ZW8100 Water Jet Loom Installation Guide

ZW8100 Water Jet Loom
Installation Guide
TSUDAKOMA Corp.
(SI)
A802-1A
INTRODUCTION
Thank you for planning to introduce TSUDAKOMA ZW8100 Water Jet Looms.
This manual will explain the required facilities, reference values, and required devices. In addition,
a case study of facilities and operators in a factory with 100 looms is included. We hope it will
help your planning.
For further data and information, do not hesitate to ask our sales staff.
Remarks:
For ease of understanding, we use the following messages for safety. Strictly follow the
instructions.
WARNING!: If you do not follow this instruction, you may be seriously injured.
CAUTION!: If you do not follow this instruction, you may be injured.
For Further Inquires:

Please feel free to ask us for detailed information about our products and this manual, by
contacting the following:
1) TSUDAKOMA Local Agent:
2) TSUDAKOMA Corp.
PHONE: Technical Support Section: (81) 76 242-1115
Sales Department: (81) 76 242-1114
FAX: (81) 76 242-4172
Contents
Chapter 1: ZW Technical Information
1. Deciding Specifications ..........................................................................1-1
2. Weaving Range ......................................................................................1-2

2.1 Weft Type & Thickness ................................................................................1-2
2.2 Pick Density.................................................................................................1-2
2.3 Warp Density ...............................................................................................1-2
3. Capacity Of Water Facilities ...................................................................1-3
4. Water Quality Standard ..........................................................................1-4
5. Weft Loss................................................................................................1-5
6. Woven Fabric Example ..........................................................................1-6
7. Woven Length & Loom rpm ...................................................................1-9
Chapter 2: Factory Layout
1. Planning..................................................................................................2-1
1.1 Remarks on the Layout ..............................................................................2-1
1.2 Layout Display (For warp beam flange: 800 mm) ......................................2-1
1.3 Others .........................................................................................................2-1
2. Foundation Drawing & Installation Drawing (Excerpt)............................2-2
3. Foundation Standard ..............................................................................2-4

3.1 Foundation...................................................................................................2-4
3.2 Foundation Bolt Type & Drilling ...................................................................2-6
3.3 Inking ..........................................................................................................2-7
3.4 Appurtenant Work .......................................................................................2-8
3.5 Standard for leveling the loom.....................................................................2-8
3.6 Leveling Procedure......................................................................................2-9
4. Noise & Vibration..................................................................................2-10

4.1 Noise..........................................................................................................2-10
4.2 Vibration as Public Nuisance ....................................................................2-11
5. Electrical Equipment.............................................................................2-12
5.1 Specifications.............................................................................................2-12
5.2 Electric Installation Capacity......................................................................2-13
5.3 Power Source Connection ........................................................................2-14
5.4 Electric Wiring............................................................................................2-15
5.5 Items To Be Prepared................................................................................2-16
5.6 Phase Advance Condenser .......................................................................2-16
5.7 Inverter for Slow Inching............................................................................2-17
6. Laying LAN For TLM ............................................................................2-19

6.1 Cable Configuration...................................................................................2-19
6.2 Work Procedure.........................................................................................2-20
6.3 Wiring Route of the Cables, How to Decide the Quantity of the Switching HUB 2-20
6.4 Remarks on Laying the Rigid Steel Conduits and the LAN Cables ..........2-21
6.5 Type of LAN Cables ..................................................................................2-21
6.6 Power Supply for Switching HUB ..............................................................2-21
6.7 Type of Switching HUB..............................................................................2-22
6.8 Specifications of Computer........................................................................2-22
6.9 LAN Cable Connection of the Loom..........................................................2-23
7. Interior Conditions ................................................................................2-24

7.1 Air Conditioning .........................................................................................2-24
7.2 Ceiling height.............................................................................................2-24
7.3 Interior color: .............................................................................................2-24
7.4 Illumination: ..............................................................................................2-25
7.5 Illuminance of fluorescent lamps: ..............................................................2-25
Chapter 3: Accessories & Supplies
1. Accessory Selection ...............................................................................3-1

1.1 Reed ...........................................................................................................3-1
1.2 Heald ..........................................................................................................3-2
2. Preparation For Looming........................................................................3-4

2.1 Warp ...........................................................................................................3-4
2.2 Filling Twisting ............................................................................................3-8
2.3 Yarn Supply Package .................................................................................3-8
2.4 Catch Cord .................................................................................................3-8
2.5 Selvage Yarn ..............................................................................................3-8
3. Preparation For Starting .........................................................................3-9

Chapter 4: Loom Transportation & Trial Run
1. Loom Dimensions & Mass......................................................................4-1

1.1 ZW8100, Positive Cam, Beam Flange ø914...............................................4-1
1.2 Loom Delivery And Entrance Width.............................................................4-1
1.3 Machines & Tools for Delivery & Installation ...............................................4-2
1.4 Remarks on Delivery ...................................................................................4-2
1.5 Installation....................................................................................................4-3
1.6 Loom Storage ..............................................................................................4-3
2. Loom Installation & Trial run...................................................................4-4

2.1 Installation Procedure ..................................................................................4-4
2.2 Inspection Items in the Trial Run.................................................................4-4
2.3 Looming .......................................................................................................4-5
2.4 Running-in ...................................................................................................4-5
3. Lubrication [Recommended Oil Chart] ...................................................4-6
Chapter 5: Weaving Mill Planning Example
1. Loom Assignment ...................................................................................5-1

1.1 Loom Quantity per Operator .......................................................................5-1
1.2 Conditions for Determination ......................................................................5-1
1.3 Work Division ..............................................................................................5-1
2. Operation Arrangement Of A Plant With 100 Looms ................................5-2
3. Weaving Mill Planning Example [Loom: 100 units] ................................5-3

3.1 Production Process ....................................................................................5-3
3.2 Indication ....................................................................................................5-4
3.3 Calculating Conditions.................................................................................5-5
4. Other Equipment ....................................................................................5-8

Chapter 1: ZW Technical Information
1. Deciding Specifications ..........................................................................1-1
2. Weaving Range ......................................................................................1-2

2.1 Weft Type & Thickness ................................................................................1-2
2.2 Pick Density.................................................................................................1-2
2.3 Warp Density ...............................................................................................1-2
3. Capacity Of Water Facilities ...................................................................1-3
4. Water Quality Standard ..........................................................................1-4
5. Weft Loss................................................................................................1-5
6. Woven Fabric Example ..........................................................................1-6
7. Woven Length & Loom rpm ...................................................................1-9

§1: ZW TECHNICAL INFORMATION
1. Deciding Specifications
The ZW8100 Water Jet Looms have many available settings. With a combination of those settings, the
desired cloth can be woven. First determine the fabric you want to weave. Then, consult with our sales
staff to determine the loom specifications.
To determine the specifications:
Basic Concept
Fabric style
Determine weft selection.

Determine the loom width.
Determine the shedding motion: crank, cam, or dobby.
Desired production amount
Determine the desired loom RPM.

Determine the number of looms.
Determine the loom efficiency.
Optional specifications
Section Specifications
Driving Main motor (Capacity), loom pulley, etc.
Pump (Type, cylinder size, pump spring), nozzle
Weft selection
(Nozzle size, needle size), etc.
Shedding Type, number of heald frames, heald size, heald play
Let-off Type, flange diameter, roll type, easing spring, etc.
Take-up Type, cloth passage route, take-up feeler, etc.
Beating Stroke, thickness of reed, etc.
Measuring &
Type, etc.
storage
Yarn supply Stand type
Catch cord Pre-twist speed
Reed protection Moving amount
Temple Type (Number of needle rows, ring angle, etc.)
Electric Weft feeler type
Auxiliary equipment Suction blower type, etc.
Automation APR, APF, etc.
Motor pulley, heald frame, quantity of spare parts, tools,
Others
jigs, measuring instruments, etc.
1-1
A802-1A August, 2014
2. Weaving Range
2.1 Weft Type & Thickness

Yarn type Yarn thickness
Filament (Synthetic fiber, such as nylon and polyester) 22 ~ 1100 dtex (decitex)
If you need to weave the weft other than the above or mono-filament, please ask Tsudakoma.
2.2 Pick Density

(1) Lower limit of the pick density
a. The lower limit of the pick density is different depending on the loom rpm.
N: Loom rpm
Pmin: The lower limit of the pick density (picks/inch) is calculated by the following formula.
Pmin = 0.049 x N
(2) Upper limit of the pick density:

The upper limit of the pick density is 300 picks/inch (118 picks/cm).
The upper limit may be changed depending on the loom rpm and the let-off flange diameter.
N: Loom rpm
Pmax: The upper limit of the pick density (picks/inch) is calculated by the following formula.
When the flange diameter is 800 mm: Pmax = 0.556 x N
To get the upper limit in “picks/cm,” divide the calculated value by ‘2.54.’
The table below shows the possible range of pick densities according to the loom rpm.
Flange diameter 800 mm Flange diameter 914 mm Flange diameter 1000 mm
Loom rpm
picks/inch picks/cm picks/inch picks/cm picks/inch picks/cm
500 25 - 222 10 - 87 25 - 210 10 - 83 25 - 207 10 - 81
600 30 - 277 12 - 109 30 - 263 12 - 103 30 - 259 12 - 102
700 35 - 300 14 - 118 35 - 300 14 - 118 35 - 300 14 - 118
800 39 - 300 16 - 118 39 - 300 16 - 118 39 - 300 16 - 118
900 44 - 300 18 - 118 44 - 300 18 - 118 44 - 300 18 - 118
1000 49 - 300 20 - 118 49 - 300 20 - 118 49 - 300 20 - 118
2.3 Warp Density

The standard highest warp density is 25 ends/inch/heald frame when the yarn thickness is 167 dtex or
thinner.
Decide the number of heald frames of the shedding motion while considering the warp density.
1-2
3. Capacity Of Water Facilities
(1) Water consumption

Water consumption depends on the diameter of the pump cylinder, pump stroke, loom rpm and loom
efficiency.
(2) Capacity of water facilities

The capacity should be calculated with the maximum value of pump stroke, loom rpm and loom efficiency.
Extra allowances must be considered.
(3) Required water amount corresponding to loom rpm

The table below shows water consumption/loom/day according to loom rpm.
(Stroke 11mm, efficiency: 100%)
Unit: ton
Pump cylinder per pick Loom rpm (rpm)

diameter (mm) (cc) 500 550 600 650 700 750 800 850 900 950 1000
17 2.50 1.80 1.98 2.16 2.34 2.52 2.70 2.88 3.06 3.24 3.42 3.60
18 2.80 2.02 2.22 2.42 2.62 2.82 3.02 3.22 3.43 3.63 3.83 4.03
20 3.46 2.49 2.74 2.99 3.23 3.48 3.73 3.98 4.23 4.48 4.73 4.98
22 4.18 3.01 3.31 3.61 3.91 4.21 4.52 4.82 5.12 5.42 5.72 6.02
24 4.98 3.58 3.94 4.30 4.66 5.02 5.37 5.73 6.09 6.45 6.81 7.17
26 5.84 4.20 4.63 5.05 5.47 5.89 6.31 6.73 7.15 7.57 7.99 8.41
1) Calculation for the required amount of water (for one loom)
Required water amount (ton)
p x (Cylinder diameter)2 x Stroke x Loom rpm x 60 minutes x Operating time (H) x Efficiency
=
4 x 109
The unit for each item is cylinder diameter (mm), stroke (mm), and loom rpm (rpm).
2) Calculation of capacity
Capacity (ton) = Water consumption x 1.38 x Total number of looms
Note: 1.38 = 1.15 (allowance) x 1.2 (daily use, leakage, etc.)
3) Appropriate water pressure
When the automatic water supply valve is not provided, the appropriate water pressure is 0.10 -0.15MPa
(1.0 - 1.5kgf/cm2)
When the automatic water supply valve is provided, the appropriate water pressure is 0.15MPa
(1.5kgf/cm2)
If water is not supplied to the loom with the appropriate hydraulic pressure, the constant head tank will lack
water, and defective filling insertion will often occur. Maintain the appropriate water pressure.
1-3
4. Water Quality Standard
Water quality control is very important for a ZW Water Jet Loom because the filling is inserted by water.
Water quality has a strong influence on the efficiency and durability of the loom. Water containing
impurities lowers the performance of filling insertion, damages the components, and can cause rust and
bacteria. Thus, impure water makes it difficult to maintain constant operation.
Water quality tests should be performed several times a year because water quality changes with the
seasons. If trouble is found, consult with a local water specialist.
The following table shows the standard of water quality.
Allowable
Item Main components Influence on weaving and looms
standard
Turbidity 2.0 mg/liter • Organic substance: Fragments of Scale, Rust, Corrosion, Clogging, Cloth
or less animals and plants, Humus, Microbes stains
• Inorganic substance: Clay, Rock,
Soil, Iron oxide, Manganese oxide
pH (25°C) 6.5 ~ 7.5 1) Rust or corrosion caused by strong
acid or alkaline water.
2) Some sizing materials are desized by
alkaline water.
Total hardness 50 mg/liter Calcium ion Ca2+ Filling insertion defects caused by scale
or less Magnesium ion Mg2+ attached to the nozzle.
Iron 0.30 mg/liter Fe2+ 1) Corrosion
or less 2) Coloring
Whole 0.20 mg/liter Mn2+
manganese or less
Free residual 0.3 mg/liter Cl2 Serious corrosion and acidification
chlorine or less Chlorinated water such as city
water, which is not natural water.
Chloride ion 30 mg/liter Cl– The largest factor of corrosion and
or less acidification
Acid CaCO3 Hydrogencarbonate ion (HCO3–), No direct influence on the cloth
consumption 75 mg/liter Compound produced by demineralization
(pH4.8) or less (NaHCO3)
Chemical 3 mg/liter or Organic substance: Corrosion, Cloth stains, Desizing,
oxygen demand less Bacteria, Fungi, etc. Decrease of the efficiency of sizing film
(CODMn)
Electrical 8~20mS/cm Conductivity between electrodes with a Higher rate means lots of impurities
conductivity given distance in water. exist in the water.
(It depends on the electrolyte amount in
(EC)
the water.)
Water 14 ~ 20°C 1) If the temperature is high, the degree
temperature of desizing becomes high, breeding
bacteria.
2) If it is low, size and wax strength are
lowered.
3) Anyway, inappropriate water
temperature lowers the filling insertion
efficiency.
Ionic silica 40 mg/liter Scale, Rust
(SiO2) or less
Sulphate ion 20 mg/liter Metal, resin and ceramic parts are
(SO42-) or less damaged.
Note: For simple water quality control, you can judge the water quality depending on conductivity.
If the conductivity is not in the range of 8 - 20 mS/m, analyze the water quality to improve it.
1-4
5. Weft Loss
Weft loss generates on the opposing side of the yarn supply. Please see allowance for the waste when
you prepare the weft.
Reeding width + 60 ~ 80 mm (Allowance for weft loss)
1-5
6. Woven Fabric Example
(1) Yarn type

Symbol Yarn type
N Nylon
NSD Semi-dull nylon
NFD Full-dull nylon
PE Polyester
PEW Polyester textured
PEBR Bright polyester
PESD Semi-dull polyester
(2) Fabric construction

Warp type Weft type
X
Warp density (Reed density x ends/dent) Pick density
(3) Loom specifications

ZW8100 - 2C - S6
| |
Model Weft Shedding Number of shafts (Number of heald frames)
selection S: Plain
C: Cam
D: Dobby
(4) Woven fabric examples

Yarn thickness units: decitex, density unit: per inch
Fabric Construction Specifications
N 78/12 x N 78/24
190T nylon taffeta 1C-S
48 x 2 79
N 78/12 x N 78/24
55 x 2 85
N 78/18 x N 78/24
50 x 3 78
PE 56/18 x PE 84/36
Polyester taffeta 1C-S
50 x 2 77
PEW 84/36 x PEW 84/36

Pongee 1C-S
40 x 2 75
PEW 56/72 x PEW 56/72

High-density pongee 1C-S
56 x 3 103
Palace PEBR 56/36 x PE84/24, Z1000T/M 1C-S

(Single Twisted Filling) 50 x 3 84
Blended filament habutae 84/48 x 84/36

1C-S
(Cationic) 44 x 2 85
1-6

N470/48 x N470/48
Oxford 1C-S
24×2 36
N235/34 x N235/34
Oxford 1C-S
30×2 52
PEW167/48 x PEW167/48
Tropical 1C-S
28×2 47
PEW167/48 x PEW167/48
Gabardine 1C-D
29×4 50
PEBR84/36 x PE84/36
PE satin 1C-D
36×5 76
N78/17 x N78/17
N satin 1C-D
41×5 93
PEW167/48 x PEW167/48
Butcher 1C-D
20×4 65
PEW167/34 x PEW330/68
Twill 2/2 1C-D
32×4 52
N122/20 x N122/20
Twill 2/2 1C-D
35×5 72
PE22 x PE22
Organdy 1C-S
94×1 90
PE280/24 x PE280/24
Tarpaulin 1C-S
23×1 24
PEW330/84 x PE330/84
Amunzen 1C-D
42×2 56
PEW167/48 x PE167/48
Amunzen 1C-D
40×2 76
N78/17 x N180/48
Shantung 1C-S
50×2 67
NFD33/24 x NFD33/24
Thin yarn N taffeta 1C-S
66×3 136
NFD22/24 x NFD22/24
62×3 160
NSD17/7 x NSD17/7
63×3 190
PEBR22/24 x PEBR22/24
Thin yarn rip-stop 2C-S
61×3 115
PEW33/36 x PEW33/36
Thin yarn twill 1C/2C-D
44×3 132
PEBR56/36, S300T/M x PE84/72, SZ2700T/M

Crepe de Chine 2C-S
42×2 86
PEBR56/36, S300T/M x PE84/36, S3000T/M

Striped crepe 2C-S
42 x 4 84
1-7

PESD84/72, SZ1650T/M x PESD84/36, S3200T/M
Striped crepe 2C-D
45×2 72
PEBR56/24 x PE167/96, SZ1800T/M

Faille 2C-S
50×3 70
PEBR56/36 x PE167/96, SZ2500T/M

Crepe 2C-S
36×4 64
PEBR56/36, S300T/M x PE84/72, SZ2500T/M

Palace Crepe 2C-S
50×3 90
PEBR56/24, S260T/M x PE84/36, SZ2500T/M

Palace Crepe 2C-S
45×3 83
PEW84/36 x PEW84/36, SZ2500T/M

Chiffon 2C-S
40×3 80
PE84/36, S2500T/M x PE84/36, SZ2500T/M

Mat georgette 2C-S
36×4 82
PE84/36, S2500T/M x PE84/36, SZ2500T/M

Georgette 2C-S
47×2 73
PESD84/36 x PESD167/96, SZ2000T/M

2/3 twill 2C-C
39×5 86
PE84/36, S1000T/M x PE110/24, SZ1200T/M

1/4 satin 2C-C
31×6 90
PEBR56/24 x PEW84/72, SZ1900T/M

1/4 satin 2C-C
48×5 92
PEBR56/36 x PE84/92, SZ2500T/M

Satin crepe 2C-D
33×8 96
PEBR84/36 x PEW167/48, SZ1600T/M

Figured Palace 2C-D
38×3 59
PEBR84/36 x PEW167/48, SZ1200T/M

Stain Crepe 2C-D
31×5 69
Elephant Crepe PEBR56/36 x PE167/96, SZ2600T/M

2C-D
(6 x 6, 8 x 8) 52×3 77
PEW84/36 x NPE167/144, 0T/M

Peach Skin 2C-D
31×4 85
PE110/72, SZ2500T/M x PE135/42, Z100T/M

Pique 2C-D
43×4 55
PE220/108, S1600T/M x PE220/108, SZ1600T/M

Venetian 2C-D
29×5 58
PE160/48, SZ1600T/M x PE160/24, SZ1200T/M

Double weave 2C-D
40×4 96
PEW84/72 x PEW330/96
Double weave 2C-D
41×7 100
1-8
7. Woven Length & Loom rpm
Woven length of one loom per day
Woven length (m)

= Loom rpm x 24 hours x 60 minutes x Loom efficiency x 2.54
Pick density (picks/inch) x 100
Use the above formula when running the loom 24 hour day.
The number of loom revolutions is shown by rpm.
The pick density is shown in picks/inch.
The following graph shows the woven fabric length when loom
efficiency is 100%.
Woven length (m)
Pick density (picks/inch)
1-9
Chapter 2: Factory Layout
1. Planning..................................................................................................2-1
1.1 Remarks on the Layout ..............................................................................2-1
1.2 Layout Display (For warp beam flange: 800 mm) ......................................2-1
1.3 Others .........................................................................................................2-1
2. Foundation Drawing & Installation Drawing (Excerpt)............................2-2
3. Foundation Standard ..............................................................................2-4

3.1 Foundation...................................................................................................2-4
3.2 Foundation Bolt Type & Drilling ...................................................................2-6
3.3 Inking ..........................................................................................................2-7
3.4 Appurtenant Work .......................................................................................2-8
3.5 Standard for leveling the loom.....................................................................2-8
3.6 Leveling Procedure......................................................................................2-9
4. Noise & Vibration..................................................................................2-10

4.1 Noise..........................................................................................................2-10
4.2 Vibration as Public Nuisance ....................................................................2-11
5. Electrical Equipment.............................................................................2-12
5.1 Specifications.............................................................................................2-12
5.2 Electric Installation Capacity......................................................................2-13
5.3 Power Source Connection ........................................................................2-14
5.4 Electric Wiring............................................................................................2-15
5.5 Items To Be Prepared................................................................................2-16
5.6 Phase Advance Condenser .......................................................................2-16
5.7 Inverter for Slow Inching............................................................................2-17
6. Laying LAN For TLM ............................................................................2-19

6.1 Cable Configuration...................................................................................2-19
6.2 Work Procedure.........................................................................................2-20
6.3 Wiring Route of the Cables, How to Decide the Quantity of
the Switching HUB.....................................................................................2-20
6.4 Remarks on Laying the Rigid Steel Conduits and the LAN Cables ..........2-21
6.5 Type of LAN Cables ..................................................................................2-21
6.6 Power Supply for Switching HUB ..............................................................2-21
6.7 Type of Switching HUB..............................................................................2-22
6.8 Specifications of Computer........................................................................2-22
6.9 LAN Cable Connection of the Loom..........................................................2-23
7. Interior Conditions ................................................................................2-24

7.1 Air Conditioning .........................................................................................2-24
7.2 Ceiling height.............................................................................................2-24
7.3 Interior color: .............................................................................................2-24
7.4 Illumination: ..............................................................................................2-25
7.5 Illuminance of fluorescent lamps: ..............................................................2-25
1. Planning
1.1 Remarks on the Layout

The following points should be considered for planning the layout.
Item Points to be considered
Space for warp beam and cloth roll transportation.
Corridor
Space between the relative production areas.
Water supply & drainage Arrangement of water supply and drainage according to the loom layout.
Gradient: 2/1000
Gradient of Drainage
Because of the gradient, the longer the drainage ditch is, the deeper it becomes,
Ditch
weakening the foundation strength.
Space for safety, walking space between looms.
Distance between looms
Loom assignment per operator
Air-conditioning facility Effect, installation cost and operating cost
1.2 Layout Display (For warp beam flange: 800 mm)
Loom front
Drainage ditch
Standard dimensions Minimum dimensions

(mm) (mm)
Remarks
L1 800 or more 800 Sufficient space for passing of the cloth roll is necessary.
It must be 800mm or more for evacuation in an emergency.
L2 1500 1200 Sufficient space for passing of the beam carrier is necessary. If
the minimum dimension is used, install carriage guiding rails
along the center of the corridors in order to transport the loom
smoothly and prevent it from damage by carriers.
L3 600 Refer to the Sufficient space for opening or closing of the door of the control
installation drawing box. (Dimension R or more in the installation drawing)
L4 2500~3000 Sufficient space for 90° turning of the beam carrier is necessary.
L5 Refer to the This dimension depends on the loom width. (Dimension B in the
installation drawing installation drawing) The dimension of the loom with dobby should be
40mm longer than that for the loom with crank shedding.
L6 Refer to the This dimension depends on the flange diameter and cloth roll
installation drawing diameter. (Dimension C in the installation drawing)
1.3 Others
1) Mount valves for pipe cleaning at the end of the water supply pipes.
2) Water supply pipes and valves should be made of rustproof material.
2-1
A802-1 June, 2012
2. Foundation Drawing & Installation Drawing (Excerpt)
(1) ZW8100, 2C, reinforced plain shedding (800 mm flange)

[Installation drawing]
Drainage
Drainage
Control box
FDP box
Max.
Cable pick-up
[Foundation drawing] 2-M12 foundation bolt 2-M16 foundation bolt (G, H) Cable (inverter) pick-up
Note: (For 170 - 230 cm)
The position depends on the Monitor pick-up
1-M16 foundation bolt (F)
model of the beam carrier. (For 210, 230 cm)
2-M12 foundation bolt
For 170 - 230 cm LAN cable pick-up
For 210 - 230 cm Water separator

with a float
Slope
Water pipe
pick-up Slope
Slope
See Note 9.
Loom front
End of drainage or more
Section EE Section DD Section BB Section AA & CC
Heald size F Main motor H

Reeding Reeding 260 1235 3.0 kW 330
width
A B C D E width
D1
280 1245 2.7 kW or less 285
150 cm 1500 3410 1800 2060 2110 150 cm -
Width of aisle Transport method
170 cm 1700 3610 2000 2260 2310 170 cm 1280
Beam diameter +
180 cm 1800 3710 2100 2360 2410 180 cm 1380 Without rail
Let-off 500 mm or more
190 cm 1900 3810 2200 2460 2510 190 cm 1480 side Beam diameter + With center guide
250 mm or more rail
210 cm 2100 4010 2400 2660 2710 210 cm 1680
Take-up Take-up diameter +
230 cm 2300 4210 2600 2860 2910 230 cm 1880 side 250 mm or more
Note: The drawings in this Installation Guide are extracted from all the foundation and installation
drawings.
As modifications might occasionally be made, when planning factories, ask our sales staff for
the latest drawings.
2-2
A802-1 June, 2012
(2) ZW8100, 2C, cam, dobby shedding (800 mm flange)
[Installation drawing]
Ceiling
Drainage
Drainage
Control box
FDP box
Max.
or more
Cable (inverter) pick-up Monitor pick-up

[Foundation drawing] Note: Cable pick-up
The position depends on the
model of the beam carrier.
LAN cable pick-up
Water separator
with a float
Slope
Slope
Water pipe
pick-up
Slope
See Note 9. Loom front

End of drainage or more
Section DD Section BB Section AA & CC
Reeding
width
A B C D E
190 cm 1900 3810 2200 2460 2510

210 cm 2100 4010 2400 2660 2710
230 cm 2300 4210 2600 2860 2910
Width of aisle Transport method

Reeding width Model F G H
Beam diameter + 500 mm or more Without rail
Let-off
Positive cam 1352 2277 285 330
side
Beam diameter + 250 mm or more With center guide rail
Negative dobby 2700 2318 250 285
Take-up
Take-up diameter + 250 mm or more Positive dobby 28*1 2115 130 330
side
Note: The drawings in this Installation Guide are extracted from all the foundation and installation
drawings. As modifications might occasionally be made, when planning factories, ask our sales
staff for the latest drawings.
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3. Foundation Standard
3.1 Foundation
Generally, for super high speed looms such as ZW Water Jet Looms, attention should be paid to the
strength and evenness of the foundation.
Oscillations in the direction of the X axis (right and left), Y axis (back and forth) and Z axis (up and down)
become larger as loom rpm increases. The correspondence of oscillating waves of several looms causes
resonance phenomenon which makes resonance marks, lowering cloth quality, and may shorten the loom
durability or generate vibration as public nuisance. Follow the foundation standard itemized below:
The foundation in this Installation Guide is to assist the loom’s

natural ability. It doesn’t guarantee a complete absence of
vibration or noise. Careful attention should be paid to the
influence of vibration and noise upon the inside and around of
the factory.
Drainage ditch
Floor
or more
No. Item Standard

1 Reinforcing steel bar Lattice steel rods (diameter 13mm) at intervals of 150mm.
2 Cement strength Cement strength should be 21N/mm2 (210kgf/cm2) four weeks after cementing.
Cement thickness should be 450mm. Because the particularly weak soil needs
soil improvement, consult with the contractor.
3 Gravel The size should be 20~30mm in diameter.
The thickness should be 150mm or more.
A Under the loom frames The height difference of the hatched area should be within 2mm. Irregularity on
(Hatched area) the surface should be less than 0.5mm. (See Note 1 and 2.)
Adjust the levels by grinding the cement. Do not adjust them by mortar
finishing.
B Drainage ditch A gradient of 2/1000 to the drain port of the factory and a depth of 75mm or
more and 150mm or less are necessary. If the depth of the drainage ditch is
150mm or more, increase the cement thickness so that the thickness under the
ditch is 300mm or more.
When the water separator with a float is used, the end of the drainage ditch is
out the loom frame by 450mm or more for draining from the water separator.
C Inclined face Refer to the foundation drawing.
4 Water supply piping Fix pipe lines in the drainage ditch. Attach the stop valve to the water supply
piping pick-up. Refer to Section 3.4.
5 Valves Mount one valve for each loom, one per 4~6 looms for cleaning and one at
each end of the pipe lines. Refer to Section 3.4.
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No. Item Standard
D Floor Make the center of the corridors a little higher so that water does not accumulate.
Finish by painting to the floor in order to prevent dust.
Electrical wiring Do NOT use the drainage ditch for electrical wiring. Provide an exclusive ditch and
insert the pipe. Attach the flexible conduit to the electric cable from the electrical
wiring pick-up to the control box (about 150mm).
For the cable for main units of the loom, refer to Section 5 in Chapter 2.
Note 1: Leveling:
The level of the floor under the frame feet 2 mm
Frame
Frame
should be within 2mm. or less
If the difference is more than 2mm, grind

the convex parts.
Note 2: Flatness
Floor flatness under the frame feet should be within
0.5mm.
If it is 0.5 mm or more, final polishing for the floor under within 0.5 mm
the frame feet is recommended.
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3.2 Foundation Bolt Type & Drilling
There are two sizes of foundation bolts, M16 and M12.
Type L and Type I M16 bolts are available to install looms.
Please do NOT use expansion bolts as foundation bolts for looms because strength against withdrawal
force may not be sufficient.
When liner bases for height adjustment are used, consult with Tsudakoma.
For fixing the foundation bolts, follow instructions of a specialist and the instruction manual by a
manufacturer of mortar or adhesive to secure sufficient strength.
M16 bolt M16 bolt M12 bolt

Type L foundation bolt Type I foundation bolt Type I foundation bolt
Mortar
Adhesive
Adhesive
(1) L-foundation bolts

This foundation bolt are fastened with mortar.
Foundation bolt Drilling hole Remarks
Square 80 x 200 mm or
M16 bolt For installation of the main loom
diameter 80 x 200 mm
Note 1: Do NOT make a hole larger than the size specified in the table.
Otherwise, accurate leveling will be difficult.
Note 2: M12 bolt Type L is optional. Please ask Tsudakoma sales staff.
(2) I-foundation bolts

I-foundation bolts are fastened to the floor with adhesive.
Follow the instruction manual of the adhesive manufacturer to make adhesion sufficient.
Adhesive
Foundation bolt Drilling hole Remarks
amount
M16 bolt Diameter 22 x 160 mm about 26 cc For installation of the main loom
For installation of the yarn supply stand and the
M12 bolt Diameter 15 x 110 mm about 11 cc
control box
1) Drill the foundation bolt holes with a cement drill. Remove dust in the holes with a wire brush and a
vacuum cleaner.
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2) Use the adhesives listed below.
Manufacturer Bond type
KONISHI E-206
THREE BOND 3LG F-130
Note: Please arrange for adhesive by yourself.
3) Compound ratio of adhesive

For either F-206 or F-130, the compound ratio of the main agent (liquid A) and hardening agent (liquid B)
is
A:B = 2:1
4) Remarks
a. Degrease the foundation bolt with thinner.

b. Agitate the main agent and the hardening agent to make the compound.
c. After the adhesive solidifies completely (two or three days), tighten the foundation bolt.
d. Before the adhesive solidifies, remove extra adhesive.
3.3 Inking
(1) Inking of reference lines:
Ink the reference lines on the floor according to the installation and lay-out drawings.
(2) Inking of foundation holes:

Ink the positions of foundation bolts on the floor according to the reference lines and foundation drawing.
Reference
lines
Reference lines
(3) Confirmation of foundation holes:

If the inked positions are not exact, correct them.
Note: When using I-foundation bolts, drill installation holes with a cement drill at the positions inked
by process (2), above.
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3.4 Appurtenant Work
(1) Pick-up of water supply pipes
No. Item Standard
Drainage 3 Pipe Material: Rustproof
Floor
Material: Rustproof
4 Stop valve
Diameter: 1/2 inches
Note 1: For water pressure at water pickup, refer to Section 3, (3) in

Chapter 1.
Note 2: The water pipe diameter depends on the primary water
pressure and distance. Consult with a specialist.
(2) Cable pick-up

Regarding the position of cable pick-up and the position to connect with the control box of the loom, refer
to the foundation drawing and the installation drawing Tsudakoma provide.
3.5 Standard for leveling the loom

Generally, Tsudakoma’s engineer install the loom. However, you can install it following the standards
below:
Levelness of the loom = 0.5/1000 (0.5mm inclination per 1m)
Note 1: When you use the level purchased from Tsudakoma together with the looms, the allowance is
1/4 division. Also be careful to distortion of the loom.
Note 2: 3 kinds of shims 0.5, 1.0, and 2.0 mm in thickness are packed with the loom.
Insert them under the loom frame to make the loom level.
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A802-1 June, 2012
3.6 Leveling Procedure
1) Measure the levelness at A, B, and C and find
the highest point.
There is a mark at point “A”. Measure the
MAIN FRAME levelness at this point. There aren’t marks at
point “B” and “C”. Decide one point on the
processed surface and measure it at that point.
BACK TOP STAY
2) Put a level on the higher frame top.
MAIN FRAME
3) Insert a shim under the foot of the lower frame,
and level the loom.
4) Put a level gauge on the frame top under which

the shim was inserted.
5) Insert another shim under the lower frame foot.
6) Put a level gauge at point “A”.
7) Insert another shim under the lower frame foot,

so that the loom becomes horizontal at point “A”.
8) Place the loom on the inking line correctly.
9) Insert shims into the space between the loom

frame and the floor.
FOUNDATION BOLT Note 1: A shim is the same size as the loom

frame’s foot.
It has three U slots. Insert it so that the
Loom front
relative position of the slots and the
foundation bolts are the same as the
figure at left.
Note 2: When inserting a shim, use a small

jack.
BACK BOTTOM When using a jack, apply it to the front
STAY bottom stay for the loom front and to
the back bottom stay for the loom rear.
Apply a jack to Note 3: When the loom is leveled, adhere the

these positions. shims and the bottom of the loom with
FRONT BOTTOM STAY adhesive (THREE BOND 1215H).
If many shims are used, also apply
ANCHOR BOLT
adhesive between the shims.
Note 4: When inserting a shim, be sure to

Floor
insert an anchor bolt in the U slot in the
shim.
If a shim is applied to only one side, the
SHIM bottom of the frame may be broken.
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4. Noise & Vibration
4.1 Noise
(1) Permissible noise levels
For the permissible noise levels generated by mills, follow the regulations in your country.
The following table is from the regulations for permissible noise levels in Japan.
(Reference) Permissible noise level by region according to the time
Time Daytime Morning Evening Nighttime
8:00 - 19:00 6:00 - 8:00 19:00 - 22:00 22:00 - - 6:00

Region
Class 1:
50 dB or less 45 dB or less 40 dB or less
Exclusive residential region
Class 2:
Residential region
Class 3:
Commercial region & quasi- 65 dB or less 60 dB or less 50 dB or less
industrial
Class 4:
Industrial region
Note: For Region Class 2 - 4, 5dB must be reduced in a 50m distance from a school and a hospital.
(2) Noise level of ZW

Although it differs a little depending on the specifications (reed width, shedding, loom rpm) and woven
cloth, the noise level of a ZW is approximately 80~88db (A) (decibel).
The value is measured at a point that is 1m from the front of the loom, and 1.2m from the floor.
(3) Noise control and sound insulation

Noise can be reduced considerably with sound insulation.
The following table shows examples of sound-insulators and sound reduction. Plan factories so that noise
is within the permissible level. Consult with specialists.
Concrete matted Concrete board (19mm)

Sound insulator Window Steel Concrete block
material for both sides put between plywood
(Thickness) glass door (100mm)
(100mm) boards (13mm)
Sound reduction
6-8 10-14 34-36 20-23 24-26
(dB)
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4.2 Vibration as Public Nuisance
(1) Vibration level
For the permissible vibration levels generated by mills, follow the regulations in your county.
The following table is from the regulations for permissible vibration levels in Japan.
Time
Daytime Night time
8:00-19:00 19:00-8:00
Region
Class 1: Residential region 60dB or less 55dB or less
Class 2: Residential and commercial region 65dB or less 60dB or less
Note: 5dB must be reduced in a 50m distance from a school and a hospital.
(2) Vibration level of ZW

ZW vibration level depends on the factory location, ground condition, specifications (reed space,
shedding), and loom rpm. Consult our salesman.
(3) Vibration-proofing
Vibration-proofing is far more difficult than soundproofing. (The best solution is to build a rigid and stable
foundation according to the factory location and ground conditions.)
In several factories, looms were installed on a vibration-proof frame with springs.
This frame has proven to be very effective.
Regarding Tsudakoma’s loom base, please consult with Tsudakoma’s sales staff.
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5. Electrical Equipment
5.1 Specifications
The following conditions should be strictly observed to completely utilize and maintain the performance of
the devices.
Electrical equipment Description

3-phase AC voltage between 200V and 575V is to be selected.
Voltage TSUDAKOMA supplies an inverter for slow inching according to
power voltage.
Power ±10% or less (When the loom starts, ensure that there is not more
1 Voltage regulation
source than 20% drop in voltage.)
Frequency 50 Hz or 60 Hz
Frequency regulation ±5% or less
Operation
5 - 30°C
2 Environment temperature
Relative humidity 85% or less (To prevent dew condensation)
If the foundation work is not solid enough when the loom is

3 Vibration installed, abnormal vibration on the floor will damage the wire joints.
A stable and firm foundation is required. Refer to Section 3.1.
Be sure to conduct grounding work for the loom according to the

regulations in your country.
4 Grounding
The grounding wire should be connected to the grounding terminal
(Mark E) in the control box.
Install a leak breaker on the power circuit to protect operators from

Leak breaker accidents.
5
installation
For installation details, consult local electrical engineers.
Thick power wiring cables lessen the drop in voltage when the loom
6 Wiring starts, and makes stop marks less prominent.
For cable thickness, refer to Section 5.3.
Note: In a rush-start of the loom, a starting current about 20 times larger than the rating current is
flowing in a moment. Therefore, a breaker capable of handling 4 times or more of the motor
rating current must be mounted on the power distributing board.
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5.2 Electric Installation Capacity
(1) Installation capacity/loom
Installation capacity (kVA)
= Main motor + Suction blower, + FDP + ELO + ETU + Electric components in the control box
Calculate the installation capacity per loom according to the figures in the table below:
The required capacity of the main motor and the suction blower depends on the specifications.
Be careful.
Item Specifications Installation capacity (kVA)

2.2 kW 3.24
2.7 kW 3.97
Main motor
3.0 kW 4.41
3.7 kW 5.44
50 Hz 0.35
301AZ
60 Hz 0.51
Suction blower
50 Hz 0.81
406Z
60 Hz 1.25
FDP 0.36
ELO 0.62
ETU 0.60
Control box 0.10
(2) Total installation capacity

To compensate voltage drop when the loom is started, the installation capacity must be more than the
value calculated with the formula below:
Total installation capacity (kVA) = Installation capacity/loom x Total number of looms + 20 kVA
(3) Calculating example

When the loom specifications is as follows:
Main motor: 3.7 kW, Frequency: 60Hz, Suction blower: 406Z,

the installation capacity /loom is:
Installation capacity (kVA) = 5.44 + 1.25 + 0.36 + 0.62 + 0.60 + 0.10
= 8.37 kVA
For 50 looms, the total installation capacity is calculated as follows:
Total installation capacity (kVA) = 8.37 x 50 + 20
= 438.5 kVA or more
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5.3 Power Source Connection
1) Connect the 3-phase power supply for the main power
supply directly to the primary side of 6P NO-FUSE
BREAKER 2 in CONTROL BOX 1.
a. Grounding line: Terminal E

b. Grounding pole: Terminal S
2) Connect the 5-Hz 3-phase power supply for slow inching to

the three poles on the right side of 6P NO-FUSE BREAKER
For slow 2.
inching
3) Wire POWER CABLE 3 as in Figure at left.
4) The 5Hz 3-phase power supply for slow inching is supplied

by the special inverter unit.
Forward/reverse inching operation speed is 1/10 of normal
operation. It provides safe and secure operation.
Install the inverter unit separately from the loom and lay a
special cable to each loom.
Note: When an optional inverter for speed control is

provided with the loom, 5Hz power supply cable for
slow inching may not be required.
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A802-1 June, 2012
5.4 Electric Wiring
Use a cable of the thickness specified below or thicker.
Regarding wiring, Tsudakoma will provide each user with an electric wiring diagram. So, please do electric
works according to the diagram.
1) For power supply voltage: 200Vac, 220Vac
50/60Hz main power circuit 5Hz inverter power circuit

Motor rated Branch line (Sq.) Branch line (Sq.)
output (kW) Bus (Sq.) Bus (Sq.)
See Note 1. L > 10m See Note 1. L > 10m
L < 10m L < 10m
See Note 3. See Note 3.
2.2 kW 14 SQ 5.5 SQ 8 SQ 14 SQ 5.5 SQ 8 SQ
2.7 22 5.5 8 14 5.5 8
3.0 22 5.5 8 14 5.5 8
3.7 38 8 14 22 8 14
2) For power supply voltage: 380Vac
50/60Hz main power circuit 5Hz inverter power circuit

Motor rated Branch line (Sq.) Branch line (Sq.)
output (kW) Bus (Sq.) Bus (Sq.)
See Note 1. L > 10m See Note 1. L > 10m
L < 10m L < 10m
See Note 3. See Note 3.
2.2 kW 8 SQ 3.5 SQ 5.5 SQ 8 SQ 3.5 SQ 5.5 SQ
2.7 8 3.5 5.5 8 3.5 5.5
3.0 14 3.5 5.5 8 3.5 5.5
3.7 22 5.5 8 14 5.5 8
Note 1: The cable from the no-fuse breaker to the point where it branches to go into five different
looms is called the bus.
Note 2: When the bus length is long and the voltage is likely to be reduced 2% or more, use a thicker
cable.
Note 3: When the length of branch cable (L) is longer than 10m, select a cable of the appropriate
thickness corresponding to the cable length.
Note 4: When the length of the cable between the inverter box to the 6P no-fuse breaker is 50 m or
longer, use a thicker cable.
Note 5: The cable thickness listed in the table are given considering that three wires are contained in
one pipe.
Note 6: When your loom is provided with the suction blower “VEC 406Z,” use a thicker cable for the
bus.
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A802-1 June, 2012
(2) Jump wiring
Do NOT connect wires from loom to loom. (Jump wiring)
(3) Leakage detective circuit

1) Make a leakage detective circuit (Refer to the wiring diagram provided by Tsudakoma.)
A reference drawing of the leakage detective circuit is shown.
When an inverter for speed control is provided with each loom, make the sensitive current of a leakage
detective circuit larger.
(4) Piping
The main circuit (50/60 Hz) wires and an inverter circuit (5 Hz) wire must be put in different ducts.
(5) Wire
For the wire rising position and piping layout between the control box and the main body, refer to the
foundation and installation drawings provided by TSUDAKOMA.
5.5 Items To Be Prepared

(1) Items purchased from Tsudakoma
• Inverter box
• 6P no-fuse breaker
(2) Items to be prepared by user

• Leakage detector
• Housing for the no-fuse breakers
5.6 Phase Advance Condenser

A phase advance condenser is occasionally installed to improve the power factor.
When the loom is provided with the inverter for slow inching, do NOT install it on the power supply side.
Otherwise, the inverter for slow inching will be broken. Be sure to install it on the mill’s power supply side.
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5.7 Inverter for Slow Inching
(1) Inverter Box
• The inverter supplies 5 Hz AC power for automatic reverse and manual forward/reverse slow inching.
• The inverter consists of an inverter box that contains an inverter and the 6P no-fuse breaker.
(1) Inverter box

1) Type and applicable range
There are two types: IB-5 and IB-10.
Refer to the drawings of the inverter box provided box.
Inverter box Loom quantity

IB-5 50 or less
IB-10 100 or less
2) Power source voltage
For both the IB-5 and IB-10, the built-in transformer is different according to the power source voltage.
Check the tap voltage on the primary side of the built-in transformer when connecting the inverter.
3) There is one inverter in the IB-5 type and two inverters in the IB-10 type.
4) Backup when either built-in inverter is defective

The two built-in inverters of the IB-10 can respectively support 50 looms at maximum.
If one built-in inverter is defective and can not be used, the other can back up the defective inverter for a
short time.
5) Remarks on installation
a. The temperature in the mill should be lower than 30°C.

b. Keep off fluff and humidity.
c. Minimum clearance must be 10 cm around the inverter box for better heat radiation.
d. Nothing must be put on the inverter box.
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(2) 6P no-fuse breaker (NFB)
The three left poles are used for the circuit protection of the 50/60 Hz main power source circuit. The other
three are used for the circuit protection of the slow inching 5 Hz power source circuit. This special breaker
allows both poles to be turned on and off at the same time. Refer to the drawing of the 6P no-fuse breaker
provided by Tsudakoma.
This simultaneous ON & OFF for both power source systems is employed for safety.
1) Loom Quantity
One 6P no-fuse breaker can be connected up to five looms.
2) Shunt coil
The shunt coil (SHT) is built in the inverter, breaking off the outside by the leakage relay.
Refer to Figure (4) at the end of this Guide.
Rating of shunt coil 100Vac
Input 110VA
3) Rated current
Rated current differs depending on power voltage.
Power supply voltage Rated current

200Vac, 220Vac 100A
380Vac 50A
4) Housing box
Please prepare the breaker housing box. For the dimensions, refer to the 6P no-fuse breaker drawing.
(Please ask TSUDAKOMA sales staff for the drawing.)
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6. Laying LAN For TLM
By connecting each loom with a computer using a LAN, it is possible to use the Weave-Navi function, the
Weave-tips function, browse the manuals and the parts catalog, and copy the set values between the
looms through the TLM.
Note: Customer is responsible for the LAN construction.
6.1 Cable Configuration

Lay rigid steel conduits and the LAN cables under the mill floor, and connect the looms with the computer
installed in the office through the switching HUB.
Loom
Switching HUB
Computer
NF
Power source
NF
Power source
NF
NF
Steel cable conduit NF Noise filter for power source
LAN cable Power cable
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A802-1 June, 2012
6.2 Work Procedure
Order Step Description Reference
1 Plan Determine the wiring route of the LAN cables. 6-3
Determine the setting position, the quantity and the port number of the
Switching HUB.
Determine the setting position of the computer.
Make a layout plan of the LAN cable, the switching HUB, the computer, and
the power cable wiring.
2 Arrange Rigid steel conduits 6-4

Flexible metal conduit
LAN cables and connectors 6-5
Switching HUB 6-7
Power source and power cable for the switching HUB 6-6
Computer, OS software 6-8
Power source and power cable for the computer
Desk for computer
3 Construction Lay the rigid steel conduits.

Install the LAN cables.
Prepare the connectors of the LAN cables.
Setup the switching HUB.
Prepare the power supply and lay the power cable for the switching HUB.
Lay the power cable for the personal computer.
Have the computer desk in place. Set up the personal computer.
Connect the LAN cables with the looms.
4 Install the Install the OS software in the computer.

software. Install the Tsudakoma software.
6.3 Wiring Route of the Cables, How to Decide the Quantity of the
Switching HUB
Plan the mill’s layout considering the below:
1) A LAN cable must be 100m long or shorter.
2) The loom quantity that can be connected with one switching HUB is calculated by decreasing one from the
port number of the switching HUB to be used. One port will be used for uplinking.
Example: A 32-port HUB can connect with 31 looms.
3) Be sure to prepare the power supply for the switching HUB.
4) Rigid steel conduits that contain the LAN cables can be laid.
5) If the distance between the mills, or the computers are farther than 100 m, install a switching HUB in the
middle.
6) A switching HUB can have up to nine master switching HUBs.
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6.4 Remarks on Laying the Rigid Steel Conduits and the LAN Cables
RIGID STEEL CONDUIT
LAN CABLE
1) Lay rigid steel conduits exclusive for the LAN cables between:
a loom and a switching HUB,
a switching HUB and a switching HUB, and
a switching HUB and a computer.
2) Install a checkbox at certain intervals so that you can replace a defective cable.
3) Lay the rigid steel conduits as close to a switching HUB as possible.
4) Conduct the grounding according to the regulations of your country.
5) Mark symbols on both ends of a LAN cable to identify it.
6) Pick up the LAN cable at the cable pick up position (for a LAN cable) on the left side of the loom (near the
Navi-Board.).
Run the LAN cable from the floor, up the side of the loom, and connect it to the Navi-board. (About 3000
mm)
Note: If it is impossible to lay rigid steel conduits exclusive for the LAN cable:
1. Use a LAN cable with a shield wire.
2. For the LAN connector, use a non-shield type for the loom side, and a metallic-shield
type for the HUB side.
When connecting the LAN connector of the metallic-shield type to the LAN cable, strip
the outer coverings of the LAN cable to make the shield wire contact with the metallic
parts of the LAN connector securely.
3. Use a switching HUB that can handle a shield wire.
4. Keep the LAN cables 300 mm or more away from the power lines.
5. Be sure to ground the HUB.
HUB
LAN cable on the loom side
Ground
6.5 Type of LAN Cables

1) Use a 100Base-Tx cable (Category 5 or more).
2) The cable should be for straight connection with the looms and the computer.
6.6 Power Supply for Switching HUB

Install a noise filter or use an outlet tap with a noise filter.
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6.7 Type of Switching HUB
1) Use a HUB whose ports are for 100Base-Tx/10Base-Tx Full/Half Duplex.
2) The HUB should have 1000 or more MAC address registration.

Recommendation:
• A HUB that does not have a cooling fan is recommended. If your HUB is provided with a cooling
fan, house it in a box.
• A built-in power source is recommended. (Because it’s easy to disconnect an AC adapter plug.)
6.8 Specifications of Computer

Please prepare a computer that satisfies the specifications below:
Item Description
CPU Celeron 1.2 GHZ (or more)
Memory 256 MB (or more) *1
Hard disk Free space of Drive C is 2GB or more.
Graphics XGA (1024 x 768)
CD-ROM Any speed (1 drive) An external CD-ROM drive is accepted.
Network port 1 port (100 Base-Tx or more)
Main computer *3
Windows Server 2008 (SP2 or older)
Windows Vista Ultimate (SP2 or older)
Windows Vista Business (SP2 or older)
Windows XP Professional (SP3 or older)
Windows Server 2003 R2 (SP2 or older)
Main body Windows Server 2003 (SP2 or older)
Windows 2000 Server (SP4)
Windows 2000 Professional (SP4)
Sub-computer
OS*2
Windows Vista Ultimate (SP2 or older)
Windows Vista Business (SP2 or older)
Windows Vista Home Premium (SP2 or older)
Windows Vista Home Basic (SP2 or older)
Windows XP Professional (SP3 or older)
Windows Server 2003 R2 (SP2 or older)
Windows 2000 Server (SP4)
Windows 2000 Professional (SP4)
Keyboard Any type
Others Mouse Any type
Display 15 inches (or more)
The PC should be PC/AT compatible.

*1: For Windows Vista, prepare 1GB or more memory.
*2: An OS after operation check
A Service Pack after the above-mentioned OS is not supported.
*3: Windows XP Home, Windows Vista Home Premium/Home Basic can not be used for the main computer.
Choose a computer as a main computer for which 24-hour continuous work is guaranteed because a
weaving mill may operate for 24 hours. When choosing a computer, please ask a computer manufacturer.
We also recommend a computer as a sub-computer for which 24-hour continuous work is guaranteed.
Printer: When you want to print a report or manuals, please prepare a printer. Use a printer model that is
operational with the Windows operating system in use. The report of the TLM and the manuals are
designed for printing on A4 size paper.
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6.9 LAN Cable Connection of the Loom
Connect the LAN cable in the Navi-board as follows:
• The LAN cable must be 700 mm long from the cable connecting opening.
• Fix the LAN cable with the 2 fixing hooks in the Navi-board and connect the connector to the LAN cable
connection port.
LAN cable connection port
Fixing hooks for the cable
LAN cable connection opening

LAN cable
Back view of the Navi-Board
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A802-1 June, 2012
7. Interior Conditions
7.1 Air Conditioning

(1) Temperature & Humidity
Control of temperature and humidity is important to influence static elimination as well as operation
efficiency.
Windowless factories are favorable for the control of humidity and temperature. The use of high quality
heat insulation in the ceiling and walls also helps in this regard.
In cold regions, dew condensation caused by temperature differences between the outside and inside of
the factory can give rise to rust on the loom and damage warp.
In hot regions, it is necessary to enlarge the cooling capacity, which increases the initial and operational
costs.
(2) Air
The following table shows the standard of air conditioning in a weaving mill.
Item Temperature Humidity Air circulation cycle
Standard 20 to 25°C 65 to 75% 15 to 20 times/hour
7.2 Ceiling height

Determine the ceiling height considering the machine height, space and air conditioning.
A low ceiling reduces the cost of air conditioning, but the air circulation is not good and the factory seems
stuffy, giving a narrow and closed impression. A high ceiling, on the other hand, seems open because of
the wide space, but higher initial and operational costs for air conditioning (cooling and heating) are
required.
The standard height of the ceiling is as follows;
Item Crank shedding loom Dobby shedding loom

Standard 2.7 ~ 3.0m 3.2 ~ 3.5m
7.3 Interior color:

Interior color influences lighting as well as workers physiologically and mentally. Floor painting also helps
prevent dust from being generated and improves safety and comfort.
The following colors are generally used.
Section Ceiling Upper wall Lower wall Floor Line on the corridor
White, Dark brown, Dark brown,
Color White White, yellow
cream green green
Note: Adhere tiles or paint the floor after loom installation.
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A802-1 June, 2012
7.4 Illumination:
Factory lighting must provide enough light to detect the presence of small fluff. Determine the necessary
level of illumination by referring to the JIS (Japanese Industrial Standard) which is as follows:
Illuminance: Lux Work

-
3000
2000 Very fine visual work
1500
Fine visual work, such as selection

1000
Example: Cloth inspection
750
Normal visual work

500
Example: Drawing-in, on-loom
300
Coarse visual work

200
Example: Winder, Warping, Sizing
150
Very coarse visual work

100
Example: Finishing
75
7.5 Illuminance of fluorescent lamps:

Illuminance is determined by the wattage of a lamp and its distance from the loom. Install fluorescent
lamps referring to the following table showing the illuminance by direct lighting.
Illuminance by Direct Lighting (While Fluorescent Lamp)
(Unit: lux)
When the lamp is 1. When the lamp is 2. When the lamp is 3.
Height (m)
20W 30W 40W 20W 30W 40W 40W
1 160 260 440 365 580 995 1435
2 39 63 110 90 145 250 375
3 18 28 50 40 63 110 158
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A802-1 June, 2012
Chapter 3: Accessories & Supplies
1. Accessory Selection ...............................................................................3-1

1.1 Reed ...........................................................................................................3-1
1.2 Heald ..........................................................................................................3-2
2. Preparation For Looming........................................................................3-4

2.1 Warp ...........................................................................................................3-4
2.2 Filling Twisting ............................................................................................3-8
2.3 Yarn Supply Package .................................................................................3-8
2.4 Catch Cord .................................................................................................3-8
2.5 Selvage Yarn ..............................................................................................3-8
3. Preparation For Starting .........................................................................3-9

1. Accessory Selection
1.1 Reed
(1) Reed specifications
UPPER FRAME
ORNAMENTAL REED DENT

ORNAMENTAL REED DENT
Space
20 or more (Coated dents) Lower frame (Coated dents) 20 or more
Reeding width + Ornamental dent on both sides + 1 unused dent on LH + 3 unused dents on RH
1) Frame thickness
The standard frame thickness is 5 mm. When it is 6 mm, replacing the reed holder is required.
Please contact Tsudakoma.
2) Frame height
The recommended height for the upper frame is 12 mm, and for the lower frame it is 20 mm.
When the reed is used upside down, the upper frame height is also 20 mm. Because the weight is
increased, this reed is not recommended for high speed operation.
When the loom rpm is 700 rpm or more, the height of the upper frame must be 12 mm.
3) Recommended reed height

The reed height, Dimension H is determined according to reed stroke, and the shedding motion.
Shedding motion Crank, cam Dobby
Reed stroke Short Standard Long Short Standard Long
h H h H h H h H h H h H
Recommended dimension
52 90 54 92 56 94 54 92 56 94 58 96
Dimension H is restricted by reed stroke.
Reed stroke Short Standard Long
Maximum Dimension H 100 102 110
4) Coil height
The coil height must be 3 mm or less. If it exceeds 3 mm, adjust Dimension H to keep Dimension h.
5) Air space
Generally, air space is 50 - 60%. However, it is adjusted according to yarn thickness, kind, and
characteristics. If the dent thickness is thin, the reed strength sometimes decreases depending on
Dimension h. Please decide the air space while consulting with a reed manufacturer.
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A802-1 June, 2012
6) Unused reed dents
The number of unused reed dents in the figure above applies when the reed density is 30 dents/inch or
higher. If the reed density is lower, determine the number of the unused reed dents so that they are within
1.5 mm on the left, and within 3 mm on the right.
7) Overall length
The overall length depends on the reeding width and the reed is exclusively used for that reeding width.
The maximum dimension is “reeding width + 30 mm.”
So, the maximum mounting dimension is the nominal reed width + 30 mm.
(2) Reeding procedure

1) Thread the warp in order from the yarn supply side.
2) Draw the warp yarn from the 2nd dent.

If drawing the warp yarn from the 3rd or the 4th dent, the tuft length will
be long by the same length.
Note 1: Because the movable blade enters the reed, a window of 9 - 10 mm width from the reed stay is
required.
Note 2: For coated reed dents, do not twist the reed dent nor use a hook which is harder than the reed
dent. A hard hook damages the ceramic coating of the reed dent.
1.2 Heald
(1) Heald selection
Heald forms and material are different depending on heald manufacturers. Select a heald for your
application referring to the following items. For details, ask the heald manufacturer.
(2) Heald type

There are five heald types; 260, 280, 302, 330mm. A 330 mm heald is used only for dobby shedding.
(3) Heald Length “L”

Determine the heald length “L” considering the shedding amount, fabric type, loom rpm and heald
availability.
(4) Main form

There are two kinds of heald forms; duplex center mail and simplex center mail.
A simplex up mail is not used for a water jet loom.
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A802-1 June, 2012
(5) Processing
There are two ways of processing: wire press and plate stamping.
Plate stamping is superior in strength.
(6) Heald manufacturers

Kiji Reed, Grob, GTP, and others.
(7) Heald form

The following are generally used: (Unit: mm)
Shedding motion Type AxB TxW
Crank
Normal 5.5 x 1.2 0.3 x 2.2
(600 rpm or less)
Crank (600rpm or more)
Reinforced 5.5 x 1.2 0.3 x 3.2
Dobby
(8) Material
SUS 304 (Stainless steel) is generally used.
(9) Heald Density

Heald density must be less than 25 pcs per inch when the yarn thickness is 167 dtex or less.
Determine the heald density by the warp density obtained from the formula below:
Warp density = Heald Q’ty per inch x Heald frame Q’ty
If the heald density is too high, healds adhere to each other by water adhesion (the heald touching
phenomenon), causing fluff and heald soil which makes cloth stains.
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2. Preparation For Looming
2.1 Warp
The loom efficiency and cloth quality depend on warp.
“Floating” which lowers the cloth quality, never occurs in a water jet loom, unlike the rapier or shuttle loom.
When the water jet loom has defective warp shedding, it does not insert filling but stops the loom (bent
pick). Defective shedding can be reduced by making adjustments for the following defects:
(1) Warp fluff

1) Fluff of raw yarn
Generally, raw yarn fluff is 0.1 -0.3/106m
Fluff levels should not exceed 1 -2/106m.
2) Fluff by friction
Warp comes from the creel to the reed through many guides. Flaws or attached monomer on the guides
might produce warp fluff. Periodically check guides to prevent warp fluff.
3) Fluff by static electricity

A static eliminator should be mounted and perfect temperature and humidity control is necessary.
4) Other causes of fluff
a. Guide friction occurring during the transportation of warp.

b. Human or material contact with the pirn.
c. Human or material contact with the warp.
(2) Defective Leasing

Defective leasing lowers cloth quality by occurrence of fluff, warp breakage, wale streak, and loose yarn.
Defective leasing may occur in every process after beaming. Many causes of defective leasing are due to
human mistakes. Consider countermeasures.
(3) Warp remainder

Poor warp preparation and control cause fluff, defective leasing, and warp remainder.
Prepare warp so that no remainder exists, otherwise warp waste and defective weaving may occur.
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A802-1 June, 2012
(4) Assembling the Beam
The reference point is the mounted position of BEAM FLANGE 1 on BEAM GEAR 2’s side. It is not
necessary to change the position of BEAM FLANGE 1 on the LH even if the warping width changes.
The following is the procedure for assembling the beam.
1) Yarn supply side (Beam Gear 2’s side)
a. Place WARP BEAM 3 on a stand which is 10cm higher

than the radius of the flange.
b. Apply oil to the threaded portion of the beam.
c. Screw BEAM FLANGE 1 onto the threaded portion of the
beam.
d. Fix BEAM GEAR 2 with M12 x 40 hexagon coupling
bolts.
e. Adjust the position of BEAM GEAR 2 so that Clearance
A between BEAM GEAR 2 and BEAM FLANGE 1 is as
follows and fix it on BEAM FLANGE 1 with hexagon
coupling bolts. (M12 x 55)
Unit: mm
Flange diameter A
800 9 - 13
914
1-5
1000
2) Motor side
a. Apply oil to the threaded portion of the beam.

b. Screw BEAM FLANGE 1 onto the threaded portion of the
beam.
c. Screw LOCK NUTS 4 onto the threaded portion of the
beam.
d. Adjust the position of LOCK NUTS 4 so that the
clearance between LOCK NUTS 4 and BEAM FLANGE
1 is 1 - 5mm. Hold M12 x 60 (800 mm flange) or M12 x
45 (914 or 1000 mm flange) hexagon socket head bolts
with LOCK NUTS 4 in the threaded portion M12 in BEAM
FLANGE 1.
e. Adjust the position of BEAM FLANGE 1 so that the
distance between the flanges is the same as the reeding
width. Tighten the hexagon socket head bolt in the
threaded portion M12 of BEAM FLANGE 1.
3) Remarks
a. If you screw BEAM FLANGE 1 into BEAM 3 without applying oil, it will seize at the threaded portion.
b. Wipe off the oil with a cloth soaked with thinner after assembling the beam flange.
c. Check oscillation of the beam flanges on both sides during beaming. If the oscillation is too big, pat them
with a wooden hammer to adjust them.
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A802-1 June, 2012
(5) Warp Winding Direction
1) Wind warp counterclockwise viewed from the gear.
2) Wind warp evenly so that both ends of the beam are not higher
than the center.
3) Relax the beam for more than 48 hours after the sizing process,
and then go to the beaming process.
(6) Warp length per beam

1) Calculation of warp length (Max. value)
a. Calculation with the apparent specific gravity of wound warp:
Max. warp length L (m) =

p (DA 2 - DB2) x W x A x 9000
4 x dtex x N
Diameter of warp beam
9000 x W x A x p
4 x L x N x dtex
DA (cm) = + DB2
L (m) Warp length W (cm) Warp beam width

DA (cm) Outside diameter of flange - 2.0 A (g/cm3) Apparent specific gravity
(Max. diameter of warp beam) dtex Dtex number
DB (cm) Diameter of the barrel N Quantity of wound warp
The apparent specific gravity of each warp is shown below for reference.
Note that these values vary depending on the conditions.
Warper Sizer Loom beam

Warp type
Average Range Average Range Average Range
Nylon 0.90 0.80~0.92 0.76 0.70~0.82 0.81 0.80~0.82
Polyester 1.00 0.98~1.10 0.93 0.85~1.00 0.90 0.80~0.95
Textured yarn 0.61 0.56~0.63 0.52 0.48~0.56 0.60 0.50~0.70
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A802-1 June, 2012
b. Calculation with a warp sample:
If you have a sample of short warp wound to the beam, calculation is made as follows, by which actual
wound warp length can be obtained accurately.
a) If warp type, warp quantity, denier and beam are unchanged:
Max. warp length L (m) = LC x (DA

2
- DB2)
DC - DB2
2
LC (m) Warp length of the sample

DC (cm) Beam diameter of the sample
b) Calculation with the apparent specific gravity of the sample:

4 x d x N x LC
p (DC2 - DB2) x W x 9000
Apparent specific gravity A (g/cm3) =
(7) Dimensions of the beam and cloth roll

The following tables show dimensions of the beam, beam flange and cloth roll, which should be recorded
for inventory control.
1) Beam and beam flange

Reed Mass (kg)
L1 (mm)
width (cm) Dia. 800 914 1000
170 2049 142.1 178.2 218.2
180 2149 143.4 180.2 220.0
190 2249 144.7 182.2 222.2
210 2449 147.3 186.3 226.3
230 2649 149.9 190.4 230.4
d0= Diameter 178 (For 800 mm flange)
d0= Diameter 214 (For 914 or 1000 mm flange)
2) Cloth roll
Reed width
L (mm) Mass (kg)
(cm)
170 1800 5.0
180 1900 5.3
190 2000 5.5
210 2200 6.0
230 2400 7.0
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A802-1 June, 2012
2.2 Filling Twisting
(1) Preparation of filling and twisting
1) Measure the filling torque using a Kringel factor meter after setting, and adjust the torque to be less than
3.0.
2) Relaxation
Setting Jumbo winder Loom
Relaxation for 48 hours Relaxation for 48 hours
Consider space for relaxation when designing the factory, since relaxation should be performed between
the processes.
3) Filling hardness wound to the jumbo winder
Measure the strength with a yarn hardness meter and adjust it to be 60 -65°.
2.3 Yarn Supply Package

Preparation of the adapter of yarn supply package
about 185
about 50 1) Make a wooden adapter fit to the inner diameter (d) of the
yarn supply package so that the yarn supply package does
not rotate when filling is taken out during looming.
2) If using a jumbo bobbin, ask the manufacturer of the winder

for yarn supply package cores and kink preventers.
3) If using a cone, make a wooden adapter fit to the inner

about 185 diameter of the cone.
2.4 Catch Cord

Strong yarn with no knots should be used as a catch cord. Catch cord inter twines with inserted filling on
the RH to form a selvage with appropriate tension, and guides extra selvage to the dust box.
Generally, textured yarn of 110 ~ 167 dtex is used as a catch cord.
Prepare an appropriate catch cord before looming, referring to the standard below.
Yarn type Outer diameter Height
Polyester textured 110~167dtex 180 mm or less 420 mm or less
(1) Required rolls of catch cord

Four rolls of catch cord are used per loom.
(2) Consumption
<Warp length x (3.7~5.7) x 4 rolls> is used per loom.
2.5 Selvage Yarn

Two selvage yarns intertwine with filling at both ends to form selvages and prevent them from being
broken in the next process. Prepare an appropriate selvage yarn before looming, referring to the standard
below.
Yarn type Thickness

The same as warp Less than half of warp
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A802-1 June, 2012
(1) Required rolls of selvage yarn
Four rolls of selvage yarn are used per loom.
(2) Consumption
<Warp length x 1.3 x 4 rolls> is used per loom.
3. Preparation For Starting

Prepare the following before starting. The items with “*” can be purchased from Tsudakoma.
No. Name Purpose Q’ty/Loom Remarks
1 Oil See Section 3 in Chapter 4.
2 Oil pot For oil bath 1 pc/100 looms Capacity: 5 liters
For manual supply 1 pc/50 looms
3 Grease pump Maintenance 1 pc/100 looms Refer to “ZW Maintenance *
Manual, Measuring Instruments.”
4 Neutral detergent Cleaning on the filling 1 pc/30 looms Liquid detergent for home use
insertion
5 Nylon hose For test running 0.5 m x number 1m/loom for 2 colors
of nozzles
Cleaning 15m/50 looms
6 Starting cloth Thread through the take-up Fabric width = Reeding width,
section for gating Length 2~3m
7 Scissors Weaving 1 pc/person For yarn repair during weaving
Cutting 1 pc/50 looms For gaiting and doffing
8 Brush Warp arrangement 1 pc/50 looms Width: 300mm,
Hair length: 15~20mm
Horse hair is recommended.
Loom cleaning with water 1 pc/50 looms Car cleaning brush
Grease for manual application 1 pc/100 looms Paint brush
9 Watering pot Cloth rolling 1 pc/50 looms
10 Gummed cloth tape Slit tube 1 pc/25 looms Tape with ground fabric is
recommended.
11 Adhesive tape Leasing correction 1 pc/25 looms Used in sizing, too.
12 Snail wire stand Leasing correction 2 pcs/loom Iron plate 100 x 100 x 10t
Snail wire welding
13 Stroboscope To adjust timing 1 pc./50 looms Refer to “ZW Maintenance *
14 Temperature and 3 pcs./ Manual, Measuring Instruments.” *
humidity recorder 100 looms
15 Density meter To check fabric density 1 pc. *
16 Tester 1 ~ 2 pcs. *
17 Bobbin winder stand Height: about 60 cm
18 Cutter edge Maintenance To sharpen the edges of yarn *
sharpener supply cutter.
19 Vise & mounting Adjustment, maintenance 1 loom 6-inch vise
stand
20 Tools Adjustment, maintenance 1 set/fixer *
21 Level Adjustment, maintenance 1 pc. *
22 Hardness meter To measure the winding 1 pc. Refer to “ZW Maintenance *
hardness of yarn Manual, Measuring Instruments.”
23 Tension meter To measure yarn tension 1 pc. Desirable. *
24 Cord reel Maintenance, cleaning 1 pc.
25 Cloth Cleaning Up to user
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A802-1 June, 2012
Chapter 4: Loom Transportation & Trial Run
1. Loom Dimensions & Mass......................................................................4-1

1.1 ZW8100, Positive Cam, Beam Flange ø914...............................................4-1
1.2 Loom Delivery And Entrance Width.............................................................4-1
1.3 Machines & Tools for Delivery & Installation ...............................................4-2
1.4 Remarks on Delivery ...................................................................................4-2
1.5 Installation....................................................................................................4-3
1.6 Loom Storage ..............................................................................................4-3
2. Loom Installation & Trial run...................................................................4-4

2.1 Installation Procedure ..................................................................................4-4
2.2 Inspection Items in the Trial Run.................................................................4-4
2.3 Looming .......................................................................................................4-5
2.4 Running-in ...................................................................................................4-5
3. Lubrication [Recommended Oil Chart] ...................................................4-6

§4 LOOM TRANSPORTATION & TRIAL RUN
1. Loom Dimensions & Mass
1.1 ZW8100, Positive Cam, Beam Flange ø914

Nominal width Loom width W Net mass
Depth D (mm) Height H (mm)
(cm) (mm) (kg)
170 3070 2000
Depends on the
180 3170 Depends on the shedding 2040
flange diameter:
motion
190 3270 800: 1725 2080
Crank: 1245
210 3470 914: 1820 2165
Cam, dobby: 1170
1000: 1890
230 3670 2250
Note 1: The depth does not include flanges.

Note 2: The cam motion, the dobby motion, or the heald frames will be mounted on the loom after
installing the loom.
The height values for the cam and the dobby shedding do not include the cam or the dobby
machines.
1.2 Loom Delivery And Entrance Width

The required width of the factory entrance depends on the loom specifications and the method of
transportation.
For factory construction, provide a sufficiently large entrance.
For safety, transport looms according to the following.
(1) Method A
Figure (A) shows loom delivery in the direction of the
loom width to the entrance. When the entrance is wide
enough, the loom can be delivered in this method,
normally by a forklift.
Entrance width (W0):

Width (W) + (400 ~ 500) mm
Figure A
(2) Method B:
Figure (B) shows loom delivery in the direction of the
loom length to the entrance. This method is used when
the entrance is not wide enough.
Carry the loom frame through the entrance, lifting one

side (near the entrance) by a handlift and the other side
by a forklift.
Because this method is not very stable, be careful.
Figure] B Entrance width (W0):

Depth (D) + (500 ~ 600) mm
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A802-1 June, 2012
1.3 Machines & Tools for Delivery & Installation
The following machines and tools are necessary to deliver and install the loom.
Item Quantity Remarks

Forklift 1 The forks must be 1600mm or longer.
Handlift 1 3 tons or more
Baby jack 2 1.5 tons or more
Bar 2 Diameter: 40 ~ 50 mm, Length: 2 m
Hoist 4 For hoisting
1.4 Remarks on Delivery

When using a forklift or a handlift:
1) Insert the forks from the front of the loom and securely catch the front and the back bottom stays. Put a
rubber sheet or wooden plate on the forks to prevent the loom coating from being peeled away.
2) The forks of the forklift should be 1600mm long or longer. For a wooden skid, there are three wooden
supporters in the widthwise direction of the loom at the front, rear, and center. Shorter forks cannot reach
the furthest supporter, and the strength of the supporters is insufficient, resulting in breakage of the
supporters.
3) Do NOT twist the loom or handle it roughly.
4) Keep the loom balanced while transporting it.
5) Do NOT lift the loom more than 20 cm above the floor when carrying it.
6) Someone must guide the loom to the installation place in the factory.
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A802-1 June, 2012
1.5 Installation
1) Put the loom down at the installing position, and accurately
align the loom with the inked lines using bars.
2) When using a bar or a baby jack for transport or installation

of the loom, apply it to the bottom surface of the front bottom
stay for the loom front and of the back bottom stay for the
BACK loom back.
BOTTOM
STAY
3) Do NOT insert a bar under the main frame or the let-off
frame (hatched areas) to transport the loom.
Apply a jack or a
bar here.
FRONT BOTTOM STAY
MAIN
FRAME LET-OFF
FRAME
WARNING!
Be sure to insert a bar under the front bottom stay or the back bottom stay.
If a bar is inserted to either hatched area, under the main frame or the let-off frame, the parts, the main
frame, or the let-off frame will be broken or a bodily injury may occur.
1.6 Loom Storage

When it is necessary to store a loom in the mill or warehouse, please consider the following points:
(1) Place
Protect the loom from rain and wind and store it in a cool and dry place.
(2) Rust-prevention
Tsudakoma applies a rust-preventive agent to the parts and sections that may gather rust before shipping.
However, its effectiveness does not last long. Please apply a rust-preventive agent again if the storage
period is long.
(3) Breakage, loss, rust

Store the loom and the spare parts while being fully careful of breakage, loss, and rust.
Breakage, loss, or rust during storage is not warrantable.
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A802-1 June, 2012
2. Loom Installation & Trial run
2.1 Installation Procedure

Normally, Tsudakoma experts will install the loom and conduct a trial run.
However, follow the instructions below when you install the loom.
No. Procedure Remarks

Installation floor arrangement Refer to Section 3.1 in Chapter 2.
1 Water pipe arrangement Refer to Section 3.4 in Chapter 2.
Electric wiring arrangement Refer to Section 5 in Chapter 5.
2 Loom positioning Install the loom according to the inked lines.
3 Loom leveling Refer to Section 3.5 and 3.6 in Chapter 3.
4 Fixing with foundation bolts
Loom parts assembling
5 Yarn supply stands, catch cord yarn stands, etc.
(Parts that are removed for delivery, etc.)
Water pipe connection to looms Flush the water pipes, then connect them with the water tank.
Refer to the power source wiring diagram and loom electric
connection diagram.
6
Wiring connection to looms (Confirm the rotating direction of inching and running during
trial run. Also confirm the rotating direction of the suction
blower under arrangement conditions.)
Check the amount of lubricant for the loom’s oil bath
7
for the driving section and the cam or the dobby unit.
2.2 Inspection Items in the Trial Run

(1) Confirmation
1) Check that any unnecessary item is not attached to the loom, especially to moving parts.
2) Rotate the loom manually, and check that the rotation is not too heavy, or there is nothing to disturb the
movement.
(2) Lubrication
The loom has been lubricated in a factory test run before delivery. Lubricate again after installation to
ensure proper working conditions. (The oil in the oil bath of the driving section is drained after the factory
test run when the loom is shipped outside of Japan. Be careful.)
1) Check the oil level of each oil bath.
2) Lubricate all parts that need lubrication except for the oil bathes.
Note: Refer to Section 3 “Lubrication” or the ZW8100 Maintenance Manual, Mechanical Section
WARNING!
Before lubrication, turn OFF the main switch on the side of the control box.
CAUTION!
After lubrication, maintenance or inspection, mop up the oil, grease or water on the floor to prevent
slippage.
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A802-1 June, 2012
2.3 Looming
Our service engineers will explain the looming procedure.
Refer to the ZW8100 Maintenance Manual, Mechanical Section for details.
2.4 Running-in
The loom is operated at relatively low speed for a while after installation. This “running-in” is effective for
durable and smooth operation of each device. It is done for the purpose to find and solve any loom
problem during initial running early. Inefficient running-in and early continuous running at normal speed will
considerably shorten its usable lifespan.
Standards for running-in are shown below. Do running-in according to them, then begin normal operation.
(1) Period of running-in

One month or until one beam is completed.
(2) Loom rpm during running-in:

The upper limit rpm for running-in is as follows:
When the contracted loom’s RPM is lower than the upper limit below, do running-in with the rpm
contracted.
Shedding Nominal width (cm)

Weft selection
motion 170 180 190 210 230
2C Crank 750 750 700 650 650
2C Cam, dobby 700 700 650 600 600
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A802-1 June, 2012
3. Lubrication [Recommended Oil Chart]
The recommended oil names for each oil manufacturer are listed below.
The oil and grease below must not be mixed. The quantity in the table is only for reference.
Oil
Take-up gear box Let-off gear box Take-up gear

Position Driving gear box Lubrication hole
(ETU) (ELO) box (ETU)
Cycle 6 months (1000 hours for the first time) Warp-out
LH:about 3 liters
Quantity/loom about 0.15 liters about 0.9 liters about 0.55 liters about 0.05 liters
RH: about 3 liters
Method Oil bath Manual
JX Nippon Oil & FBK oil RO-100 Bonnoc M680 FBK oil RO-68
Energy Lathus 100 JOMO Reductus 680 JOMO Lathus 68
COSMO Cosmo ALLPUS 100 Cosmo Gear SE680 Cosmo Allpus 68
Daphne Mechanic
IDEMITSU Daphne Super Mechanic Oil 100 Daphne Super Gear Oil 680
oil 68
SHELL Tellus Oil C-100 Omala Oil 680 Tellus Oil C-68
Mobil DTE Oil

MOBIL Mobil DTE Oil Heavy Mobilgear 600XP680
Heavy Medium
YS High Lub
YANASE YS High Lub MGN-5K High Tack EP680
400N
WARNING!
Before lubrication, turn OFF the main switch on the side of the control box.
CAUTION!
After lubrication, maintenance or inspection, mop up the oil, grease or water on the floor to prevent
slippage.
4-6
A802-1 June, 2012
Grease
Sliding section
Grease nipple Centralized lubrication
Position Main motor
Open gear teeth (Shedding section, beating)
Roller chain
Cycle Warp-out 1 week 6 months
Quantity/loom about 1.5 kg Until grease overflows about 10 g
Apply with a grease gun

Method Apply with a grease gun. Apply with a grease gun.
and a brush
JX Nippon Oil EPNOC grease AP (N) -2 EPNOC Grease AP (N) 1 Multinoc grease 2
& Energy Lisonix Grease EP-2 Lisonix Grease EP-1 Lisonix Grease 2
Cosmo grease Dynamax Cosmo grease Dynamax EP

COSMO Cosmo grease Dynamax No. 2
EP No. 2 No. 1
Daphne Eponex Grease Daphne Eponex Grease EP
IDEMITSU Daphne Eponex Grease No. 2
EP No. 2 No. 1
SHELL Alvania EP Grease 2 Alvania EP Grease 1 Alvania Grease S2
MOBIL Mobilux EP-2 Mobilux EP-1 Mobilux 2
YANASE Multi EP Grease No. 2 Multi EP Grease No. 1 -
KYODO
Unilube No. 2 Unilube No. 1 -
YUSHI
Note 1: Do NOT use grease that contains an extreme pressure agent (EP grease) for the main motor.
It increases the temperature of the bearing.
Note 2: For the shedding device by other manufacturers, refer to the instruction manual by the
manufacturer.
4-7
A802-1 June, 2012
Chapter 5: Weaving Mill Planning Example
1. Loom Assignment ...................................................................................5-1

1.1 Loom Quantity per Operator .......................................................................5-1
1.2 Conditions for Determination ......................................................................5-1
1.3 Work Division ..............................................................................................5-1
2. Operation Arrangement Of A Plant With 100 Looms ................................5-2
3. Weaving Mill Planning Example [Loom: 100 units] ................................5-3

3.1 Production Process ....................................................................................5-3
3.2 Indication ....................................................................................................5-4
3.3 Calculating Conditions.................................................................................5-5
4. Other Equipment ....................................................................................5-8

§5: WEAVING MILL PLANNING EXAMPLE
1. Loom Assignment
1.1 Loom Quantity per Operator

(1) Controllable loom quantity
This is determined by repair time and frequency though it depends on the working system.
Obtain the loom quantity per operator by referring to the following formula:
Working time x 0.7

Loom Q’ty per Operator =
(Warp repair time) x Freq./Loom + (Filling etc. repair time x Freq./Loom)
Note: Regard the efficiency of 0.7 as general.

Conditions
Working time 8 hours

Warp repairing 5 min./case
Warp repair frequency
Filling etc. repairing 2 min./case

Efficiency 70%
Note: The time “min/case” includes
travel time.
Filling repair frequency
If an operator controls 75 looms, he has to repair warp trouble 0.5 times per loom every 8 hours and one
filling trouble per loom every 8 hours. Otherwise, he is overloaded and cannot maintain good operation.
1.2 Conditions for Determination

1) Trouble frequency and repair time
2) Repair time by the operator’s technical level

Choose either one operator responsible for all repairs or a division of work according to the operators’
technical level.
For Water Jet Looms, dividing the work is generally used.
1.3 Work Division

The work is divided into two.
1 Easy jobs like filling repair, etc.
2 Technical jobs like warp repair.
For better operation, we recommend the combination (1) and (2) if all workers’ technical level is not so
high. A operator in charge of (1), does filling repair and replacement of yarn supply package as well as
other easy jobs. The operator in charge of (2) can be engaged in a highly technical job such as warp
repair. Therefore, total efficiency and the fabric quality are raised, which will lead to effective factory
management.
5-1
A802-1 June, 2012
2. Operation Arrangement Of A Plant With 100 Looms
The following table shows the required number of operators for operation and maintenance in a factory
with 100 looms.
(Operation time: 24 hours)
Item Nylon taffeta PE palace crepe Conditions and others
Loom Q’ty 100 looms 100 looms 8 H/loom

Working PE Palace
Nylon taffeta
Weaver time Crepe
2 persons x 3 shifts 2 persons x 3 shifts
(Includes yarn supply 5 min. 0.7 Freq. 0.7 Freq.
= 6 persons = 6 persons
and doffing)
2 min. 1.0 Freq. 1.5 Freq.
Adjustment 1 x 3 shifts = 3 1 x 3 shifts = 3 Bobbin winder, looming, cleaning

Maintenance 1 x 1 shift = 1 1 x 1 shift = 1 after weaving are included.
Dryer 1 x 3 shifts = 3 1 x 2 shifts = 2

Inspector 3 x 2 shifts = 6 2 x 2 shifts = 4
Warper (1 set) 1 x 2 shifts = 2 1 x 2 shifts = 2
Sizing (2 sets) 2 x 3 shifts = 6 2 x 3 shifts = 6 Assist when creel is changed over.
Beaming (1 set) 1 x 2 shifts = 2 1 x 2 shifts = 2 Assist when creel is changed over.
Warp leasing
Automatic drawing 1 x 1 shift = 1 1 x 1 shift = 1 A concurrent job with beaming
machine
Drawing machine (2 x 1 shift = 2) (2 x 1 shift = 2)
A concurrent job with an auto-

Reed drawing machine (1 x 1 shift = 1) (1 x 1 shift = 1)
drawing machine
Size control
Warp preparation and
1 x 2 shifts = 2 1 x 2 shifts = 2 A concurrent job with reed and
maintenance
heald cleaning
Pirn winder 2 x 3 shifts = 6
Twisting 2 x 3 shifts = 6
Setting 1 x 3 shifts = 3
Jumbo winder 2 x 3 shifts = 6
Filling preparation and

1 x 2 shifts = 2
maintenance
Others 1 x 1 shift = 1 1 x 1 shift = 1 Boiler, electric, water disposal, etc.
Total 33 people 53 people
5-2
A802-1 June, 2012
3. Weaving Mill Planning Example [Loom: 100 units]
Factory facilities and conditions are shown below to control 100 looms.
3.1 Production Process

(1) Fabric: Nylon taffeta
Unit for thickness: dtex, density: per inch
N 78/17 N 78/24 1731
x x
48.5 x 2 75 6600
Raw warp yarn Creel Warper Sizing machine Beamer Beam carrier
Leasing Reed drawing

Drawing Beam stocker
machine machine
Bobbin winder Beam carrier
Cloth inspection
Raw filling yarn Loom Cloth roll carrier Dryer
machine
(2) Fabric: Polyester Palace Crepe

Unit for thickness: dtex, density: per inch
PEBR 56/36 S300T/M x PE 84/36 SZ2500T/M 1235
x
52 x 3 87 7586
Sizing
Raw warp yarn Pirn winder Double twister Creel Warper
machine
Beamer Beam carrier Leasing Drawing
Reed drawing Beam stocker

Beam carrier
machine
Raw filling yarn Pirn winder Double twister Setter Jumbo winder
Beam carrier Loom Cloth roll carrier Dryer
Bobbin winder Cloth inspection

machine
5-3
A802-1 June, 2012
3.2 Indication
(1) Example
Fabric name: Palace crepe
PEBR 56/ 36, S300T/M PE 84/36, SZ2500T/M 1235

x x
52 x 3 87 7586
A B C
A: Warp type, dtex/filament q’ty, Twist direction, Twisting number/meter

Reed dents/inch x warp ends per dent
B: Filling type, dtex/filament Q’ty, Twist direction, Twisting number/meter

Pick density/inch
C: Reeding width (mm)

Total warp ends
(2) Yarn type & symbol
N Nylon
PE Polyester
PEBR Polyester bright
PEW Polyester textured
5-4
A802-1 June, 2012
3.3 Calculating Conditions
No. Name Formula Nylon taffeta PE palace
1 Fabric Refer to the previous page. Refer to the previous page.
2 Loom ZW-190-1C, SDP ZW-170-2C, FDP
3 Loom rpm rpm 800 600
4 Loom efficiency EF % 98 95
Actual
5 ET % 96 93
efficiency
Working
6 days/month 28 28
days/month
800 x 60 x 24 x 28 600 x 60 x 24 x 28
rpm x min x hr x days
Monthly woven x 0.0254 x 0.96 x 0.0254 x 0.93
7 x 0.0254 x ET
length/Loom 75 87
Pick density
= 10487 = about 10500m = 6568.5 = about 6570m
Yarn Apparent
volume x specific gravity x 9000 [(800 - 20)2 - 1782] x p [(800 - 20)2 - 1782] x p
Denier x Warp Ends/inch
x 0.85 x 25.4 x 9000
Warp beam x 0.85 x 25.4 x 9000
8
winding mount Apparent specific gravity 4000 x 70 x 97 4000 x 50 x 156
Raw yarn: 0.85 = 12955 = about 13000m = 11278 = about 11300m
Finished yarn: 0.70
Warp Warping - Weaving - Finishing
9 7.5~8.0, 2.2~2.5 12~13, 9~11
contraction %
Beam winding amount x Pick density 13000 x 75 x (1 - 0.08) x 100 11300 x 87 x (1 - 0.13) x 100
Weaving days
10 x (1 - Contraction) x Loom q’ty 800 x 60 x 24 x 2.54 x 0.98 600 x 60 x 24 x 2.54 x 0.95
for a beam
rpm x min x hour x 2.54 x EF = 31.3 days = 41.0 days
Monthly woven length x (1 +

10500 x (1 + 0.08) x 100 6570 x (1 + 0.13) x 100
Number of Contraction) x Loom q’ty
11 13000 x 28 11300 x 28
beams/day Beam winding x Working
= 3.11 = about 3.2 pcs. = 2.34 = about 2.4 pcs.
length days/month
m/pcs. 52 57
Cutting roll q’ty 20 16
Daily doffing
12 Monthly woven 10500 x 100 = 36 rolls 6570 x 100 = 25.7
Q’ty
length/loom x Loom q’ty 28 x 52 x 20 28 x 57 x 16
days x cutting length x pcs. = about 26 rolls
Warp out loom Total loom q’ty 100 = 3.19 = about 3.2 sets 100 = 2.43 = about 2.5 sets
13
Q’ty/day Weaving days 31.3 41.0
5-5
A802-1 June, 2012
No. Item Formula Nylon taffeta PE palace

Warper Note (Creel spindles: 1200 pcs.)
Total warp ends of fabric 6000 7586
Yarn quantity on creel Beam q’ty on beamer 6 = 1100 spindles 7 = 1084 spindles
Warper’s beam > creel spindle 6 beams 7 beams
quantity/Loom beam m/min 400 m/min 400 m/min
A Yarn speed % 65% 65%
Monthly
Efficiency woven length
Unit quantity per loom x (1 + contraction) 10500 x (1+0.08) x 6 x 100 6570 x (1+0.13) x 7 x 100
x beam q’ty x loom Q’ty 400 x 60 x 24 x 28 x 0.65 400 x 60 x 24 x 28 x 0.65
Yarn speed x min. = 0.64 ...1 unit = 0.49 ...1 unit
x hrs. x days x efficiency
Sizing machine
Yarn speed m/min 150 m/min 150 m/min
Efficiency % 85% 85%
Unit quantity Monthly
B
woven length 10500x (1+0.08) x 6 x 100 6570 x (1+0.13) x 7 x 100
per loom x (1 + contraction) 150 x 60 x 24 x 28 x 0.85 150 x 60 x 24 x 28 x 0.85
x beam q’ty x loom q’ty
Yarn speed x min. = 1.32 2 units = 1.01 2 units
x hrs. x days x efficiency
Beamer
Yarn speed m/min 120 m/min 100 m/min
Efficiency % 50% 50%
Monthly
Unit quantity woven length
C
per loom x (1 + contraction) 10500 x (1+0.08) x 100 6570 x (1+0.13) x 100
x loom q’ty 120 x 60 x 16 x 28 x 0.5 100 x 60 x 16 x 28 x 0.85
Yarn speed x min.
x hrs. x days x efficiency = 0.70 1 unit = 0.55 1 unit
Beam carrier
Number of positions 7 positions
(Between beamer and loom)
D Operating time 0.25/H
Unit quantity Positions x hour 7 x 0.25 x 3.2 7 x 0.25 x 2.4
x required number of beams/day 24 24
Days = 0.20 ... 1 unit = 0.17 ... 1 unit
Leasing machine
Speed pc/min 200 200
Efficiency % 50 50
E Total warp ends 6600 x 3.2 7586 x 2.4
Unit quantity x required number of beams/day
200 x 60 x 24 x 0.5 200 x 60 x 24 x 0.5
Speed x min.
x min. x hrs x efficiency = 0.15 ... 1 unit = 0.13 ... 1 unit
Auto drawing-in machine

Efficiency % 60 60
F-1 Unit quantity Total warp ends 6600 x 3.2 7586 x 2.4
x required number of beams/day
Speed x min. x hrs x efficiency 150 x 60 x 8 x 0.6 150 x 60 x 8 x 0.6
= 0.49 ... 1 unit = 0.42 ... 1 unit
Drawing-in machine
Speed pc/min 80 80
Efficiency % 60 60
F-2 Total warp ends
Unit quantity x required number of beams/day 6600 x 3.2 7586 x 2.4
= 0.92 ... 1 unit = 0.79 ... 1 unit
5-6
A802-1 June, 2012
No. Item Formula Nylon taffeta PE palace

Reed drawing-in machine
Speed pcs/min 100 100
Efficiency % 50 50
G Unit quantity Total warp ends 6600 x 3.2 7586 x 2.4
x required number of beams/day
Speed x ends/dent x min. x hrs x 100 x 2 x 60 x 8 x 0.5 100 x 3 x 60 x 8 x 0.5
efficiency = 0.44 ... 1 unit = 0.25 ... 1 unit
Tying machine
Efficiency % 50 50
H Total warp ends
Unit quantity x required number of beams/day 6600 x 3.2 7586 x 2.4
= 0.22 ... 1 unit = 0.18... 1 unit
Beam stocker (Beam q’ty
I = number of looms x 1.5) 50 - 10 50 - 10
(Spare beams) - (Beams in use) = 40 ... 40 beams/stocker = 40 ... 40 beams/stocker
Cloth roller carrier
Operating time min/time 6 6
Operating time x frequency /day
J 6 x 36 6 x 26
min. x hrs
60 x 24 60 x 24
= 0.15 ... 1 unit = 0.1 ... 1 unit
Cloth roll stocker (Cloth roll q’ty
= number of looms x 1.5) Empty rolls: 25 pcs & Empty rolls: 25 pcs &
K 1/2: being dried, 1/2: empty rolls Rolls being dried: 25 pcs Rolls being dried: 25 pcs
must be stored. must be stored.
Selvage bobbin winder 1/2 (47+19) x p x 2600 rpm
1000
Average yarn speed = 269 m 269 m/min 269 m/min
Efficiency % 70 70
Monthly
Unit quantity
L woven length
per loom x (1 + contraction) 10500 x (1+0.2) x 4 x 100 6570 x (1+0.2) x 4 x 100
x bobbin q’ty x loom q’ty 28 x 269 x 60 x 8 x 2 x 0.7 28 x 269 x 60 x 8 x 2 x 0.7
Days x yarn speed x min. = 0.99 ... 1 unit = 0.62 ... 1 unit
x hrs. x spindle number x
efficiency
Drying machine
Speed m/min 40 50
Efficiency % 80 80
Monthly
M Unit quantity woven length
per loom x loom q’ty 10500 x 100 6570 x 100
Yarn speed x min. 40 x 60 x 24 x 28 x 0.8 50 x 60 x 24 x 28 x 0.8
x hrs. x days x efficiency = 0.81 ... 1 unit = 0.81 ... 1 unit
Cloth inspection machine
Speed m/min 25 25
Efficiency % 60 60
Monthly
N Unit quantity woven length
per loom x loom q’ty 10500 x 100 6570 x 100
Yarn speed x min. 25 x 60 x 16 x 28 x 0.6 25 x 60 x 16 x 28 x 0.6
x hrs. x days x efficiency = 2.6 ... 3 units = 1.63 ... 2 units
5-7
A802-1 June, 2012
4. Other Equipment
(1) Calculation of the required number of double twisters

1) For warp yarn
Rotating speed of spindle 10000 rpm

Conditions
Efficiency 90%
Unit quantity = Loom’s warp speed (m/min) x Total number of warp ends x Efficiency x Loom Q’ty
Double twister’s yarn speed (m/min) x Efficiency x Number of spindles/unit
25.4 x Loom rpm

x Total number of warp ends x Efficiency x Loom Q’ty
1000 x Pick density (picks/inch)
=
2 x Spindle rpm x Efficiency x Spindles/loom x (1 - Contraction after twisting)
Twist/meter
25.4 x 600 x 7586 x 0.93 x 100

= 1000 x 87 = 8 sets
2 x 10000 x 0.90 x 256
300
2) For filling yarn

Rotating speed of spindle 15000 rpm
Conditions Efficiency 95%
Contraction 20%
Loom’s filling speed (m/min) x Efficiency x Loom Q’ty

Unit quantity =
Double twister’s yarn speed (m/min) x Efficiency x Number of spindles/unit
0.01 x (Reeding width + Waste selvage yarn x Contraction)(cm)

= x Loom rpm x Efficiency x Loom Q’ty
2 x Spindle rpm
x Efficiency x Spindles/loom x (1 - Contraction after twisting)
Twist/meter
= 0.01 x (123.5 + 5 x 1.01) x 600 x 0.93 x 100 = 31 sets

2 x 15000 x 0.95 x 256 x (1 - 0.20)
2500
S-twist: 15.5 sets, Z-twist: 15.5 sets
[Reference]
Contraction after twisting
Number of Yarn type
twist PE 56 dtex PE 84 dtex
1000 T/M 2% 3%
2000 T/M 10% 15%
3000 T/M 20% 30%
Contraction after weaving

Twisted textured yarn
1% Note: Loss of yarns during weaving and
Twisted raw yarn
preparation is not considered.
5-8
A802-1 June, 2012
(2) Calculation of the required number of pirn winder
Yarn speed (m/min) 500 m
Conditions
Efficiency 90%
(Double twister’s)
30 days x (1 + Contraction)
Unit quantity = Number of spindles x Yarn speed x 24 x Efficiency x
(Rewinder’s) Yarn speed x 24 x Efficiency Working days
1) For warp yarn
2048 x 2 x 10000 x 24 x 0.90

300 x 30 = 292 spindles
500 x 24 x 0.90 28
Required number of spindles = 292 = 2.92 sets = about 3 sets

Spindles/unit 100
2) For filling yarn
2 x 15000 x 24 x 0.95
7936 x
2500 x 30 x (1 + 0.2) = 259 spindles
500 x 24 x 0.90 28
Required number of spindles = 259 = 2.59 sets = about 3 sets

Spindles/unit 100
(3) Calculation of the required number of cylinders of the double twister / day
1) Production (g) / day / spindle
Yarn
thickness (d) x Yarn speed (m/min) x 60 x Operating time x Efficiency x (1 + Contraction)
9000
= Yarn thickness (d) x 2 x Spindle RPM x 60 x 24 x Efficiency x (1 + Contraction)

9000 x Twist/m
= 75 x 2 x 15000 x 60 x 24 x 0.95 x (1 + 0.2)

9000 x 2500
= 164.16 (g)
2) Total production (kg) / day
Production/day/spindle x Number of spindles

1000
= 164.16 x 7936
= 1302.77 (kg)
1000
3) Required number of cylinders / day produced by the double cylinder

When 1 kg cylinder is used: 1302.77 ... 1303 cylinders
5-9
A802-1 June, 2012
Item Formula Nylon taffeta PE palace

Pirn winder As for the formula, refer to
Section 4. (2).
P For warp (Rewinder) 292 spindles: 3 sets
For filling (Rewinder) 259 spindles: 3 sets
Double twister As for the formula, refer to
Section 4. (1).
Q
For warp (Double twister) 8 sets
For filling (Double twister) 31 sets
Set box (Marui Model SC-1060
1303 pcs.
Cylinder storage/day 120 pcs.
Number of cylinders As for the formula, refer to 1303 x 2 = 0.90 ... 1 set
R Section 4. (3). 120 x 24
Produced number/day
x Time (includes transport)
Stored number x hrs
Jumbo winder
Yarn speed m/min 500
Efficiency % 85
Double twister’s yarn speed x
Unit quantity
S Number of spindles x Efficiency
2 x 15000
Winder’s yarn speed x Efficiency x 7936 x 0.95
x Set number of spindles 2500
500 x 0.85 x 24
= 8.87 ... 9 units
Reed & heald cleaning
Capacity/time Heald: 20 frames,
Reed: 3 pcs.
Time 2 hours/time
T Frequency Warp-out loom Q’ty x Number 3.2 x 4
of pcs of heald frames and reeds 20 x 1 2.5 x 6
Capacity x frequency = 0.60 ... once/day 20 x 1 = 0.75 ... once/day
Reed: 3 Reed: 2 - 3 pcs.
On-loom heald or reed Frequency: arbitrarily 1 set 1 set
U cleaning machine
Electric installation Main motor 2.2 kW 2.2 kW

capacity Suction blower 301 AZ (60Hz) 301AZ (60Hz)
X (3.24 + 0.51 + 0.62 + 0.60 + (3.24 + 0.51 + 0.36 + 0.62
Installation capacity kVA 0.10) x 100 + 20 +0.60 + 0.10) x 100 + 20
=527 = 563
Water installation capacity
Cylinder Dia. (mm) 18 22
Pump stroke (mm) 10 10
As for the formula, refer to 3.14 x 182 x 10 x 800 x 60 x 24 3.14 x 222 x 10 x 600 x 60 x 24
Section 3. (3) in Chapter 1. 4 x 109 4 x 109
ton/loom x 0.98 =2.87 x 0.95 = 3.12
Y Max. required water - Pump stroke: 12
amount - Efficiency: 100% 3.14 x 182 x 12 x 800 x 60 x 24 3.14 x 222 x 12 x 600 x 60 x 24
4 x 109 4 x 109
Installation capacity Required water amount x = 3.52 = 3.94
1.38 x number of looms
(Refer to Section 3.(3) = ton/All looms 3.52 x 1.38 x 100 3.94 x 1.38 x 100
in Chapter 1.) = 487.76 ... 490 = 543.72 ... 550
5-10
A802-1 June, 2012
ZW8100 Water Jet Loom
Installation Guide
A802-1 June, 2012
TSUDAKOMA Corp.
18-18 Nomachi 5-chome, Kanazawa
921-8650 Japan

ZW8100 Water Jet Loom Installation Guide

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ZW8100 Water Jet Loom Installation Guide

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ZW8100 Water Jet Loom

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For Further Inquires:

Chapter 1: ZW Technical Information

1. Deciding Specifications ..........................................................................1-1

2. Weaving Range ......................................................................................1-2

3. Capacity Of Water Facilities ...................................................................1-3

4. Water Quality Standard ..........................................................................1-4

6. Woven Fabric Example ..........................................................................1-6

7. Woven Length & Loom rpm ...................................................................1-9

Chapter 2: Factory Layout

2. Foundation Drawing & Installation Drawing (Excerpt)............................2-2

3. Foundation Standard ..............................................................................2-4

4. Noise & Vibration..................................................................................2-10

6. Laying LAN For TLM ............................................................................2-19

7. Interior Conditions ................................................................................2-24

Chapter 3: Accessories & Supplies

1. Accessory Selection ...............................................................................3-1

2. Preparation For Looming........................................................................3-4

3. Preparation For Starting .........................................................................3-9

1. Loom Dimensions & Mass......................................................................4-1

2. Loom Installation & Trial run...................................................................4-4

3. Lubrication [Recommended Oil Chart] ...................................................4-6

Chapter 5: Weaving Mill Planning Example

1. Loom Assignment ...................................................................................5-1

2. Operation Arrangement Of A Plant With 100 Looms ................................5-2

3. Weaving Mill Planning Example [Loom: 100 units] ................................5-3

4. Other Equipment ....................................................................................5-8

1. Deciding Specifications ..........................................................................1-1

2. Weaving Range ......................................................................................1-2

3. Capacity Of Water Facilities ...................................................................1-3

4. Water Quality Standard ..........................................................................1-4

6. Woven Fabric Example ..........................................................................1-6

7. Woven Length & Loom rpm ...................................................................1-9

To determine the specifications:

Determine weft selection.

Desired production amount

Determine the desired loom RPM.

2.1 Weft Type & Thickness

2.2 Pick Density

(2) Upper limit of the pick density:

2.3 Warp Density

(1) Water consumption

(2) Capacity of water facilities

(3) Required water amount corresponding to loom rpm

Pump cylinder per pick Loom rpm (rpm)

1) Calculation for the required amount of water (for one loom)

Required water amount (ton)

Note: 1.38 = 1.15 (allowance) x 1.2 (daily use, leakage, etc.)

3) Appropriate water pressure

(1) Yarn type

(2) Fabric construction

(3) Loom specifications

(4) Woven fabric examples

Fabric Construction Specifications

PEW 84/36 x PEW 84/36

PEW 56/72 x PEW 56/72

Palace PEBR 56/36 x PE84/24, Z1000T/M 1C-S

Blended filament habutae 84/48 x 84/36

Fabric Construction Specifications

PEBR56/36, S300T/M x PE84/72, SZ2700T/M

PEBR56/36, S300T/M x PE84/36, S3000T/M

Fabric Construction Specifications