.2.1 Installation, Adjustment, and
Preparatory Operation

Use a cheese on the trimmed selvage stand as the
yarn for trimmed selvage. A total of six cheeses
excluding a cheese for the leno weave selvage will
be used for the trimmed selvage.

[ 1 ] How to run the trimmed selvage yarns

through

(1) Hook a yarn from cheese 9 to rod 3 through

2

cheese spindle

•

To run the yarn to cheese spindle 2, use a
tool (J8213-01010-00).

then through a thread eye 4.

(3) Pass the yarn coming out of the thread eye

to a gland drop box 6 (pass through the drop-

4

per) through the eye of a tenser spring 5.

M4 - 4

Section 1 Mechanical

(4) Guide the yarn coming out of the pile dropper

box through a heald 7 and a reed 8; entwine it
with a weft at the cloth fell. The yarn will run
through a temple 9 and be cut with the RH cut­ter.

(5) The yarn is run through the guide rollers

and 11, held by a weft band roller 12 and
ejected to a waste box 13.

10

[ 2 ] Trimmed selvage cheese specifica-

tions

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

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

M4 - 5

M4. Selvaging Machine

4.3 Gripper

This is an auxiliary device for better solidifying the leno weave of selvage by holding the filled yarn ends (left­hand ends).

4.3.1 Installation Adjustment

(1) [Positional relationship with the temple]

Determine a clearance “a” between the end
face of a temple ring 1 and a gripper holder
as 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 and
the left-hand end of No. 1 blade of the reed
becomes 1 mm.

2

3

(3) [Vertical position]

Set the crank angle to 0°. Adjust the gripper
holder 2 so as to have a warp held with a yarn
guide spring 4 and the gripper holder 2 be
positioned at the same height as the cloth fell
height C.

(4) [Contact pressure of yarn guide spring]

Adjust the contact pressure of the yarn guide
spring 4 by turning a nut 5 so as to have the
warps arranged on one line with the cloth fell
height 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 pres­sure is excessive. Decrease the contact
pressure.

•

Care should be taken for the yarn guide
spring 4 coming off the gripper holder 2 if
the contact pressure is either excessively
strong or weak.

M4 - 6

Section 1 Mechanical

1

2

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 from

occurring 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 caused
by the piling motion.

(2) A let-off controller L rotates the beam by

obtaining information from the loom main con­trol M and a load cell 4.
It feeds a tension value, etc. of the load cell
to the loom main control M.

(3) A spring mechanism is designed to sharply

change the spring constant according to the
pile or plain weaving.

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

2) Because pile tenser plate 1 overlaps with
guide plate 2 at plain weaving such as border
weaving, a spring constant becomes higher to
cope with the high tension.

4

M5 - 1

5.2 Outline of Let-off Control

M5. Pile Let-Off

(1) Plain weave “a”

The beam rotates according to the density
data forwarded from the loom’s main controller

M

. In addition, difference between the set and
actual tensions is used for regulating the beam
rotation.

(2) Pile weave “b”

The beam rotates according to the density
data (including the pile length) forwarded from
the loom’s main controller M. In addition, differ­ence between the set and actual tensions is
used for regulating the beam rotation.

(3) Shift from the plain to pile weave “C”

The beam rotates to deliver yarns to attain a
piling tension when the woven texture is
switched.

(4) Stop pile weaving “d”

Immediately upon the loom stopping, the
beam rotates to deliver yarns for easing ten­sion to a level appropriate for non-pile weaving
state.

M5 - 2

Section 1 Mechanical

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:

Make the dimension A longer evenly.
If overlengthened, pile yarns may be entan­gled during easing.

(4) Make adjustment in fast pick or plain weave

state so that a pipe holder arm 2 will become
vertical.
When making individual adjustment, loosen a
bolt 3.
When making overall adjustment, loosen a
bolt 4.

(5) Check that the easing roller 1 can be turned

smoothly by hand.
If not, it may cause uneven piling.

Should uneven pile be generated,

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 (in

the 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 of
the deflection roller 1.

(3) Determine the height of the sensor stay by

retaining a clearance of 1.0 mm between the
deflection 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 tor­sion 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

7

11

2

5

12

3

4

1

10

X

6

8

9

(to 0 kg).

NOTE:

0 kg cannot be attained depending on

the 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 direc­tion of X.

(4) Turn the warm 4 while rocking the tension

roller with hand until the tension roller bracket

7

reaches a right angle to the warp line (gland

warp path).

Ensure to follow the procedures below to pre­vent the warm from any damage.

•

Shake the tension roller by hand

•

Turn warm 4 by hand

*Do not turn it with a tool forcibly.

(5) Check that a notch 5 points at 0 in a scale 1.

If not pointing at the scale 0, loosen a screw
and adjust the position of scale 1.

3

M6 - 1

Section 1 Mechanical

12

13

(6) Match to the shedding timing in the plain

weave state. (Standard is 310°.)
In the pile weave state, produce a state where
a temple 12 is closest to a reed 13.

(7) Rewind the beam from the function panel and

tighten the warp tension to a set value. Make
adjustment by turning the warm 4 so as to
have an indicator 9 to point at between 0 and 5
of the scale 10.

NOTE:

When the warm 4 is adjusted, the warp
tension changes.
Therefore, repeat the adjustment of the warp
tension and the warm 4.

2

(8) Tighten the bolt

NOTE:

If the bolt 2 is loose, the warm 4 may

to fix the warm 4.

rotate during operation to change the setting.
Be sure to tighten it correctly.

M6 - 2

M6. Torsion Back

1

2

3

4

5

6

7

8

9

10

11

12

X

(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, loosen
the bolt 2 and turn the warm 4 to make adjust­ment.

NOTE:

Don’t adjust the warm 4 during opera­tion, or the warm starts oscillating when the
plain 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 scale
to a tension of 50 kg.

(3) Tighten the bolt 2.

(4) Enter a desired set tension from the function

panel and press the gland warp tension return
switch.

(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
and turn the warm 4 to make adjustment.

NOTE:

tion, or the warm starts oscillating when the
plain weaving is switched to the pile weaving,
which is quite dangerous.

Don’t adjust the warm 4 during opera-

2

6.3 Machine Stop or Disabled Operation due to Abnormal Tension

1) A proximity switch 11 is provided for preventing machine damages. Operation will not start if the proxim­ity switch 11 is OFF. If the function panel indicates an “Abnormal tension” message, readjust the warm 2.

Proximity switch 11 LED12

ON Lighted

OFF Off

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

M6 - 3

Section 1 Mechanical

6.4 Height Adjustment

If 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 and

a nut 11 of an adjust bolt 10.
To lower the height, loosen the adjust bolt
and widen the clearance between the frame.

(2) Loosen a bolt 2.

(3) Loosen a nut 7, and turn an adjust bolt 6 to

adjust the height.

(4) Check that the side A of the back bracket is

flush with the flame 4.

(5) Tighten the bolt 2.

(6) Tighten the nut 7.

(7) Tighten the bolt 9 so as to allow the dropper

box bracket 8 to have the same inclination as
before the adjustment.

(8) Tighten the nut 11 so as to have the adjust bolt

10

make a light contact with the frame 4.

10

M6 - 4

M7. Warp Stop Device

7.1 Longitudinal Position

M7. Warp Stop Device



Warp stop device (dropper box)

The dropper box is located above the warp line in
the rear of a loom. If a warp is cut, the dropper
drops to energize a contact bar 3. The signal is
transmitted to the loom control box via a contact
plate 4 and cable 5 to stop the loom operation. In
addition, a towel weaving loom is provided with the
dropper boxes for the gland 6 and the pile 7 so as
to indicate which side of the yarn is broken.

(1) Lock the emergency stop pushbutton switch.

(2) Loosen the bolts 3 and 4 (each 4 bolts) that fix

the main units 1 and 2 of respective dropper
boxes.

(3) Remove a fixing bolt 6 of a pile easing support

5

inside the loom.

NOTE:

pile easing support 5 differs by the width of the
reeds.

(4) Set respective dropper boxes to the positions

indicated below:

Gland dropper box A=28mm

Pile dropper box B=36mm

NOTE:

installation, which may be different depending
on the type of fabric.

(5) Tighten the bolts

and (3).

The number of the fixing bolt 6 of the

The above is the positions for standard

3, 4

, and 6 loosened in (2)

M7 - 1

Section 1 Mechanical

7.2 Vertical Position

The standard vertical position shall be 1 to 2 mm
between the gland yarn and the oval tube and 4 to
5 mm between the pile yarn and the oval tube.

Adjustment may be made with the number of shim

14

or by making vertical adjustment of a dropper
box bracket 8. In the beginning, adjust with the
number of shim 14.

If adjustment is insufficient with the method of
changing the number of shim 14 only, make vertical
adjustment 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 fix

the main units 1 and 2 of respective dropper
boxes.

(3) Remove a fixing bolt 6 of a pile easing shaft

lever 5 inside the loom.

NOTE:

lever 5 may vary depending on the reed width.

The number of the pile easing shaft

(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:

lever 5 and the bolt hole of a joint plate 7 do
not match, loosen a bolt 8 to match the bolt
hole.

If the groove of the pile easing shaft

[ 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 an

adjust bolt 11.

NOTE:

adjust bolt 11, overall inclination may be
changed.

(5) Tighten the bolts 6, 9, and 10 loosened in (2)

and (3) for the height and inclination adjust­ment to fix the dropper box bracket 13.

NOTE:

lever
plate 7, loosen the bolt 8 to match the hole.

Since the only contact point is the

If the groove of the pile easing shaft

5

does not match the bolt hole of the joint

(6) Tighten a nut

12

of the adjust bolt 11.

M7 - 2

M8. Lubrication

Lubricating intervals

Lubricating points

D

D

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 Man­ual.”

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

tion Manual.”)

8.1 Lubrication Cycle and Applicable Fluids

(1) Grease lubrication

Every 1.5 to 2.0 months

at warp beam change

Grease

gun

Oiler Brush

Gland yarn beam gear (left-hand side)

10 hours Every 10 days

Electric centrallzed

lubrication system

Grease

gun

Oiler Brush

Lower beam pinion (left-hand side)

M8 - 1

Section 1 Mechanical

Lubricating intervals

Lubricating points

D

D

D

D

Pile yarn beam gear (left-hand side)

Upper beam pinion (left-hand side)

10 hours Every 10 days

Electric centrallzed

lubrication system

Grease

gun

Oiler Brush

Every 1.5 to 2.0 months

at warp beam change

Grease

gun

Oiler Brush

RH cutter (mechanical) cutter bracket mid point

Electric winding gear

M8 - 2

M8. Lubrication

Lubricating intervals

Lubricating points

A

D

D

Movable temple, bearing

Torsion bar guide voller

10 hours Every 10 days

Electric centrallzed

lubrication system

Grease

gun

Oiler Brush

Every 1.5 to 2.0 months

at warp beam change

Grease

gun

Oiler Brush

Pile easing shaft BKT

(2) Dobby

For the lubrication points, type of fluid and lubrication cycle, follow the instruction manual for the dobby
loom.

(3) Jacquard

For the lubrication points, type of fluid and lubrication cycle, follow the instruction manual for the jacquard
loom.

M8 - 3

Section 1 Mechanical

1

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:

(2) Drain used oil by inserting a drain tool into the

drain port.

(3) Fill oil until the oil level reaches the center of

the level gauge 1.

NOTE:

Machine “Instruction Manual.”

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

Refer to “M.3 Lubrication” in the Standard

8.3 Oil Change of Jacquard Bevel Gearbox

(1) Oil change period is as follows:

(Standard lubrication quantity is 2 liters.)

Reference:

(2) Drain used oil by inserting a drain tool into the

drain port.

(3) Fill oil until the oil level reaches the center of

the level gauge 1.

(4) Check oil level monthly. Replenish oil if below

the required level.

NOTE:

Machine “Instruction Manual.”

Refer to “M.3 Lubrication” in the Standard

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

M8 - 4

M9. Electronic Terry Motion

1

2

3

M9. Electronic Terry Motion

This section describes the mechanical points of the electronic terry motion. The related electrical details are
given in Section E6.

For the Mechanical Terry Motion, refer to Section M5.

9.1 Adjusting the Stoppers

Adjust 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 or

ground 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 touches

the expansion bar lever 3.
Make sure that both the RH and LH stoppers
are 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 contact
with each other, and adjust for light contact.

M9 - 1

Section 1 Mechanical

Hole A

Hole B

Proximity switch

Flag

0 to 1

Flag

2.5 to 3.5

Proximity switch

9.2 Zero-point Restoration Proximity Switch

Do 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 inverter

servo amplifier box to the MANUAL position.

(2) Move the terry motion lever with the FWD-

REV switch until lever’s hole
aligned with hole B provided in the sub frame.

(3) Check the alignment by inserting a straight pin

A

or bolt (ø8 mm) into holes

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 dimensions
shown at left.
Turn the machine power on and check that the
proximity switch LED is OFF.

A

becomes

M9 - 2

9.3 Reverse Current Absorber Cover

NEVER touch the reverse current absorber cover
(located between the control box and the RH
frame) when the machine is in operation or shortly
after the machine comes to a stop. The cover is
HOT!

9.4 Lubrication of Terry Motion Gear Box

M9. Electronic Terry Motion

The oil type and oil change interval are the same as
for the main gearing box. (Typical oil volume to be
fed: 4.5 liters)

Reference:

(1) Insert the oil drain tool into the drainage port of

the terry motion gear box and then drain the
gear box.

(2) Supply oil until the oil level reaches above the

center line of the oil sight glass when the
machine is on halt.

NOTE:

Machine “Instruction Manual.”

Type:
Oil B
#150 (Mobil 629) or equivalent
Change interval:
Once every year after the first oil
change.

Refer to “M.3 Lubrication” in the Standard

M9 - 3

Section 2 Electrical

E1. State of Indicator Lamps and Mode Display

The following table outlines the comparative indication of the color of the indicator lamps, their lighted or blink­ing 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 lamp

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: 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

LET-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

Mode display

Remarks

Main control

control

E1 - 1

E1. State of Indicator Lamps and Mode Display

Indicator lamp

Color State Control section

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

ABNORMAL

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: 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

Mode display

Remarks

Upper let-off
control

Main control

E1 - 2

Section 2 Electrical

E2. Setting of Towel Loom-related Function Panel

Refer to “0.3 Detailed Explanation of Function Panel” of the Standard Machine “Instruction Manual” for the
basic handling procedure of the function panel.

2.1 Towel Screen Setting Method

Touch the [ Map ] – [ Towel ] icon to display the
screen shown in the bottom at left.

[ 1 ] Operation for ground weaving only

Use this mode when not using the terry motion for
gaiting.

[ 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 is

detected in the same color with two picks
in succession during boarder weaving.

[ 3 ] Select the cutting, preliminary weave

pick, cutting pick and the type of cut­ting operation.

(1) Cutting when [ NUMBER STOP ] is selected.

The loom stops operation when the number for
the cutting is reached.

NOTE:

[ MANAGER ] – [ COUNTER ] screen.

NOTE:

pick is not used.

Set the number for the cutting on the

Preliminary weaving pick or cutting

E2 - 1

E2. Setting of Towel Loom-related Function Panel

Note that the loom stops once and restarts
automatically if the selected pattern for extra
weaving is not a weaving pattern.

(2)

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

Operator Loom

1) When the cutting number reaches the set cutting
number, 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

4) Turn the loom start pushbutton ON.

7) Cut the cloth.

8) Turn the loom start button ON.

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

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

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

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

NOTE:

Set the number of picks for the cutting on

the [ Operator ] – [ CUTTING ] screen .

E2 - 2

Section 2 Electrical

Note that the loom stops once and restarts
automatically if the selected pattern for extra
weaving is not a weaving pattern.

Note that the loom stops once and restarts
automatically.

(3) Cutting [ Cut stop ]

The following cutting operation will be made:

Operator Loom

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

4) Cut the cloth.

5) Turn the loom start button ON.

2) Upon completion of the weaving of extra woven
pattern, clears the piece number counter and
starts weaving a towel pattern.

3) After weaving a number of set picks for the cut­ting, the loom stops operation. (Set the number
of picks for the cutting so as to have the extra
length of weaving reaches a position for cutting
with ease when the loom stops.

E2 - 3

E2. Setting of Towel Loom-related Function Panel

[ 4 ] Setting the warp manual stop position

Select the warp manual stop position during pile
weaving.

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

NOTE:

for 8 picks if L4 for 3-pile, which does not exist in
the pattern, is selected.

Be careful since the machine does not stop

E2 - 4

Section 2 Electrical

2.2 How to Set [ PILE ]

[ 1 ] Electronic dobby specification

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

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

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

Pile: Select the pile, ground or border.

GD : Ground weave
BD : Border
P3 - 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 picks
F2 : 2nd pick of fast picks
F3 : 3rd pick of fast picks
L1 : 1st pick of loose picks
L2 : 2nd pick of loose picks
L3 : 3rd pick of loose picks
L4 : 4th pick of loose picks

E2 - 5

2.3 Pattern Initialization

E2. Setting of Towel Loom-related Function Panel

Pile-Length: Input the pile length.

Input the terry motion operating length for the
pick.
The screen at left shows an example of 10.0
mm 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 rotation
L: Low-speed rotation
(to be selected mainly for border weaving)
Refer to Chapter E2 2.6 Setting an Inverter
for the desired rpm.

Touch [ Pattern 1st pick ] at left on the

[ Operator ] screen to start the pattern from the first
step.

E2 - 6

Section 2 Electrical

E3. Setting and Operation of Towel Loom Beam-related

Function Panel

Touch the [ Map ] – [ Letoff ] icon.

[ 1 ] Setting for bottom beam control

In the two-stage tension specifications, set the ten­sion for border weaving higher than that of pile
weaving.
When two-stage tension is not applied, set them
with the same numerical value.
(Or, when 0 kg is set as the tension for border
weaving, the tension applied for pile weaving is
applied for border weaving as well.)

The items regarding pile → border adjustment is
effective at the time of two-stage tension change is
applied.
The kilogram value shown at left indicates a numer­ical value to adjust the high tension at the time of
the tension change.
This numerical value is the one to correct the differ­ence that may occur by machine when fixing a cyl­inder while tension is high, though the inclination
that is applied to the load cell changes accordingly.

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

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

→

border

[ 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 pile
weaving.

NOTE:

(Pile).

(4) Beam diameter

Input the top beam diameter.

(5) Tension adjustment (border

This setting corrects the pile yarn let-off
amount upon switching weaving from border
to pile.

Always set it lower than the tension for

→

pile)

E3 - 1

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

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

(6) Tension adjustment (pile → border)

This setting corrects the pile yarn let-off
amount upon switching pile → border weaving.
Set the value to around 0.4.
When the final pile becomes smaller upon
switching into the border weaving, increase
the value by 0.1.
Conversely, when the final pile becomes
larger, decrease the value by 0.1.

→

(7) Tention adjustment (run

stop)
This setting corrects the pile yarn let-off
amount upon loom stop during pile weaving.
The value should be around 0.2.
If the actual tension is constantly higher than
the 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) beam
is rotated forward for the set amount (unit: cm).
Press the full running switch. Full operation
restarts after the upper beam rotates in the
reverse direction.
If upper beam tension reset, individual forward
rotation or individual reverse rotation is tried
between warp stop and full running switch
operation, the upper beam is not rotated in the
reverse direction.

(9) Beam diameter proximity switch error

This is to set whether the loom stops or just
issues an alarm when the input of the beam
diameter proximity switch has an error.
Select the alarm for continuous operation
when an auxiliary beam diameter proximity
switch is not available.
The operation can be continuous with a fea­ture of let-off correction, however, you still
need to confirm whether or not the pile length
has an error.

(10) Use / Not use of top beam

Set the top beam as not used for weaving
other than towel that does not require the top
beam.

E3 - 2

Section 2 Electrical

[ 3 ] Setting for beam change

Touch the [ Operator ] – [ Beam Change ] icon to
display the screen shown at left.

(1) [ BOTTOM BEAM ] switch

Press this switch for setting upon bottom beam
replacement.
Refer to 3.2 [4] b [ BEAMSET ] Switch in “0.3
Detailed Explanation of Function Panel” of the
Standard Machine “Instruction Manual” for the
operation method.

(2) [ TOP BEAM ] switch

Press this switch for setting upon top beam
replacement.
Refer to 3.2 [4] b [ BEAMSET ] Switch in “0.3
Detailed Explanation of Function Panel” of the
Standard Machine “Instruction Manual” for the
operation method.

(3) Style name and Beam name

•

The style name and beam name are regis­tered as the host data in the TMS or TTCS
specification for use as management data.

•

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

NOTE:

mechanical terry motion specification, check
the “convergence status” described in “
Mechanical terry motion
Also correct the pile length as required.

If the top (pile) beam is replaced in the

2.2 [ 1 ]

”

E3 - 3

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

Switch

[ 4 ] Yarn beam operation from function panel

Touch the Manual page through [ Map ] – [ Lefoff ]
to display the screen shown at left.

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

Function

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

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.

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

E3 - 4

Section 2 Electrical

[ 5 ] Operation of Forward/Reverse Beam

Rotation Switch on the L.H. Frame

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

When the switch is turned clockwise, the beam
rotates in forward direction while the switch is being
turned.

Conversely, when the switch is turned counter­clockwise, the beam rotates in reverse direction
while the switch is being turned. When the switch
is released, the beam stops.

NOTE:

weaving machine is in operation.

NOTE:

second and then rotates faster.

These switches are not operable when the

The beam rotates slowly for the first 0.5

E3 - 5

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

LET

-OFF
2

　1

2

3

CN5

CN4

CN2

CN1

CN3

CN9

CN10

CN7

SW1
SW2

8

7

5

12
13

16

9

3

4

6

2

14

11

10

15

High voltage:
Be careful!

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 let­off motions are integrated in main control box 1.

Servo amplifier board
motion (ground let-off motion).

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

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.

2

controls the lower let-off

[ 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 motor

model 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

E4 - 1

Section 2 Electrical

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

SW1SW2

ON ON

CN2

CON

CK3

CK2

CK9

LED1

CK7

C262

[ 2 ] LED display and check pins

LED No. Name Color Use Normal Error Major error cause

LED1 CHARGE Red Main circuit power monitor ON OFF

LED2 CON Green Control power (+5 V) monitor ON OFF

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

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

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

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

Error detection by servo amplifier
board. Eliminate the error.

Control power (DCPS10/+5 V) is

4.5 V or less

E4 - 2

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

1

3

TAKE

UP

LET-OFF

1

[ 3 ] Setting the standard let-off tension

In any of the following cases, set the basic let-off
tension according to the let-off tension calibration
and zero adjustment procedure.

•

When “WARP TENSION CALUBRATION NEC­ESSARY” 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 is
replaced with a new one.

•

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

•

When the warp beam is replaced.

[ 3.1 ] Tension calibration / zero adjustment

Lower let-off (ground let-off)

(1) If warps have been loaded on the machine,

slack them until no warp tension is applied
onto the tension roller.

(2) Touch “Calibration of the tension” on the Man-

ual page of [ Map ] – [ Lefoff ] on the function
panel.

(3) “Adjust the tension to 0?” appears. Touch

“Yes”.
Tension adjustment and zero adjustment are
completed now. The display automatically
returns to the Manual page of [ Map ] –
[ Lefoff ].

(4) Then check that the “Real Tension” shows –2

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

E4 - 3

Section 2 Electrical

(5) Measure the warp beam diameter at operation

restart and enter it on the [ FIXER ] – [ WARP ]
screen.

(6) Start tension restoration.

Touching the tension restoration switch

11

starts the tension restoration.

[ 3.2 ] Tension calibration / zero adjustment

Upper let-off (pile let-off)

(1) Read the scale 1 of the torsion back and

7

11

2

5

12

X

record 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 of

the torsion bar 6.

(5) Calibrate the tension on the function panel.

(See steps (2) through (4) of tension calibra-

6

10

8

9

tion / zero adjustment of ground let-off for ten­sion calibration.)

(6) Turn the worm 4 until the scale 1 reaches the

3

1

4

previous level.

(7) Tighten the bolt 2.

(8) Measure the warp beam diameter at operation

restart and enter it on the [ FIXER ] – [ WARP ]
screen.

(9) Start tension restoration.

Touching the tension restoration switch

2

starts the tension restoration.

E4 - 4

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

CN 9 CN 10

SW 2

SW 1

SW 2

ON

4
3
2
1

[ 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:

card or take a memo before the following operation.

Since all data set in the LET-OFF mode on the function panel are lost, save the data on the memory

[ 4.1 ] RAM clearing procedure

(1) Turn the loom power off.

(2) Set all bits of DIP SW2 on the let-off servo

amplifier board to ON. (See the figure at left.)

(3) Tuirn the loom power on.

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

seconds.

(5) Return all bits of DIP SW2 on the let-off servo

amplifier baord.

(6) Turn the loom power on.

(In this state, the indicator lamp is blinking in
red, and the error message is being dis­played.)

[ 4.2 ] Operation after clearing the RAM

(1) Calibrate the tension.

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

(2) Actually measure the warp beam diameter

upon restarting operation, and input it on the
[ FIXER ] – [ WARP ] screen.

(3) Restore the tension.

(See Chapter 0. “Subsection 0.3.1 Display
configuration and switch operation method” of
the Standard Machine “Instruction Manual” for
the adjustment procedure.)

(4) Restart operation.

(After restarting operation, the rd-blinking indi­cator lamp goes off and the error message is
cleared.)

E4 - 5

Section 2 Electrical

CN 9 CN 10

SW 2

SW 1

SW 1SW 2

8
7
6
5
4
3
2
1

ON

ON

4
3
2
1

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

Enlarged view

[ 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

Use Loom specification

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.



DIP switch (SW2) setting table

Pin No.

4321

Ground let-off ON ON ON

Pile let-off ON

Set “OFF” to a blank space.

Motor

capacity

Check the motor capacity on the servo motor nameplate.

Servo motor type Motor capacity

VLBST-05030T 500 W

VLBSE-06040T 600 W

VLBST-08030T 800 W

87654321

Pin No.

E4 - 6

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

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?

[ 6 ] Troubleshooting

For the bottom- and top-mounted let-off motions

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

E4 - 7

Section 2 Electrical

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 differs

by the shedding manufacturer whether 0 or white in the screen display refers to either 0 or 1 for the
following 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 which

position in the screen display. This too requires confirmation from the shedding manufacturer.

A-6) Color selection H
A-7) Color selection M
A-8) Color selection L

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

000Abnormal

001Color 1

010Color 2

011Color 3

100Color 4

101Color 5

110Color 6

111Abnormal

A-9) Density H
A-10) Density M
A-11) Density L

A-9) A-10) A-11) Significance

000Density (0)

001Density (1)

010Density (2)

011Density (3)

100Density (4)

101Density (5)

110Density (6)

111Density (7)

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)”

E5 - 1

E5. Instrumentation and Electronic Jacquard for Towel Weaving Machine

A–12) Ground weave and pile H
A–13) Ground weave and pile M
A–14) Ground weave and pile L

A-12) A-13) A-14) Significance

0003-pick pile

0014-pick pile

0105-pick pile

0116-pick pile

1 0 0 Preliminary weave

1 0 1 No-load weave

110Border

1 1 1 Ground weave

A-15) Winding stop

A-15) Significance

0 Winding stop (density selection invalid)

1 (density selection valid)

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

A-16) Number counter

A-16) Significance

0 Number counter present

1 Number counter not present

A-17) Border control

A-17) Significance

0 Controlled

1 Not controlled

A-18) Single pile

Effective for an electronic type terry motion specifications.

A-18) Significance

0 Single pile

1 Double pile

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.

E5 - 2

Section 2 Electrical

A-19) Pile length H
A-20) Pile length M
A-21) Pile length L

Effective for an electronic type terry motion specifications.

A-19) A-20) A-21) Significance

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.

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 fluctuate

slightly.

A-22) Pick H in the pile
A-23) Pick M in the pile
A-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 pick
immediately:

→

Enter 2L to all the picks of the boarder.

A-22) A-23) A-24) Significance

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 battery

board on the servo amplifier.

SS1 MANUAL-AUTO switch Should be set to the AUTO position for normal operation. To operate

the terry motion independently, set this switch to the MANUAL position.

NOTE:

could happen when you change this switch from the MANUAL to
AUTO 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 motion
lever and the cloth fell shifts to the needle roller; turning it in the REV
direction 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 alarm

state.

NOTE:

shooting.

Be careful with sudden movement of the terry motion which

Be sure to take necessary actions referring to [ 5 ] Trouble-

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°), press
this swich.

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

shipment.

Servo amplifier Controls the terry motion servomotor. If a terry motion error has

occurred, check the error codes on the servo amplifier display.

Inverter Controls the machine speed (rpm).

E6 - 1

Section 2 Electrical

PL1 ZERO POS.

PL2 ZERO POS. ALARM

PL3 BATTERY ALARM

SS1 MANUAL−AUTO
SS2 FWD−REV.

BS1 ALARM RESET

BS2 ZERO POS.

(Back of the
inverter box
cover)

Normally: OFF
(turned downwards)

ZERO POS. RESET



Location of LEDs and Switches in the Inverter Box

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 min­utes until the internal voltage decreases and
open it.

PL1 PL3 PL2

G

SS1 SS2 BS2 BS1

RR

TSW

NF1

NOISE
FILTER

CNA
CNB

NC1

INVERTER

BT

SERVO
AMP

BATTERY

SA

TB1

1234 5 67 8910111213
E CC BC AC JP1 PA E R1 S1 T1 O PQ

ACL

E6 - 2

E6. Electronic Terry Motion

[ 2 ] Installation

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



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

Section 2 Electrical

R

R

R

G

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.

[ 3 ] Adjustment

(1) FWD-REV movement in manual operation

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

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

NOTE:

or REV direction, the mechanical overrun pro­tector will work for safety, showing alarm 16 or
18 on the servo amplifier display. If this hap­pens, press the ALARM RESET button.

(2) Zero-point restoration

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

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

If you move it excessively in the FWD

[ 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 under­stood as abnormal.

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

E6 - 4

[ 5 ] Troubleshooting

SET

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

YES NO

Remove whatever caused error (referring to
the next page), press the ALARM RESET
button, and then start the machine.

E6. Electronic Terry Motion

NOTE:

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

internal 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 ampli­fier 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. (Replace
it.)

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

E6 - 5

Section 2 Electrical



Alarmlist

Alarm Alarm name Detecting method Cause and counter measures

AL01 Over-current (OC) IPM of the power supply

detected following troubles.
(Model 035P or lower versions can
detect 1 only.)

1. Over-current

2. Overheating

3. Gate power supply low

AL02 Over voltage (OV) Main circuit DC power supply

(PN voltage) is over 400 VDC.

AL03 Low PN voltage

(PNLV)

AL04 Main power supply

input trouble (ACINF)

AL05 Function undefined

AL06 Resolver

disconnected (RELV)

AL07 Power status error

(POWFAIL)

AL08 Servo amplifier

overheating (SOH)

AL09 Counter current

resistance
overheating (RGOH)

AL10 Reverse current

absorption error
(RGST)

AL11 Function undefined

AL12 DSP error (DSPERR) DSP stopped working. The amplifier is out of order.

AL13 Resolver ABS battery

low voltage (BLV)

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

Low main power supply (AC) input
voltage.

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

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

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

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

The reverse current absorption
transistor is ON over 50ms.

The battery voltage is below 3.4V. Replace the battery.

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.

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.

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.

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

2. Main power supply was disconnected during
operation.

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.)

unit configuration.

2. The amplifier is out of order.

Above problems are likely.
Please contact the manufacturer.

1. Temperature rise inside the control panel.

2. The cooling fan inside the amplifier is out of
order.

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.

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.

Please contact the manufacturer.

If AL24 has not been issued, the zero point setting
is still saved.

E6 - 6

E6. Electronic Terry Motion

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

Alarm Alarm name Detecting method Cause and counter measures

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.

AL15 Over-current

detection (OCS)

AL16 Speed amplifier

saturation (VAS)

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

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

AL17 Motor overload

(MOL)

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

AL18 Instant thermal (POL) This alarm is issued when output

current is more than 120% of the
motor rated current.

AL19 Resolver error

(RESERR)

The resolver feedback counter made
erroneous counting.

AL20 Overspeed (OSPD) The rotation rate exceeded 120% of

the maximum rotation setting.

AL21 Deviation counter

over (FULL)

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

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

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.

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.

1. Load is too much for the motor output capacity.

2. Operation cycles are too short for the motor
capacity.

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.

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.

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.

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

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

error (ABSE)

AL23 Resolver ABS broken

line (ACN)

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

AL24 Resolver ABS battery

alarm (BAL)

The ABS battery voltage dropped
below 3.2V.

Please contact the manufacturer.

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.

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

E6 - 7

Section 2 Electrical

Turn ON
the power

AL23 and
AL32 issued

Alarm
resetting

Turn OFF
the power

Turn ON
the power

Confirm that only
AL32 is issued.

Alarm
resetting

Setting
ABS position

Alarm Alarm name Detecting method Cause and counter measures

AL25 Option alarm

(CPALM)

AL26 Parameter setting

error (CERR)

AL27 Resolver ABS error

(AEERR)

AL32 Zero point saving

error (MZE)

AL33 Resolver ABS invalid

zero point (CLD)

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.

No or incorrect parameter setting. This error occurs upon first power input. Please

take contact with us.

CHA and CHB signals are kept ON
while the power is ON but were
turned OFF perhaps by

1. ABS cable was disconnected.

2. Bad contact of the connector. Check that CTD,
CHA and CHB signals are ON.

disconnection or line break.

When the resolver ABS is used, ABS
setting is not completed with the
ABS motor. Or this alarm is issued

In case of the ABS motor, AL32 is always issued
with the factory setting.

Set the ABS position int the following steps:
together with AL06, AL19, AL22,
AL23, and AL27.
When the encoder is used, the alarm
is issued together with AL42, 43, and
AL45.

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

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.

disconnected (ABT)

NOTE:

How to reset alarm codes
Press the SET key of the display unit while an alarm code is displayed. Or turn ON the reset input signal to
clear 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 by
the reset input signal.

E6 - 8

E6. Electronic Terry Motion

Zero-point restoration

Set the MANUAL-AUTO switch
to MANUAL.

↓

Press the ZERO POSITION
button.

(2) If the “Abnormal terry volume” message appears on the function panel (The yellow lamp of the signal

indicator 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 of

the 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 LED
comes on.

↓

Press the ZERO POSITION button.

↓

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

2) Carry out the zero-point restoration.

•

If this operation has returned the cloth fell to
the zero point, check the wiring between the
servo amplifier and the main control box.

•

If this operation has failed to return it, turn
off the machine power, unplug and plug the
resolver cable connector of the servo
amplifier, and then turn on the machine

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

3) Adjust the mounting position of the zero-point
restoration proximity switch. (Refer to Section
M9.2.)

E6 - 9

Section 2 Electrical

LED2

[ 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 beam

condition on the function panel or modify the pile length. Only the pile beam diameter setting should be
modified.

[ 7 ] Inverter Control Substrate

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

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

[ 7.1 ] Monitor LED

A monitor LED is located on the inverter substrate
and indicates the state of the inverter by on/off
state. Refer to Subsection 1.1A.7 of the Standard
Machine “Instruction Manual” for LED display.

[ 7.2 ] Rotary Switch



Rotary Switch 1 (SW1)

Set the power supply voltage. Set the voltage sup­plied to the loom. The output voltage to the motor is
calculated based on this value. Wrong setting may
not supply correct voltage to the motor.

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



Rotary Switch 2 (SW2)

Not used. Always set to 0.

E6 - 10

E6. Electronic Terry Motion

ON

OFF

12

ON

OFF

12

[ 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.

E6 - 11