RX300 Installation Manual ENG

Model RX300 RING SPINNING FRAME
Installation Guide
(FIRST EDITION)
Thank you for purchasing the RX300 Ring Spinning Frame.
This instruction manual describes the correct installation, operating principles, function, adjustment, and maintenance of
the RX300 motions, all of which should be familiar to all personnel concerned.
Before operating, adjusting, or maintaining the RX300, be sure to read this manual carefully to understand the RX300.
Always keep this manual in a safe and fixed place.
If you have any questions concerning the machine, please contact us at the following locations:
HEAD OFFICE: TOYOTA INDUSTRIES CORPORATION

TEXTILE MACHINERY SERVICE DIVISION
1, Toyodacho 2-chome, Kariya-shi, Aichi, 448-8671 JAPAN
PHONE: +81 566 22 2511
FACSIMILE: +81 566 27 5679
INDIA: KIRLOSKAR TOYODA TEXTILE MACHINERY (P) LTD.

Plot No.10-13, Phase Ⅱ, Jigani Industrial Area
Anekal Taluk, Bangalore District, Karnataka-562 106, INDIA
Tel：+91(080)7826201 to 06
Fax：+91(080)7826207
E-mail: kttml@kttml.com
Specifications, operating instructions, and dimensions in this manual are subject to change for improvements without
prior notice.
TOYOTA shall take no responsibility for loss, damage, expense or claims for bodily injury or property damage arising
from incorrect usage which is not in accordance with the instructions given in this manual.
In no event will TOYOTA be liable for products resulting from the use of this machine.
Your manual may not contain all of them since it is edited to conform to the specifications of the spinning
frame you have purchased.
Each chapter gives the outline of the mechanism and its sketch, which are followed by the details consisting of
description and photos/sketches.
One of the follwing titles will be prefixed to each description:
, , NOTE:, OUTLINE:, FUNCTION:, OPERATION:, ADJSTMENT:, and

REFERENCE:.
(1)
The safety alert symble is used in this manual, alerting you to a situation that might cause serious
injury or death to the operator if he or she does not follow the instructions in this manual necessary to avoid any
dangers in the machinery.
(2)
The safety alert symble is used in this manual, alerting you to a situation that might cause minor
injury to the operator if he or she does not follow the instructions in this manual necessary to avoid any dangers in
the machinery.
(3) NOTE:
The NOTE: mark is used here, alerting you to possible damage to the machinery if the operator fails to follow the
instructions in this manual.
(4) OUTLINE:, FUNCTION:, OPERATION:, ADJSTMENT:, and REFERENCE:
These marks have been adopted in order to help the operator understand the contents of this manual.
■ Abbreviations and Notations

This manual uses the following notations for clarity purposes.
• Ring spinning frame, model RX300 RX

• Stationary cop doffer installed on RX300 SCD
• Bobbin exchanger connected to the RX300 ring spinning frames TBC
• Gear-end frame of RX300 GE
• Out-end frame of RX300 OE
• Middle-head of RX300 MH
• RX300 ring spinning frames consisting of OE, MH and GE 3-head version
• RX300 ring spinning frames consisting of OE and GE only 2-head version
• 2-head frames with the OE auxiliary gearing Long frame
• 2-head frames without the OE auxiliary gearing Short frame
Contents
CHECK SHEET FOR PREPARATION OF RX INSTALLATION(for sending back) ㌀
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㌀㌀1
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Chapter S Safe Work ㌀

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S.1 Safe Work ㌀
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S.1.1 Rules for Installation Work ㌀
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S.1.2 Rules for Safe Operation ㌀㌀㌀
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S.1.3 Rules for Maintenance ㌀㌀
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S.1.4 Rules for Operating or Checking the Electrical Devices ㌀㌀
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Chapter 1 Preparation for Installation ㌀

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1.1 Building ㌀
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1.2 Foundation work ㌀
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1.3 Structure of foundation (2-head version for your reference)㌀
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1.4 Structure of foundation (3-head version for your reference)㌀
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1.5 Laying the foundation for wiring andpiping ㌀
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1.7 Wiring ㌀
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1.7.1 In-plant Electric Facilities ㌀
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㌀㌀㌀46
Chapter 2 Procuring Installation Tools ㌀

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2.6 Preparing general tools ㌀
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Chapter 3 PREPARATIONS FOR OPERATION ㌀

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3.1 Item Requuired for Spinning ㌀
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3.3 Bobbin Drawings Used for RX (Reference) ㌀
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3.5 TBC Full Bobbin Box Diagram㌀
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3.6 Peripheral Units ㌀
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Chapter 4 OTHER DEVICE ㌀

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4.1 TMS (TOYOTA MONITORING SYSTEM) ㌀
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4.1.2 Network Connection Concept ㌀㌀㌀㌀㌀㌀
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4.1.5 Wiring Sample Diagram ㌀㌀㌀㌀
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4.1.7 Network Cable Connection to RX300 ㌀㌀㌀㌀
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CHECK SHEET FOR PREPARATION OF RX INSTALLATION(for sending back)
CHECK SHEET FOR PREPARATION OF RX

INSTALLATION(for sending back)
1
Chapter S Safe Work
Chapter S Safe Work
S.1 Safe Work

There is no such thing as a perfectly safe machine when
improper handling or ignoring precautions stands in the
way. Any incorrect usage could possibly result in a
serious bodily injury, in the worst case it could cause
death, and/or substantial property damage.
TOYOTA has made every effort to assure as safe work as

possible, which cannot be completed, however, without
your understanding and cooperation.
It is impossible for the manufacturer to take into account

individual operating conditions of the machinery at the
user site and prepare an instruction manual covering all
information relating to the machine operation. We,
therefore, ask you to establish your own individual safety
standards for each safe job of installation, operation,
adjustment, and maintenance.
2
Chapter S Safe Work
S.1.1 Rules for Installation Work

[1] Before Installation
(1) Check the safety rules and the workmanship standards for the plant.
(2) Make sure that all personnel involved know the nature of the job and the installation procedure, and agree as
to the best way to get them done.
(3) Make sure that all personnel involved know the nature of the job and the installation procedure, and agree as
to the best way to get them done.
(4) For jobs requiring a group effort, agree beforehand on words or gestures for giving and confirming signals.
(5) Wear safety shoes.
(6) Check the work places and their surroundings. If any unsafe point is found, take the necessary action to
make it safe.
1. When foundation bolts, power cable conduits

and air inlet piping are spread out before
installation, mark them clearly with brightly
colored cloth or a flag so that workers can avoid
tripping or hitting the RX and carriers against
them during installation.
2. If there is any unstable footing due to any pits

(for exhaust, piping, wiring, or other purposes)
which are dangerously uncovered, put on a
temporary cover to prevent falling accidents.
3. Use specified tools matched to the job to be
done.
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Chapter S Safe Work
[2] During Installation

[2.1] General Points for Installation Work
(1) Always wear a helmet whenever installation is
being carried out at the same time as other jobs,
such as construction and piping.
(2) Always wear gloves whenever there is the
possibility of injuring hands or fingers.
(3) Never use gloves if there is the possibility of

their becoming caught in a rotating section of
the RX.
(4) Never get oil or grease on the floor, since these
can cause slipping accidents.
(5) Always provide a stable platform or scaffold
for those jobs in places too high to reach from
the floor.
(6) Never climb onto a heavy hoisted object nor get

under it.
(7) Keep your tools, parts, devices and instruments
neatly arranged, and observe the following
rules:
1. Put them where they are not likely to fall
down.
2. Whenever standing or leaning them against
something else, do what is necessary to
prevent them from falling over.
3. Whenever piling round bars or pipes, do
what is necessary to prevent them from
falling down.
(8) Observe the following rules when conducting a

group effort:
1. Choose a supervisor whose instructions
should be followed thoroughly by all.
2. Agree beforehand on words or gestures for
giving and confirming signals.
3. Be especially careful when handling heavy
objects. If the weight exceeds 20 kg, two or
more workers should handle them.
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Chapter S Safe Work
[2.2] Transport
(1) Check out the transport route beforehand;
thiswill give you a chance to minimize
obstacles, bumps or slopes.
(2) Before bringing in machinery, always prepare
well-maintained carriers.
(3) When unloading the machinery from a truck,
be sure to:
・use a fork lift with sufficient load capacity (3
ton or more)
・secure long packages with ropes or belts to
prevent the machinery from falling down or
toppling.
(4) Never lift the load on the carriers any higher

than 200 mm above the floor.
(5) Never stand in small spaces between the load
and wall during transportation.
(6) Always assign a guide and transport according
to his or her instructions. The guide should pay
sufficient attention to any protruding parts,
bumps or slopes on the transport route.
(7) Whenever inserting wooden blocks under the
load, never let fingers get between the load and
floor.
(8) Always push hand carts when carrying loads.

Never pull them.
(9) Fix the load with ropes or other means if
necessary, to prevent the load from falling
down during transport.
(10) Always lift up the GE using ropes or belts from
the front door side (since the center of gravity
lies at the front door side), in order to prevent
the frame from falling down.
(11) When transporting the intermediate units with a fork lift, be sure to check that the fork catches the skid
and balances it securely.
(12) When using a dedicated hoisting carriers or transporting tools, make sure that the transporting beam holds
the spindle rail of the intermediate units and balances them securely.
(13) Heavy components including spring pieces, spindle rails, roller beams and fluted rollers, and long
components
including draft rods and tin pulley shafts are palletized or packed in boxes.
When bringing these in with a fork lift or cart, secure them with ropes if necessary, in order to prevent
them from falling down.
(14) Heavy components including main shafts and doffing bars are packed in boxes. When bringing these in
with a fork lift or cart, secure them with ropes if necessary, in order to prevent them from falling down.
(SCD specification)
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Chapter S Safe Work
[2.3] Unpacking and Cleaning
Never apply gasoline or other volatile cleaning agents for cleaning.
(1) Parts are coated with rust-preventive oil.

Take necessary action so they will not slip
when carrying them.
(2) When washing parts, use waterproof paper to
prevent the floor from becoming stained.
(3) Use Nippon Oil Corporation New-sol Delux or
an equivalent cleaning fluid.
Never use trichloroethylene-base cleaning
fluid; otherwise the painting will peel off or
discolor.
(4) Never put anything on the parts storage area,
passages, or footing area.
Never pile up spring pieces, spindle rails or
draft rods any higher than three layers.
When temporarily storing tin pulley shafts,
creel pillars, and other parts, make sure they are
secured and will not fall down.
(5) Watch out for stray nails or tie hoops which
may come out during unpacking.
Do not step on them or hurt yourself with them.
[2.4] Handling Heavy Components

When handling heavy components as given below, work in a comfortable position. If the weight exceeds 20
kg, two or more workers should handle it.
・ GE ASSYs, spring pieces, draft rods, spindle rails, OE ASSYs, tin pulley shafts and MH ASSYs
・ Main shaft, and doffing bar (SCD specification)
[2.5] Handling Long Parts
(1) Long parts should be placed so that they will not fall. If necessary, provide anti-slipping measures or
protective fences.
(2) Pay attention to the surroundings when handling long parts as given below. If one person is not enough,
have several workers handle them.
・Draft rods, spindle rails, tin pulley shafts, ring plates, fluted rollers, line shafts, traverse bars, wire
ducts, pneumatic ducts, roving pipes, creel pillars & rails, lappet angles, and tension pulley shafts etc.
・Doffing bar, tilting rod, main shaft, etc. (SCD specification)
[2.6] Working in Low Positions
(1) In working with adjustment bolts in a low position, be careful when standing up so as not to drop
straightedges and parallel rulers which may cause injury.
(2) When centering the tin pulley shafts or installing the tin pulleys and line shafts in a bent over or low
position, keep communicating with co-workers through words or gestures. Be careful when standing up,
not to injure your head.
(3) In working with tray rails in a low position, be careful when standing up so as not to injure your head and
upper part of your body. (SCD specification)
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Chapter S Safe Work
[2.7] Assembly and Adjustment

(1) Rough assembly
1. When removing skids from the GE head, OE head, and MH, communicate with co-workers
sufficiently to prevent hands from becoming crushed.
2. When using the dedicated transporting tools for approaching the intermediate units to the adjacent
units or GE/OE heads and MH, move the intermediate units slowly and carefully. Link the RXs as
a team and communicate with co-workers sufficiently to prevent hands from becoming crushed.
(2) Levelling the RX
1. When using straightedges, parallel rulers, or levellers, be careful not to drop them onto the workers
below, who are busy with the adjustment bolts. Never attempt to move these devices alone or in a
strained position.
2. When moving straightedges, parallel rulers, or levellers, be sure to do so together with the aid of
coworkers.
(3) Installing the tin pulley shafts
When using, moving or setting dedicated tools for centering the tin pulley shafts or positioning tin
pulleys, be careful not to drop any of these on your feet.
(4) Installing the creel parts
1. Watch your step when climbing onto or off of the RX or any platforms used. Also, use only platforms
which are sufficiently stable and sturdy.
2. When workers are busy below, never install the creel rails or bobbin hangers since those components
are always installed above. Dropping parts or tools can cause injury to those below.
(5) Installing the roller parts
1. When connecting the rollers, fix the connecting tools securely with no danger of slipping, onto the
fluted rollers.
2. When installing the bottom rollers onto the roller stands, do so as a team and assign a leader,
communicating with words or gestures.
(6) Heat-bonding the spindle drive belts
For belt bonding, use a heater. Be careful with the heater, which can reach temperature of from 80°C
to 90°C.
(7) When installing the doffing bars, main shafts, and tilting shafts, work as a team and never
try one-man operation in a difficult position. (SCD specification)
(8) When installing the timing belts, take care to prevent hands from becoming crushed. (SCD specification)
(9) Wiring
1. Never allow non-qualified workers to carry
out connection or disconnection of the
primary power lines.
2. Before starting wiring work, be sure to
check that the main circuit breaker is open
and the warning notice (tag) is put up for
all to see.
3. Before starting wiring work, make sure
that the lines are not alive or no voltage is
applied to the lines.
4. Make sure that the grounding wire pro-
vided on the plant's power supply is
connected to the PE terminal inside the
control box.
7
Chapter S Safe Work
[3] Before Trial Running

(1) Clear away bolts, nuts, tools and other unnecessary things around, on and under the RX.
(2) Check that all sections of the RX are securely tightened and that the safety covers are on.
[4] During Trail Running

(1) Rotate the drive belts and chains on each of the drive sections manually to check for fraying, breaks or other
damage. Make sure to communicate clearly with co-workers so that no one’s hand becomes caught in
running belts or chains.
(2) Check the wiring and routing of the RX are correctly made.
(3) Check the rotation direction for: the suction motor, doffing motor, and fan motor.
(4) Check the functions of each of the stop motions and limit switches.
(5) When starting the RX, communicate your intention to co-workers, and wait for them to confirm it. Then,
check that the RX starts and stops normally.
(6) When adjusting the tape tension pulleys while they are rotating, do so in a careful, comfortable position.
(7) For centering of the spindles, first stop the RX and center them while turning the running parts by hand.
Never do this while the RX is in operation; it is extremely dangerous.
(8) Never reach out towards the reciprocating sections activated by the air cylinder in the peg tray transporting
unit. (SCD specification)
(9) When checking the rotating sections (e.g., pulleys, gears, and shafts) for abnormal vibration, noise, or heat
of bearings, never touch those sections. (SCD specification)
8
Chapter S Safe Work
S.1.2 Rules for Safe Operation

[1] General Rules
[1.1] Absolute Precautions
(1) Never allow non-qualified workers to carry out
connection or disconnection of the primary
power lines.
(2) Never try any hot-line job when changing the
wiring on the RX.
(3) Never start the RX without communicating
your intention to co-workers or without
confirming their answer to your signal.
(4) Never touch rotating or operating parts until the
RX comes to a complete stop.
In the automatic doffing operation, be careful
even if those moving parts seem to have
stopped. The RX may stop temporarily, but it is
still dangerous.
(5) Never operate the RX in clothes which could
become entangled in the rotating parts.
(6) Never remove a warning notice, caution plate
or instruction plate from the RX, no matter
what.
[1.2] Handling Abnormal Situations

(1) Always turn the power off before making any adjustments or repairs to correct abnormalities occurring
during operation.
(2) If you turn off the RX, be sure to put up the warning notice on the power switch.
(3) The temporary warning notice should be removed only by the person who put it up, once it has become
unnecessary.
[1.3] Other Precautions
(1) The supervisor should understand these safety rules given in this section and make sure that each worker
sufficiently observes them, for ensuring safe work and operation.
The supervisor should always keep in mind that if any of these safety rules is not observed, serious injury
or death might be caused to the related workers.
(2) Observe the safety regulations enforced in the destination country for the RX.
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Chapter S Safe Work
[2] Precautions for Spinning

[2.1] Starting
When two or more workers are to handle jobs, they must always communicate with words or gestures before
starting up the RX.
[2.2] During doffing
(1) No one other than the person in charge must take recovery action if any of the electrical parts in the
control box operates so as to cause the SCD or RX in operation to either stop or become non-workable.
(2) While the SCD or RX is in operation:
1. Never touch the running portion.
2. Never reach out towards the reciprocating sections activated by the air cylinder in the peg tray
transporting unit.
3. Never open or remove any of the safety covers.
4. Never try to remove yarn or fly.
(3) When the doffing bar is in operation, never stand in the area between the RXs.
(4) If the RXs equipped with an SCD come to full-bobbin state, immediately go out of the area between those
RXs.
(5) If it is unavoidable to put roving carts or other carriers into the area between the RXs, be sure to check
that those RXs will not come to full-bobbin state soon. Also, be careful not to bump those carriers against
the SCD when travelling through.
(6) Do not operate the SCD or RX in these types of clothes:
1. Never touch the running portion.
2. Never reach out towards the reciprocating sections activated by the air cylinder in the peg tray
transporting unit.
3. Never open or remove any of the safety covers.
4. Never try to remove yarn or fly.
(7) Never put scissors or tools in a non-flap breast pocket.
(8) Never restart the SCD or RX without permission if it is stopped by:
1. A person in charge of maintenance
2. A patrol inspector
3. A person in charge of lubrication
4. Other responsible people
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Chapter S Safe Work
[2.3] Other Precautions

(1) When removing fly or fleece entangled around
the top rollers, remove the top roller from the
RX or hold it in one hand. Be careful that fly or
fleece removed from the element never falls
onto your feet or the rotating section.
(2) Put on a gauze mask in the room when the

machine is in operation. There will be a lot of
invisible fly, fleece or yarn particles floating
around.
(3) Put on a pair of ear plugs to protect your ears

from noise when working around operating
machines for a long time. When the RX is in
operation, the noise level usually exceeds 70
dB (A).
(4) Be sure to clean the machine to prevent fire as

follows:
・Periodically wipe off fly or fleece accumu-
lating around the motors. Even though the
thermal sensor works if the motor tempera-
ture exceeds the specified level, this is no
excuse to neglect any cleaning.
・Periodically remove fly or fleece accumulat-
ing around the magnet switch and its
surroundings in the control box, using a
vacuum cleaner. When activated normally,
the magnet switch will spark which could
result in fire if fly or fleece accumulates
around the magnet switch.
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Chapter S Safe Work
S.1.3 Rules for Maintenance

[1] Before Maintenance Work
[1.1] Checking the Work Procedure
Check the work procedure with co-workers in advance. Be sure to inform the spinning operators that the RX is
to be stopped, and always put up the maintenance notice on the power switch.
[1.2] Checking the Tools
Select and inspect the tools for the job purpose. Use spanners and wrenches suitable for the sizes and locations
of bolts and nuts.
[1.3] Keeping Things Neat and Tidy
Determine the storage location for disassembled parts, making sure that passages are clear for frame operators.
[2] Precautions for Maintenance Personnel

(1) If you stop the RX for maintenance, be sure to
put up the warning notice saying “DON’T
TURN THE SWITCH ON.”
(2) Never put tools or any items on top of the RX
whether it is in operation or on halt.
Otherwise, they may fall into the frame, causing
damage or bodily injury.
(3) Never use compressed air for cleaning your skin
since it may cause infection at an open wound.
(4) Lubricant, paint, bond, sealing agent or deter-

gent may damage skin or eyes. Always wear
suitable protection such as safety gloves and
goggles when using such materials.
If any of these come into contact with skin or
eyes, wash them with water immediately and
seek medical treatment.
When using any washing solution, always
ventilate the room sufficiently.
Follow the instructions provided by the material
manufacturer or supplier.
(5) For any work which could damage the eyes,

always wear safety goggles.
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Chapter S Safe Work
[3] During Maintenance Work

[3.1] Maintenance
(1) Installing or removing the parts inside the GE ASSY
1. Since the GE ASSY incorporates a variety of automatic devices, be sure to stop the RX in the
reference position, so that parts will not have to be forced in or out.
2. Parts can easily become slippery due to grease, oil, fly or fleece, so clean them off as thoroughly as
possible and hold them securely, preventing dropping and injury.
(2) Installing or removing the motor pulleys, timing pulleys, and driving pulleys
1. When installing or removing the flat belts or timing belts, be careful not to get your hands caught in
the belts.
2. Since the pulleys are heavy, install or remove them in a comfortable position.
(3) When removing the motors and impellers from inside the filter box, do so in a comfortable position,
communicating with co-workers.
(4) When adjusting the tape tension pulleys during operation, make sure that your hand does not directly
contact the dangerous rotating section, and work in a comfortable position.
(5) When replacing broken spindle tapes, be sure to stop the RX; otherwise, those tapes may become
entangled in the tin pulleys.
(6) Installing or removing tin pulley shafts require the workers to operate in a difficult squatting or bending
position; communicate with co-workers during the job. Also, be careful of your head and body.
(7) Since the power cylinder is heavy, install or remove it in a comfortable position.
(8) When adjusting the peg tray, be sure to stop it.
(9) When adjusting the timing belt of the doffing bar, be sure to clamp the main shaft with a stopper in order
to prevent the doffing bar from falling down.
(10) When the surface of the resin product has become dirty, remove the dirt lightly with a soft cloth soaked in
neutral detergent the density of which has been made about 200 times lower with water. (The surface
may crack, depending on the ingredients or density of the detergent.) Never use a cleanser, alkaline
detergent, scrubbing brush, or a hard cloth.
[3.2] Lubrication
(1) Make sure that the RX has stopped before greasing of the bearings or gears.
(2) Always wipe up oil spilled on the floor after supplying oil to the oil bath.
(3) Waste oil drained from the oil bath should be disposed of in containers specified by the plant.
13
Chapter S Safe Work
S.1.4 Rules for Operating or Checking the Electrical Devices
The capacitor, inverter, servo amplifier and control power supply board of the main circuit of the
machine are charged, and they remain at a high voltage for a while after the main circuit breaker
(CB1) is turned off. Any operation must be waited until you make sure that CHARGE LEDs of all
inverters and servo amplifiers turn off after at least three minutes from turning the main circuit
breaker off.
Also, before starting an operation, measure the voltage of parts which may be touched and ensure
safety.
(1) All operating and checking jobs must be carried out by persons with appropriate special qualifications (e.g.,
duly trained persons or electrical experts).
(2) Always turn off the main switch before opening the control box.
(3) After turning off the main switch, be sure to put up the warning tag “DON’T TURN THE SWITCH ON” on
the main switch.
(4) Handle an electrical component or part only when no power is supplied to it. Note that the primary side
terminals of the main switch are applied with a voltage even when it is turned off.
(5) Voltage application may be needed for checking control system functions. Be especially careful when
conducting such a job.
(6) Use the measuring devices and tools, all kept in proper condition.
(7) When connecting the power supply to the loom, always connect the protective wire (green or yellow/green
spiral) first to the PE terminal. For disconnection, be sure to disconnect the protective wire last of all.
(8) During electrical installation work, the observer responsible for security of the workers must absolutely,
without fail, attend at the field. The observer should be limited to someone with know-how concerning
electrical troubles.
(9) Never try to modify an electrical unit or device because it may cause a malfunction or accident.
If it is inevitable, please consult with us.
(10) Precautions for disposal of components
When disposing electrical components or wires, they should be separated from general garbage for disposal.
Due caution is needed especially for disposal of items below.
1. LCD panels and backlight
The backlight, a component of the function panel, contains mercury.
Upon disposal, comply with applicable ordinances or regulations.
2. Batteries
EU Directives: 2006/66/EC
The symbol illustrated indicates the need for handling batteries (including accumlators)
separately from general garbage for disposal.
Batteries (including accumulators) contain substances harmful to the environment and
human body.
In case chemical symbols are displayed below the illustrated symbol, the battery (or
accumulator) contains heavy metals above the standard concentration level.
The following is the standard:
Hg: Mercury (0.0005%), Cd: Cadmium (0.002%), Pb: lead (0.004%)
14
Chapter 1 Preparation for Installation
1.1 Building
(1) Make sure that the building has been completed
enough to protect the RXs and related facilities from
rain and wind.
(2) Make sure that the width and height of the carrying-
in entrance are enough to carry in the center section
of the RX.
1. Width: 3500 mm (enough to carry in the center
section laid on a forklift horizontally)
2. Height: 2300 mm
15
1.2 Foundation work

Build up the foundation of the RX with anchor bolts as
shown at left.
(1) Number of anchor bolts to be used:

2 at the GE
4 at the OE
2 at the MH
16
1.3 Structure of foundation (2-head version for your reference)

NOTE: The foundation will greatly influence the degree of vibration which the RX will cause, as well as the RX
performance. For constructing the foundation, consult your professional builder referring to the drawings
submitted to you.
17
1.4 Structure of foundation (3-head version for your reference)

NOTE: The foundation will greatly influence the degree of vibration which the RX will cause, as well as the RX
performance. For constructing the foundation, consult your professional builder referring to the drawings
submitted to you.
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1.5 Laying the foundation for wiring andpiping

・ Employ either the underground feeding system (“A”
shown at left) or the pit feeding system (“B”)
depending upon your factory environments; either
one has advantages and disadvantages.
・ For factories which are to use the ever-popular

automatic delivery systems, the overhead feeding
system (suspension from the ceiling) may be
recommended in order to avoid interference with
wiring and piping of the RXs.
Required wiring Required piping

Power cables and signal lines Air pipes
(Other related wirings, e.g., for monitoring and automatic (Other related piping, e.g., water piping)
delivery systems)
NOTE: Consult your professional builder for the composition of foundation and depth of underground cables,
taking into account the wiring and piping.
NOTE: Lay down the wiring so that the voltage drop is kept within 5%.
When anchor bolts, power piping and air inlet piping are
embedded before installing the RX, clearly mark them
with bright colored clothes or flags to prevent stepping
over them or crushing the RX or transportation tools with
them.
When exhaust, piping, wiring and other pits are exposed

without covers, install tentative covers to prevent
dropping or falling accidents.
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1.6 Floor-related Preparations

First, examine the floor surface conditions, e.g., the irregularity in the floor levelness and the floor strength of the plant.
If those conditions are out of the specifications given in this section, improve them.
Particularly, the areas where the GE, MH and OE are to be positioned should be firm and flat in order to prevent surface
irregularities of the floor from getting caused due to the vibration during operation, since they will undergo considerable
weight.
Next, mark reference lines and then lay anchor bolts.
1.6.1 Floor surface conditions and reference installation height

■ Allowable irregularities in the floor levelness
・The floor surface should be firm and flat.
・The standards should be 20 mm or less per 75 m in the longitudinal direction.
20
■ Measuring irregularities and determining the reference installation height

Based on the floor where the OE is to be positioned (as a reference plane), measure irregularities in the floor
levelness to obtain the difference between the base floor level and the highest floor level, using a transit.
According to the greatest irregularity obtained, determine the reference installation height as follows:
As shown at left, the reference installation height (“A”
shown at left) refers to the distance from the floor level
to the bottom of the RX base. Its typical value is 13
mm. You should increase or decrease “A” depending
upon the greatest irregularity measured above.
EXAMPLE:
If the floor where the GE is to be positioned is 10
mm higher than the floor where the OE is to be
positioned.
13 + 10 = 23 mm
The reference installation height “A” should be 23
mm.
21
1.6.2 Marking reference lines on the floor

According to your floor plan, mark reference lines as shown below.
Line A: Installation reference line

Use this line for linear alignment when installing the middle section (as a plumb bob line) and for
positioning of the OE and GE.
REFERENCE:
If a winder is to be connected, mark centerline 30 m longer than line C.
Line B: OE frame inside line
Use this line for positioning the OE frame. This line should be used as a reference line in the
longitudinal direction.
Line C: OE frame rear line
Use this line as a guide when installing the OE frame, and as a reference line when connecting a winder.
Line D: GE frame inside line
Use this line for positioning the GE frame.
Line E: GE frame front line
Use this line for positioning the GE frame.
REFERENCE:
How to check the perpendicularity
Measure the oblique side formed by a line drawn for
9 m from the intersection with another line drawn
for 12 m in the direction at right angle thereto. If the
length of the oblique side is 15 m, the two lines are
at right angles.
Measurement standard: 15 m (within ±1 mm)
Measuring instrument: Steel measuring tape
1.6.3 Checking before installation

Check the relations of respective positions to the RX before installation:
(1) Power supply and air supply starting positions
(2) Position of the underground pit for pneumatic exhaust
(3) Foot positions of air-conditioning pit port and the spring piece
REFERENCE:
For the dimensions of relational positions, refer to a drawing submitted to customer (different according to the
specifications).
22
1.6.4 Excavation of holes for anchor bolts

Excavate holes for the anchor bolts of GE, OE, and ME
heads and bury the piping for power line, compressed
air supply, etc. in advance.
(1) GE head base section
Excavation of holes for anchor bolts: two (2)
locations
(2) OE and SCD head sections
Excavation of holes for OE anchor bolts: two (2)
locations
Excavation of holes for SCD anchor bolts: four
(4) locations
(3) MH base section (3-head machines only)
Excavation of holes for anchor bolts: two (2)
locations
IMPORTANT
The excavating position illustrated here is for
reference.
Since the actual excavating position varies with the
machine model and specifications, please excavate
according to the drawing for the customer submitted
from TOYOTA.
23
1.6.5 RH and LH sections
(1) Divide the head to R-hand and L-hand sections as described below by standing in front of Gear End (GE) and
looking at TOYOTA marking:
Right-hand side is RH.
Left-hand side is LH.
24
1.7 Wiring
1.7.1 In-plant Electric Facilities
The in-plant electric facilities should be set up as specified below to make the most of the RX performance while
maintaining safety.
For details, consult with electric specialists or power companies.
(1) Allowable fluctuation of power supply
Power supply voltage: Contracted rated voltage ± 5%
Frequency: 50/60HZ ± 2.5%
Inter-phase voltage irregularity (continuous): 3% or less
Pay full attention to the electric equipment/construction so that the frame never has a voltage drop which is
outside of ±5% for even a moment.
(2) Earth leakage breaker
If a ground-fault interrupter is installed, use “Inverter-supported type.” Conventional interrupter may
malfunction due to harmonic from an inverter. Pay attention to that if a ground-fault interrupter has already
been installed.
(3) Class D grounding
Connect the grounding wires to the ground terminal (marked PE) in the control box.
(4) Capacity of the circuit breaker on the switchboard
Use the circuit breaker of which capacity is equivalent to or larger than the breaker installed on the RX.
Otherwise, the current charged by the capacitor in the inverter may trip the breaker when the power is supplied
to the RX.
(5) Cable size selection
Select a cable size of which voltage drop total caused by the power supply voltage fluctuation and cable is
within 10% the contracted voltage.
(6) Prohibited installation of capacitor for improving power factor of the power supply
Inserting a capacitor for power factor improvement to the power supply side has no effect.
If a capacitor is inserted on the output side (motor side) of the inverter, a large current flows into the capacitor
to cause the inverter trip. If this is repeated, the device will be damaged, so do not insert any capacitors.
Reference: For power factor improvement with a capacitor on the input side, another apparatus is required.
(7) When private electric power supply is used
If a load which generates harmonic currents of an inverter is connected as a load of a power generator,
harmonic currents will be induced on field winding and damper winding whereby loss of the field winding and
damper winding may increase and heat may be produced. Please consult a private electric generator
manufacturer.
(8) Operational environment
1. Ambient temperature 40 °C or lower
2. Ambient humidity 85%RH or lower
3. Altitude 1000 m or lower
NOTE: If RX is operated outside of the environmental range above, shortening of lives of electrical
components, performance degradation, and damage troubles will occur.
Please improve facilities before RX is introduced. Also please consult us in advance if RX is installed
in a place with the altitude of 1000 m or higher.
25
1.7.2 Circuit Breakers
1: Plant switchboard Ⓐ: Non-fuse circuit breaker on the switchboard

2: RX ①: Cable between switchboard and RX
[1] Capacity of Non-fuse Circuit BreakerⒶ on the Switchboard

(1) The switchboard of RX must be equipped with a non-fuse circuit breaker for use in maintenance, inspection,
and troubleshooting.
(2) It is recommended to install a non-fuse circuit breaker on each spinning frame.
(3) Note that the breaker with insufficient capacity may be easily tripped.
(4) Determine the capacity of the non-fuse circuit breakerⒶ by considering the current flowing into the RX,
power supply transformer type, power supply unit type, and power cable length.
(5) The table below shows the capacity of non-fuse circuit breaker for the RX.
(6) Check if the switchboard breaker has a capacity enough to protect the cables installed.
Circuit breaker operation cur-

Min motor capacity
rent
37kW
175A
45kW
55kW
225A
65kW
75kW
85kW 350A
90kW
26
1.7.3 Cable Size

The cable size shall be determined according to the motor rated current, taking the supply voltage fluctuation and
the line voltage drop into account. Please consult the person in charge of electricity or electric specialists for
construction.
[1] Supply Voltage Fluctuation and Line Voltage Drop
The voltage received by the RX drops due to supply voltage fluctuation and the voltage drop caused by the
starting current. Keep the total voltage drop within 10% of the contract voltage.
27
[2] Motor Rated Current

A. Main motor rated current (inverter input current) Unit (A)
Voltage
380V 400V 415V 440V 460V
Motor capacity
37kW 70 66 64 60 57
45kW 83 78 76 71 68
55kW 102 96 93 88 84
65kW 121 114 110 104 99
75kW 139 132 127 120 114
85kW 145 138 132 125 119
90kW 167 158 152 144 137
B. Pneumatic motor rated current Unit (A)

Voltage
380V 400V 415V 440V 460V
Motor capacity
5.5kW 11.0 11.0 10.6 9.6 9.2
7.5kW 14.3 13.9 13.4 12.3 11.8
5.5kW(OE) + 2.2kW(GE) 15.5 15.5 14.6 13.5 12.9
7.5kW(OE) + 2.2kW(GE) 18.7 18.3 17.4 16.2 15.5
D. Electron draft motor load current Unit (A)

RX
380V 400V 415V 440V 460V
Specification
2-head version 11.4 10.8 10.4 9.8 9.4
3-head version 17.0 16.2 15.5 14.6 14.0
E. Compact suction motor rated current Unit (A)

RX
380V 400V 415V 440V 460V
Specification
2-head version 30 28.5 27.4 25.9 24.7
3-head version 38 36.1 34.7 32.8 31.3
28
[3] Cable Selection

Select the cable that meets the requirements described in [1] and [2] above.
(1) Obtain the current flowing in the cable ① between the circuit breaker on the switchboard and the RX.
[Rated current I (A)]
Electron draft version = A+B+C+D+E
Machine draft version = A+B+C+E
[Starting current IST (A)]
Electron draft version = A×1.5+B×7+C+D×1.5+E×1.5
Machine draft version = A×1.5+B×7+C+E×1.5
A: Main motor rated current

B: Pneumatic motor rate current
C: Other apparatuses・・・6A
D: Electron draft motor load current
E: Compact suction motor rated current
(2) Select the cable ① so that the total voltage drop of the supply voltage fluctuation and the voltage drop
caused by cable ① are within 10%. Obtain the voltage drop using IST.
(3) Cover the wiring holes in the control box with the patty provided for preventing invasion by fly, fleece and
dust after cable ① is installed.
A standard Ø50mm diameter hole is provided in the control box for the power supply wiring purpose.
29
1.7.4 Interlock with Adjacent Machine during Doffing

Install the interlock to the RXs to prevent doffing of two adjacent frames at a time with limit spaces between the
RXs.
(1) Frame width and space between two adjacent frames

A = 1540 mm : Max. width during doffing
B = 1110 mm : Max. width during stopping
C = 1900 mm : Min. distance between two adjacent
frames
When C = 2000 mm or less, it is recommended to

incorporate
the SCD interlock.
(2) Interlocking method

1. Loop frames using the 4-core cables.
NOTE: As the cable length varies according to space between frames and the wiring route at your
factory, the cables should be purchased by the user.
2. Connection diagram
Refer to the connection diagram on the next page.
30
31
1.8 Air Compressor for SCD

1.8.1 Compressed-air Requirements for SCD
Compressed air to be used for the SCD should be oil-free, clean, and dry. The standard requirements are given
below.
Dry: Dew point : –17°C

(under atmospheric pressure) Use a dryer to remove moisture.
Not contaminated (oil-free) : Oil content: 0.1% or less
It is best to use an oil-free compressor. If an oil injection compressor is to be
used, install an oil-removing filter.
Constant pressure : Compressor output pressure: Within 0.7 MPa (7 kg/cm2G)
SCD input pressure: 0.6 MPa (6 kg/cm2 G) or more.
The pressure loss will increase if the pipe is small in diameter or has many
bends.)
Pressure fluctuation: Nominal pressure ±0.05 MPa (0.5 kg/cm2 G)
Suitable temperature : It is desirable that the temperature of the output air be almost equal to
that of the spinning room.
1.8.2 Pneumatic Requirements
It is necessary to supply dry and clean air satisfying the following requirements from the OE of each RX.
(1) Compressed-air requirements:

• Temperature： Room temperature
• Pressure： 0.6 MPa (6 kg/cm2)
• Dew point (under compression)： –17°C or below
• Oil content： 0.1% or less
• Solid matter： 5 μm or less
(2) Air consumption for doffing:
170+{0.09× (number of spindles-500)} NL/minutes
(3) Instantaneous rush flow (for driving the grippers)
0.0325×number of spindles NL/2 seconds
(4) Air consumption by a tray transfer unit
162 NL/minutes
1.8.3 Piping materials and jobs

(1) Piping materials to be used inside the SCDs should be procured by TOYOTA. (Note that the piping jobs
should be done by your company.)
(2) An air source for supplying air to the inside of the SCDs should be prepared by your company.
(3) For the gas pipe at the air source, external threads designed for PT3/8 should be procured for each RX by your
company. Also the piping job to the SCD should be arranged by your company.
32
1.8.4 Choice of Air Compressor Type and Number of Compressors

Oil-free Reciprocating Compressor (HITACHI VNC, VN, VNL)
Type Screw compressor Reciprocating compres-

Characteristic sor
Compressed air Small pulsation Wide range from low to
high pressure
Vibration Weak Strong
Noise Soft Loud
Efficiency High Low
Output temperature Low High
Size Compact Medium
[1] Calculating Air Volume Required for RX

Q = Qo × (1 + Kz) × No (N m2/H).............. ①
Where Q : Total air volume required (N m2/H)
Qo : Air consumption per RX (N m2/H)
Kz : Piping loss rate (0.2, taking air leakage from pipes into account)
No : Number of RXs
NOTE: The above air volume and consumption are under 20°C and 0.1 MPa (760 mmHg) conditions.
[2] Selecting the compressor

a = Q/(Qc × Nc) ........................................ ②
Where a : Compressor operating efficiency
This should be 0.85 or less for reciprocating compressors and 0.90 or less for screw compressors.
Q : Total air volume required (N m2/H)
Qc : Air output volume per compressor (N m2/H) (*1)
Nc : Number of compressors required
According to formulas ① and ②

(1) For reciprocating compressors
0.85 × Qc × Nc ≥ Q Then, Qc × Nc ≥ Q/0.85
Or, Qc × Nc ≥ 1.412 × Qo × No
(2) 0.9 × Qc × Nc ≥ Q Then, Qc × Nc ≥ Q/0.9
Or, Qc × Nc ≥ 1.333 × Qo × No
・For the air output volume per compressor marked with (*1), refer to the compressor manufacturers'
catalogs. The major compressors are given on page 1-4-4.
・It is recommended that a spare compressor be prepared in order to prevent your production from
becoming interrupted at the time of compressor breakdown or periodical maintenance.
・For controlling the compressor capacity, be sure to choose an unloader type.
33
[3] Calculating the Approximate Power Consumption of Compressor

(1) For oil-free reciprocating, oil-free screw and dry screw compressors
W = W1 × n × [ a + b ( 1 - a )]
Applicable model : HITACHI: VNC, VN, VNL, DSP, SDS, etc.
KAJI: VS
MITSUI SEIKI: Z
(2) For oil injection screw compressors
W = W1 × n × B’
Applicable model : HITACHI: OSP, etc.
(3) For compressors with their shaft input power known
W = Shaft input power × n × [ a + b ( 1 – a )]
Applicable model : ATLAS ZR, etc.
Where W : Total power consumption (kWH)

W1 : Motor power consumption (kWH per motor) = Motor rated output/Motor rated output
(The motor efficiency can be assumed as 0.9.)
a : Compressor efficiency (0.85 or less for reciprocating compressors, 0.90 or less for screw
compressors)
b : Power ratio of unloaded compressor with relative to full-loaded compressor 0.20 to 0.25
for reciprocating compressors 0.20 to 0.40 for screw compressors
n : Number of compressors
B' : Power ratio with relative to the ratio of required air volume and the compressor output
volume
NOTE: Generally, the power consumption W1 should be calculated with the shaft power, not with the motor
output. To obtain approximate power consumption, however, calculate it with the motor output since the
shaft power and motor efficiency vary depending upon motor models.
34
1.8.5 Layout Examples of Air Compressors and Related Equipment
35
1.9 Exhaust System and Centralized Cleaning System

1.9.1 Pneumatic Cleaner Exhaust System
(1) The pneumatic cleaner exhaust system is avail-
able in three types:
1. Underground exhaust system

2. Ceiling exhaust system
3. Room exhaust system
NOTE:
Refer to the drawings submitted to you for the
system dimensions (which vary with the
specification).
(2) Without sufficient exhaust air, the temperature

rises in the OE, affecting the main motor
operation adversely. Construct the exhaust system
having a flow rate 20% higher than that specified
in the table below.
Pneumatic motor capacity (kW) 2.2 3.7 5.5 7.5

3
Exhaust flow rate (m /min) 43 45 80 88
36
1.9.2 Centralized Cleaning System

(1) The centralized cleaning system is available in
two types:
1. Underground exhaust system
2. Ceiling exhaust system
NOTE:
Refer to the drawings submitted to you for the
system dimensions (which vary with the
specification).
(2) Insufficient capacity of the cleaning system will

cause poor waste collection or frequent yarn
breakage. Prepare the cleaning system by refer-
ring to the following capacity table.
Cleaning system capacity table

Pneumatic version Cleaning system required performance Application section
[ OE: Out End､GE: Gear End､ ( ): Option ]
2-head 3-head
Pneumatic Suction pres- Flow amount Duct diameter ～672 ～1200 1248～1440 1248～1824
motor capacity sure [m3/min] [mm] [Spindle] [Spindle] [Spindle] [Spindle]
[kW] [Pa]
2.2 2700 38 250 - - - GE
3.7 2300 30 250 OE - - -
(Motor 5.5kW)
5.5 2700 38 250 - OE - OE
7.5 3300 45 250 - (OE) OE (OE)
37
1.9.3 EST3 Compact Exhaust Evacuation 【Essential】

(1) EST3 Compact Exhaust Evacuation System
① Underground
② Overhead
③ Without evacuation (with dust collec-
tion bag)
NOTE:
Refer to Customer Drawing for detailed
dimensions.
③ Without evacuation is not recommended

because dust in exhaust air will scatter in
spinning room.
① or ② is recommended.
(2) IMPORTANT:
There is a risk of deterioration in yarn quality
due to Compact suction pressure drop if the
evacuation is not sufficient.
The evacuation system should be able to

accomodate the exhaust volume in below table.
Spindlage Maximum Exhaust Volume

/ Frame (m3/min)
192 12.8
288 19.2
384 25.6
480 32.0
576 38.4
672 44.8
768 51.2
864 57.6
960 64.0
1056 70.4
1152 76.8
1200 80.0
1248 83.2
1344 89.6
1440 96.0
1536 102.4
1632 108.8
1728 115.2
1824 121.6
Refer to the next page for the recommended size

of evacuation duct.
38
(3) Recommended size for evacuation duct (Φdmin)
Symbol Unit Definition

Φdmin m Minimum diameter of evacuation duct
L m Total length of evacuation duct
N spindles Total number of spindles
V m/sec Average flow velocity
3
Q m /min Total exaust volume
Refer to the table in next page for Φdmin to control back pressure within 0.1kPa.
The actual evacuation duct should be bigger than Φdmin.
The above illustration shows overhead evacuation system, but the table can also be applied to underground
evacuation system.
39
(4) Calculation Table for dmin
ｄmin(m) L(m)
N Q(m3/h) 5 10 15 20 25 30 35 40
1200 4800 0.280 0.322 0.349 0.370 0.387 0.401 0.414 0.425
1800 7200 0.330 0.379 0.411 0.435 0.455 0.472 0.486 0.500
2400 9600 0.370 0.425 0.461 0.488 0.510 0.529 0.546 0.561
3000 12000 0.404 0.464 0.504 0.534 0.558 0.579 0.597 0.613
3600 14400 0.435 0.500 0.542 0.574 0.600 0.622 0.642 0.659
4800 19200 0.488 0.561 0.608 0.644 0.673 0.698 0.720 0.740
6000 24000 0.534 0.613 0.665 0.704 0.736 0.763 0.787 0.809
7200 28800 0.574 0.659 0.715 0.757 0.792 0.821 0.847 0.870
8400 33600 0.610 0.701 0.760 0.805 0.842 0.873 0.901 0.925
9600 38400 0.644 0.740 0.802 0.850 0.888 0.921 0.950 0.976
10800 43200 0.675 0.775 0.841 0.891 0.931 0.966 0.996 1.023
12000 48000 0.704 0.809 0.877 0.929 0.971 1.007 1.039 1.067
13200 52800 0.731 0.840 0.911 0.965 1.009 1.047 1.079 1.109
14400 57600 0.757 0.870 0.943 0.999 1.045 1.084 1.118 1.148
15600 62400 0.782 0.898 0.974 1.032 1.079 1.119 1.154 1.185
16800 67200 0.805 0.925 1.003 1.063 1.111 1.153 1.189 1.221
18000 72000 0.828 0.951 1.031 1.093 1.142 1.185 1.222 1.255
19200 76800 0.850 0.976 1.058 1.121 1.172 1.216 1.254 1.288
20400 81600 0.870 1.000 1.084 1.149 1.201 1.246 1.285 1.319
21600 86400 0.891 1.023 1.109 1.175 1.229 1.274 1.314 1.350
22800 91200 0.910 1.045 1.134 1.201 1.256 1.302 1.343 1.379
24000 96000 0.929 1.067 1.157 1.226 1.282 1.329 1.371 1.408
25200 100800 0.947 1.088 1.180 1.250 1.307 1.355 1.398 1.436
26400 105600 0.965 1.109 1.202 1.273 1.331 1.381 1.424 1.463
27600 110400 0.982 1.128 1.224 1.296 1.355 1.406 1.450 1.489
28800 115200 0.999 1.148 1.245 1.318 1.379 1.430 1.475 1.515
30000 120000 1.016 1.167 1.265 1.340 1.401 1.453 1.499 1.539
31200 124800 1.032 1.185 1.285 1.361 1.424 1.476 1.523 1.564
32400 129600 1.047 1.203 1.305 1.382 1.445 1.499 1.546 1.588
33600 134400 1.063 1.221 1.324 1.402 1.466 1.521 1.568 1.611
34800 139200 1.078 1.238 1.343 1.422 1.487 1.542 1.591 1.634
36000 144000 1.093 1.255 1.361 1.442 1.507 1.563 1.612 1.656
37200 148800 1.107 1.272 1.379 1.461 1.527 1.584 1.634 1.678
38400 153600 1.121 1.288 1.397 1.479 1.547 1.604 1.654 1.699
39600 158400 1.135 1.304 1.414 1.498 1.566 1.624 1.675 1.720
40800 163200 1.149 1.319 1.431 1.516 1.585 1.644 1.695 1.741
42000 168000 1.162 1.335 1.448 1.533 1.603 1.663 1.715 1.761
43200 172800 1.175 1.350 1.464 1.551 1.621 1.682 1.734 1.781
44400 177600 1.188 1.365 1.480 1.568 1.639 1.700 1.753 1.801
45600 182400 1.201 1.379 1.496 1.585 1.657 1.718 1.772 1.820
46800 187200 1.213 1.394 1.512 1.601 1.674 1.736 1.791 1.839
48000 192000 1.226 1.408 1.527 1.617 1.691 1.754 1.809 1.858
49200 196800 1.238 1.422 1.542 1.633 1.708 1.771 1.827 1.876
50400 201600 1.250 1.436 1.557 1.649 1.725 1.789 1.845 1.894
40
ｄmin(m) L(m)
3
N Q(m /h) 5 10 15 20 25 30 35 40
51600 206400 1.262 1.449 1.572 1.665 1.741 1.805 1.862 1.912
52800 211200 1.273 1.463 1.586 1.680 1.757 1.822 1.879 1.930
54000 216000 1.285 1.476 1.601 1.695 1.773 1.839 1.896 1.948
55200 220800 1.296 1.489 1.615 1.710 1.788 1.855 1.913 1.965
56400 225600 1.307 1.502 1.629 1.725 1.804 1.871 1.929 1.982
57600 230400 1.318 1.515 1.642 1.740 1.819 1.887 1.946 1.998
58800 235200 1.329 1.527 1.656 1.754 1.834 1.902 1.962 2.015
60000 240000 1.340 1.539 1.670 1.768 1.849 1.918 1.978 2.031
(5) Example 1
＜Question＞ What is the preferable size of evacuation duct (20m long) to accommodate the exhaust of RX300
(1440sp) 10 frames?
＜Answer＞ With N = 14400sp and L = 20m, Φdmin = 0.999(m) is found in the table.
⇒ The evacuation duct size should be 1.0m, for example, that is bigger than Φdmin = 0.999(m).
(6) Example 2
＜Question＞ Is the square evacuation duct (1.2m X 1.0m, 30m long) big enough to accommodate the exhaust
of RX300 ( 1200sp ) 20 frames?
＜Answer＞ Step 1: Calculate the equivalent round pipe size (de) with the following formula.
de ≒ (a + b) / 2 × 1.1
= (1.0 + 1.2) / 2 × 1.1
= 1.21 (m)
Step 2: From the table with N = 24000sp and L=30m,

Φdmin=1.329m is found in the table.
Conclusion: The square duct is not big enough
(de ＜ Φdmin).
Step 3: Revise the square duct size (b = 1.5m)

de ≒ (a + b) / 2 × 1.1
= (1.0 + 1.5) / 2 × 1.1
= 1.37 (m)
Conclusion: The revised square duct size is big
enough (de ＞ Φdmin).
Please contact TOYOTA if you have difficulty to find Φdmin in the table.
The above guideline is only the reference.
The actual pressure drop will also depend on the way of connecting and the internal surface roughness of the
evacuation duct.
Please consult with duct specialist before implementation.
41
1.10 Other Facilities

1.10.1 Temperature Regulator and Air Conditioner
To maintain the consistent operating condition, it is essential to keep the spinning room at constant temperature and
humidity.
The ambient temperature and humidity depend on the weather of the factory location, conditions of the location,
building structure, and air conditioning. The table below lists the recommended temperature and humidity.
Process
Material Temperature & hu- Blending Carding Combing Drawing Roving Spinning Winding
midity
Cotton Temperature 24～30℃
Humidity 45～60% 45～55% 60～65% 50～65% 50～60% 50～65% 60～70%
Polyester/cotton Temperature 24～30℃
Humidity 55～60% 55～60% 55～60% 55～60% 55～60% 65～70%
Rayon, Temperature 24～30℃
rayon Humidity 70～75% 60～65% 60～65% 60～65% 55～60% 65～70%
blend
Polyester Temperature 24～30℃
Humidity 60～70% 55～65% 60～65% 60～70%
Acrylic Temperature 24～30℃
Humidity 60～70% 55～65% 58～65% 56～62% 60～70%
1.10.2 Lighting (lux)

Allowable luminance
Typical luminance
Process Measuring location range
(lux)
(lux)
Opening and picking
On the fluted roller or equivalent place 100 50～150
machine
Carding machine On the web 100 50～150
Sliver lap machine On the table 130 70～170
Ribbon lap machine On the Ermen's cleaner cover 130 70～170
Comber On the table 130 70～170
Drawing frame On the trumpet plate 100 50～150
Roving frame On the flyer ends 130 70～170
Spinning frame On the roller beam 150 100～200
Winder On the cheese bobbins 150 100～200
42
1.10.3 Prevention from Fly, Fleece and Dust

The mechanisms of the RX are covered to prevent fly, fleece, and dust from getting into them.
The RX is also equipped with a pneumatic suction unit for broken yarns.
Such covering and unit are, however, not sufficient, so the spinning factory itself should have some preventions
against fly, fleece, and dust, which also plays an important role for the production efficiency.
For example, an air-conditioning system which serves both as a temperature/humidity controller and underground -
pit suction cleaner is recommended.
It is also recommended that your RX be equipped with a pneumatic blower traveling cleaner and automatic dust
collector which can:
1. Reduce the cost of cleaning by hand, with a minimum of machine stops for cleaning.
2. Decrease yarn breaks due to fly, fleece or dust, and increase the number of RXs which one worker can take
care of.
3. Decrease the spinning-in problems of fly, fleece and waste yearn.
4. Improve the working environment.
43
1.10.4 Installation of Blow Cleaner

When you prepare the blow cleaner without purchasing the RX with blow cleaner, pay attention to the following
points.
(1) Blowing positions

(2) Power supply to the blow cleaner
NOTE: Provide a discrete control board for the blow cleaner.
Never feed from controlled source of RX300 (AC210V, AC100V, DC24V, DC12V, DC5V). Such
feeding may cause a glitch in the FL or damaged components.
Connect cables of the blow cleaner to the secondary (R2, S2, T2, E) of the breaker CB2 in the RX
control box if the motor is up to 1.5 kW.
(3) Interface signal between blow cleaner and RX
1. Since the blow cleaner interferes with the SCD during doffing, the blow cleaner must be stopped at the
OE or GE.
Connect the A contact (no-voltage contact) that turns on when the blow
cleaner is at the evacuation position to the terminal shown on the left.
2. For automatic operation of blow cleaner linked with the RX

Blow cleaner stop instruction : Open the CR1 contact.
Blow cleaner run instruction : Close the CR30 contact.
(4) Operation panel for blow cleaner

Since the blow cleaner operation panel is not provided with the RX, prepare the panel separately.
Installing a control box with Auto, Manual, and Stop selector switch on the OE head is recommended.
NOTE: Refer to the typical installation of blow cleaner on the next page, for your reference.
44
45
1.10.5 Centralized Cleaner Interface Signal(When the traveling cleaner

is prepared by you)
When the traveling cleaner is prepared by you for centralized pneumatic cleaning, the centralized cleaning signals
need to be controlled as follows.
(1) Send centralized cleaning signals periodically and sequentially to the RX.
(2) Stop the traveling cleaner while the centralized cleaning signals are active and resume operation of the
traveling cleaner 3 seconds after the signals are off.
(3) When the RX sends an evacuation signal, the traveling cleaner goes to the evacuation position and stops there.
TOYOTA will prepare the relays in the control box.

Reference: For model with traveling cleaner, what should be prepared by you is (1) only.
■ Timing Chart of Centralized Cleaner
(*1) Only while the waste collection valve is open (waste is actually collected), the pneumatic cleaner is stopped. A
stopping time can be set.
When centralized cleaning signal turns on while the pneumatic cleaner is running, the cleaner stops 3 seconds
later.
The pneumatic cleaner resumes its operation when the set time tPN (default: 10 sec, setting range: 0 to 20 sec)
expires after the pneumatic cleaner stopped. (The pneumatic cleaner starts again immediately if the centralized
cleaning signal turns off while the pneumatic cleaner is stopping.)
(*2) The traveling cleaner immediately stops if the centralized cleaning signal turns on while the cleaner is running.
If the centralized cleaning signal turns off while the traveling cleaner is running, the cleaner resumes its
operation 3 seconds later.
46
■ Centralized Cleaning Interface
47
Signal name Direction of signal Operation

Manual cleaning signal (CR90) Spinning frame to cleaner This signal turns on (CLOSE) when the manual
cleaning switch of the operation panel of the RX is on.
This signal goes off (OPEN) when the manual cleaning
switch is turned off.
Set the cleaner to RUN when this signal is on. Set the
cleaner to off when this signal is off.
Centralized cleaning signal Cleaner to spinning frame Turn this signal on (CLOSE) while the cleaner is
(Prepared by user) running. At
this time, the spinning frame stops the pneumatic
cleaner.
When the 3-head version is used, prepare two signals of
one is for OE and one is for GE since the pneumatic
apparatus is branched to OE side and GE side.
START/STOP signal Spinning frame to travel- CR30 ON: Turns on when the spinning frame starts to
(CR30) ing cleaner activate the traveling cleaner.
CR30 OFF: The traveling cleaner stops at the
evacuation position.
Forced stop signal Spinning frame to travel- CR1 ON (contact open): The traveling cleaner stops
(CR1) ing cleaner immediately.
Example: Control circuit for centralized cleaner

The control circuit is supplied by the traveling cleaner
manufacturer.
Limit switch (LS) ON/OFF status

(The traveling cleaner is waiting at the OE evacuation
position.)
48
Chapter 2 Procuring Installation Tools
2.1 Setting up the unpacking and carrying-in tools

Set up the unpacking and carrying-in tools listed below.
Tools Quantity Tools Quantity
Hammer, 1-to 2-pound 2 Forklift, 3 t or more 1
Bar, 1.5 m × ø40 2 Hand lift, 3 t or more 2
Wooden bar, 120-mm square 8 Small jack, 1.5 t or more 2
2.2 Precautions for handling packed machinery
(1) Storage
If delivered to the site, the packed machinery will be stacked until the day of unpacking. You should stack those
packages in the following manner so that you may carry them out in the order of unpacking:
1. Group those packages according to the markings (see below).
2. Stack each group so that you may carry out packages having smaller marking numbers first.
3. Place each group facing to a passage.
49
2.3 Unpacking
Components in all packages are treated with rust-preventing oil in order to protect them from rust during transportation
and storage. Unpacking those packages too early may cause the components to rust, so it is recommended to unpack
those packages after arrival of TOYOTA’s supervisors.
If it is necessary to unpack them before arrival of TOYOTA’s supervisors, observe the following:
(1) According to the packing list, check the components in each package.
(2) Unpack packages in the order of assembly, then group the components for each RX.
(3) Group small parts and bolts for each RX, then put them into the parts boxes and bolt boxes described in Subsection
3.1.1 [ 7.6 ]. (Be sure not to mix parts with different sizes.)
(4) Carefully check the inside of the packing materials and packages so as not to leave any parts behind.
2.4 Cleaning
It is essential to remove rust-preventing oil from each component and parts before the start of operation. If there will be a
long time period before the start of operation, however, follow the procedure given below in order to protect them from
rust.
(1) Do not completely degrease components having exposed metallic surfaces, but wipe off oil lightly to leave thin oil
coat.
(2) Immediately before the start of operation, wipe off rust-preventing oil thoroughly again.
(3) Completely degrease sections which will come into direct contact with roving, using solvent and French chalk.
NOTE: If you unpack the packages before arrival of TOYOTA’s supervisors, only wipe off rust-preventing oil lightly as
instructed in step (1).
50
2.5 Accessories
(1) Bolt box
Procure bolt boxes to be used for grouping bolts and
small parts by size for installation work. Each box
should be partitioned as shown at left.
Material: Wood or plastic
Number of partitions required: 60 to 80
(2) Parts box

Procure parts boxes to be used for grouping small
parts and allowing workers to move about freely
while carrying small parts, bolts,
and tools.
After installation, it can be used for storage of spare
parts.
Material: Wood or plastic
Number of boxes required: 20 to 30
(3) Chair
1. Low chair
・Procure low chairs to be used for time-
consuming parts installation and centering jobs
at the lower or middle areas of the RX frames
(e.g., installing tape tension pulleys, spindles,
and SCD-related parts).
・Material: Wood (You may use packing
materials to make low chairs.)
・Number of chairs required: 4 to 6
2. High chair
・Procure high chairs to be used for parts
installation and centering jobs at the middle
area of the RX frames (e.g., installing spindles,
antiballoon rings, and lappets).
・Height: 550 to 600 mm
・Number of chairs required: 4 to 6
(4) Cleaning bath
Procure a cleaning bath to be used for cleaning parts
with cleaning oil. It has a size equivalent to half of
20-liter can.
51
2.6 Preparing general tools

General tools are required separately from dedicated tools arranged by us for installation operation. Please prepare
necessary number of general tools by user.
52
2.7 Preparation
2.7.1 Lubricants
Appropriate lubrication is very important not only for extending machine life and saving driving power and
maintenance cost, but also for maintaining excellent productivity and quality of spun yarn.
The following gives the type of recommended lubricant, properties, lubricating points, and lubrication interval.
When supplying lubricant, it is recommended the same brand as the previous one be used.
Japanese prod- Chevron Texaco

Symbol
Type
Lubricating point Shell Mobil ESSO AGIP Others

uct (Caltex)
Ordinary bear- Kyodo, Alvania Multifak No.2 Mobilux Beacon GR
ing Unilub Grease Grease S2 EP-2 EP-2 MU2
A and No.2
Lifting screw
nut
Open-type gear Kyodo, Alvania EP Multifak EP No.2 Mobilux Beacon GF Texparts
Unilub Grease Grease 2 Chevron EP-2 EP-2 MUEP2 TG2(0026877)
D DL No.2 DURA-LITH
NIPPON OIL Grease EP2
Epinok No.2
Bottom roller Kyodo, Multifak AFB2 Mobile Templex GR
Grease
neck Powerlite Grease N2 LP2

H
bearing No.2 XHP222
Top roller
Spindle Kyodo, Alvania Mobilith Templex
Tape tension Multemp SRL Grease S3 SHC 100 N3
J
Main motor
Pulley
Front bottom Sumiko Molycoat Grease
coupling Lubricant Paste
M
and Moly Past 500 (Alpha Molycoat)
Other couplings
Top roller bear- Texparts
N
ing TG2(0026878)
Spindle Tellus Oil Rando HD10 DTE21 OSO 10 BP
(CS1/CS1-S) 10 Energol HLP-HM10
(HPS68/HPS68-NASA) Castrol
Hyspin AWS10
C
Spindle Tellus Oil Rando HD46 DTE25 OSO 46 BP
(CS1-12) 46 Precis Energol HLPHM46
(CS21 12) CLP46
Oil
(L-HPS68)
Gear end Idemitsu Oil Omara Oil Meropa 320 Mobilgear
Main gearing Alfa Worm 460 320 Chevron Gear 600 XP 320
and Nippon Oil G-C Oil Compound EP320
L
Draft gearing Bonnock 320SE
Lifting worm AX460
box
53
■ Properties of Grease
Viscosity
Manufacturer Brand name Symbol Soap radical
(at 25°C)
Unilube Grease No.2 A Lithium 280
Power Light No.2 H Lithium 280
Kyodo Yushi
Multemp SRL J Lithium 242
Unilube Grease DL No.2 D Lithium 280
Alvania Grease S2 A Lithium 276
Shell Alvania Grease S3 J Lithium 240
Alvania EP Grease 2 D Lithium 282
Multifak 2 A Lithium 280
Chevron Texaco Multifak EP2 D Lithium 280
(Caltex) Multifak AFB2 H Lithium 280
Chevron DURA-LITH Grease EP2 D Lithium 280
Mobilux Grease EP2 A・D Lithium 265/295
Mobil Mobil Grease XHP222 H Lithium complex 280
Mobiris SHC100 J Lithium complex 280
Beacon EP2 A・D Lithium 280
ESSO Templex N2 H Lithium complex 280
Templex N3 J Lithium complex 230
Sumiko Lubricant Moly Paste 500 M Special viscosity in- 280
creasing agent
Alfa Molycoat Molycoat Grease Paste M Lithium
TG2(0026877) D Lithium 265/295
Texparts
TG5(0026878) N Barium 285/315
GR MU2 A Lithium 280
AGIP GR MU EP2 D Lithium 280
GR LP2 H Calcium complex 280
54
■ Properties of Oil
Viscosity (cSt)
Manufacturer Brand name Symbol
40°C 100°C
Tellus Oil 10 10.0 2.5
C
Tellus Oil 46 46.0 7.0
Shell
Orama Oil 320 320.0 24.5
L
G-C Oil 320SE 320.0 24.1
Spindler 10 10.0
C
Chevron Texaco Rand HD46 44.0 6.7
(Caltex) Meropa 320 306.0 23.7
L
Chevron Gear Compound EP320 320.0 23.2
DTE21 10.0 2.7
C
Mobil DTE25 44.2 6.7
Mobile Gear Oil 600 XP 320 L 320.0 24.1
Nuto H10 9.6 2.6
C
ESSO Nuto H46 46.0 6.7
Spartan EP320 L 309.0 24.7
OSO 10 11.0 2.8
AGIP C
OSO 46 45.0 6.8
Idemitsu Oil Alfa Worm 460 E 462.1 50.0
Nippon Oil Bonnock AX460 E 435 48.9
■ Oil and grease required for operation

Lubricant Symbol Lubricating points Usage indication
*
C Spindles ※
Oil GE gearing, Lifting worm box ※ 4.0 to 5.0 L/unit
L
※ 3.0 to 4.0/unit
Spindle drive pulley shaft bearing ※
A Thin coat with a brush
Screw shaft lifting gear
• OE auxiliary gearing ※
D • MH auxiliary gearing ※ Thin coat with a brush
Grease
Traverse drive unit
H Each bottom roller bearing 9 g/unit (48 spindles)
Each bottom roller connection part
M Thin coat with a brush
Lifting line shaft both ends
*
Parts with the mark have already been lubricated on arrival; however, it is desired that they are prepared in advance of
installation against the requirement of lubrication.
55
■ Lubrication for spindles

For the initial lubrication, two types of lubricators are available: the TexParts lubricator and Novibra
lubricator.
NOTE: Lubricating methods may differ depending upon the lubricator manufacturer.
(1) TexParts using the TexParts lubricators

The TexParts lubricator has a nozzle which
handles both cleaning and lubricating.
Through the cleaning-lubricating nozzle, apply
the specified amount of oil.
FUNCTION:
During cleaning and lubricating, the lubricant
is supplied from the side and passes over the
insert bearing tops.
EFFECT:
The insert bearings become lubricated.
*
When using a new RX or after replacing
spindles, lubricate the new spindles so that the
bearings are fully lubricated.
(2) When Using the Novibra Lubricators

The nozzle equipped with the Novibra Lubricator
is used for Oil-filling and cleaning.
The designated amount of lubrication is applied
through filling and cleaning nozzle.
FUNCTION:
The lubrication is applied by passing through
the upper side of the insert bearing laterally.
EFFECT:
The insert bearings become lubricated.
56
■ Preparation and lubricant storage
(1) Prepare the following lubrication tools and store

them in a ready-to-use state.
① Grease gun
(Tool No. 77140-00007)
② Oiler (Commercially available)
③ Oiler (Commercially available)
④ Brush (Commercially available)
⑤ Spindle lubricator
(Commercially available)
The following two types of spindle lubricators are

available:
・TexParts lubricator
・Novibra lubricator
The using method is different from each other.
(2) Before lubrication, make sure that no air is
entrapped inside the grease gun.
Air entrapped inside the gun will prevent correct
greasing.
Periodically check the feeding amount of grease.
(3) Before lubrication, check that the grease nipple of
each lubricating point is not damaged or broken.
(4) Lubricant storing notes
1. Seal up the lubricant containers and place
them in a well-ventilated room separated
from the machine rooms.
2. Avoid storing lubricants for more than one
year, since even high-quality lubricants may
deteriorate as time passes.
3. Never mix different brands of grease or oil.
57
2.7.2 Precautions for cleaning the RX and SCD at the time of unpacking
・ Use Nisseki New-sol Deluxe or equivalent cleaning fluid. Never use trichloroethylene-base cleaning fluid;
otherwise, the painting will peel off or discolor.
・ Use French chalk only immediately before the start of spinning in order to degrease the fluted sections of the
bottom rollers completely.
58
Chapter 3 PREPARATIONS FOR OPERATION
3.1 Item Requuired for Spinning

Prepare the following items before starting the actual operation.
No. Item Remarks

1 Roving ・Prepare required amount of roving used in operation of RX/RXW.
・Prepare bobbins having the shape recommended by us.
2 Bobbins ・Prepare the number of bobbins required for operation of the RX/RXW.
・Classify bobbins by colors.
・The number of gear teeth and the number of front/back gears for
3 Change gears
determining the spinning conditions.
・Travelers for smoothening the rings
4 Travelers
・Travelers for actual spinning
5 Spare parts ・Request our recommended spare parts list.
・Hand picker
6 Daily and periodical cleaning tools ・Brush
・Floor brush
Cart for carrying full bobbins ・Cart for carrying full bobbins to the winder
(The cart is necessary when RX/
7
RXW is not linked with the
winder.)
・Provided with cheese bobbins
8 Required winder ・Capable of heat setting or non-heat setting
・Capable of waxing knits
59
3.2 Bobbin
(1) Drawings of recommended bobbins for RX are submitted to customers.
(2) For the RX with SCD, failure to meet the conditions described on the drawings may lead to machine trouble.
Trouble that may occur

Item Standard
if the standard is not met
Tilting of bobbin to
the bottom as the 1 mm max. Stop of bobbin feed
reference line
5.9 to 9.8 N (600 to 1000 g) according Doffing error, incomplete insertion
Spindle pull-out
to the specified TOYOTA gauge (floating), popping up of bobbin during
force
(R8239-010**-**) rotation of spindle
Base of bobbin bot- Stop of bobbin feed and/or damaged
Required
tom picker
20.05+0.05-0 ×30Height (forRX)
Bottom inside di-
18.75+0.05-0 ×30Height (for RX) Damaged grippers
ameter
20.01+0.05-0 ×30Height (for RXW)
Roundness at the
3R max. Damaged grippers
top
(3) When placing an order with a bobbin manufacturer, customer is required to demand quality requirements such as
color, heat resistance, rigidity, etc. on top of the full compliance with the conditions stated in the TOYOTA
drawings.
(4) When receiving delivery from the bobbin manufacturer, customer is required to always conduct a receiving
inspection to check on the delivered quality. (The gauge for acceptance inspection (at cost) is to be delivered as a
special gauge. In case of need, please order for it at an early time.)
60
3.3 Bobbin Drawings Used for RX (Reference)

6-inch lift (For RX)
61
62
63
64
7.5-inch lift (For RXW)
65
3.4 Traveler
(1) There are several types of ring flange widths and ring surface treatments. Make sure to select a suitable traveler
according to the ring type in use.
Be careful as use of inappropriate traveler not suitable to the ring will cause frequent yarn break and adversely
affect the traveler and ring lives.
(2) Types of ring flanges and use according to degree of yarn spinning (supplied by Kanai)
(3) Relation between traveler speed and ring (supplied by Kanai)
66
(4) Recommended combination between ring and traveler
KW KS KS2 KM RIORA
Flange type
4.0mm 3.35mm 3.2mm 2.5mm RR-L RR-M RR-S
cotton 100% PK/hf MS/hf (TR-L/hf)
～Ne16 BZ/hf YS-2/hf TR-L/hf
O,O/hf
Ne16～Ne80 MS/hf MS/hf (TR-L/hf) TR-M/hf TR-S/hf
YS-2/hf YS-2/hf TR-M/R
OSY/hf OSY/hf
OS OS
Ne60～ OSS TR-M/hf TR-S/hf
OSS/hf TR-M/R
P/C blended PK/hf MS/hf (TR-L/hf)
～Ne16 BZ/hf ZS/hf TR-L/hf
O,O/hf O
ZS/hf ZSB/hf TR-M/R
O ZSC/hf
Ne60～ OSS TR-M/hf TR-S/hf
OSS/hf TR-M/R
synthetics 100% PK/hf MS/hf (TR-L/hf)
～Ne16 BZ/hf ZS/hf TR-L/hf
O,O/hf O,OH
ZS/hf ZS/hf TR-M/R
O,OH OY,OYH
synthetics wool OH OHY TR-L/R
100% OH-WZ OHY-WZ
Nm24～Nm48
Nm48～Nm72 OH OHY TR-M/R
OH-WZ OHY-WZ
67
3.5 TBC Full Bobbin Box Diagram

For the TBC specification, the bobbin box cart is required separately.
Prepare referring to the figure below.
68
3.6 Peripheral Units

Typical peripheral units required for operating the RX are listed below. Prepare the most suitable units according to your
frame specification.
(1) Cot grinder

Example: HUBER + SUHNER BERKOL GRINDING MACHINE
(2) Cot ultraviolet processor
Example: HUBER + SUHNER BERKOL BERKOLIZING MACHINE
(3) Clearer cleaning machine
(4) Picker
(5) Yarn quality tester
Example: ZELLWEGGER USTER UT4. TENSORAPID. AFIS
(6) Spindle lubricator
Example: SKF, SUESSEN
69
Chapter 4 OTHER DEVICE
4.1 TMS (TOYOTA MONITORING SYSTEM)

You can use our TMS (TOYOTA MONITORING SYSTEM) and other network applications (optional) by connecting
the RX240 Ring Spinning Frame to the network.
You are requested to provide your own network piping, wiring-related equipment, computer arrangement and
construction work on your account.
4.1.1 Scope of Your Work

● Designation of TMS options of RX240
Since the network board and software CD-ROM exclusively for RX300 are necessary, lease inform TOYOTA
of these TMS options when determining the RX240 specifications.
● Network design based on RX300 connection study diagram
Study the RX240 connection method by entering the wiring route in the plant layout drawing.
Please prepare the network design appropriate for your plant by referring to "4.1.3 Network
Design" and determine the required cable length as well as the quantities and installing positions of switching
hubs and routers.
● Network construction
Network cables should be laid under the plant floor with protecting metal conduits for prevention of noise and
damage. The power supply (100 VAC or 200 VAC) for the line concentrators (switching hubs) for network
construction is also required. Please perform piping, network cabling, and power supply equipment installation
by referring to "4.1.4 Piping Work".
● Preparation of equipment and materials
Please prepare the equipment and material listed in 1) to 5) below.
Determine the necessary quantities by referring to "4.1.3 4) Network Equipment Selection and Ordering".
(1) Computer
(Selection standards)
・Since the network board and software CD-ROM exclusively for RX240 are necessary, lease inform
TOYOTA of these TMS options when determining the RX240 specifications.
・CPU: Frequency at or above 800 MHz
・Memory: 256 MB or more
・HDD: 2GB or more of HDD, C drive space
・LAN: Ethernet port installed as network interface (compatible with 100BASE-TX or 10BASE-T)
・Required peripherals: Display unit, keyboard, mouse, desk and chair
・PC card drive: Type I or Type II × 1 slot (TMS can be operated by data collection from the memory card
during network down. This is not mandatory.)
(2) Software
・Microsoft Internet Explorer version 5.5 or later
・Microsoft Excel 2000 (or newer Microsoft Excel)
70
(3) Switching hubs

・All ports must be compatible with 100 BASE-TX/10BASE-T, full/half duplex communication.
・At least 1,000 MAC address entries should be provided.
・Built-in power supply (since the adapter type involves possible jack disconnection)
・Desirably without a cooling fan (because the fan is likely to be broken)
(4) Router (when the number of looms is 200 or more)
・All ports must be compatible with 100 BASE-TX/10BASE-T, full/half duplex communication.
・Built-in power supply (since the adapter type involves possible jack disconnection)
・Desirably without a cooling fan (because the fan is likely to be broken)
・A local router function should be provided. The local router function allows independent IP address
assignment to each router port for mutual communication between different networks.
・The local router function, if used, allows inter-connection between different networks as follows:
・Please contact us if you need further details of these units and their ordering information.
(5) Network cable

・Must use 100BASE-TX (category 5 or above).
・Straight connection is necessary.
Note:
Installation work materials such as metal conduits and power cables are also required.
If you have any problem with 1) to 5) for TMS introduction, please consult with the Service or Sales
Department of TOYOTA Industries Corporation.
71
4.1.2 Network Connection Concept

For networking in a plant, connect the network boards (optional) in respective loom control panels using switching
hubs.
● Key Points for Wiring Design

・Construct one network (TMS network) by ring frames and a computer installed with the TMS (Toyota
Monitoring System). To connect the TMS network with your plant network, use a router in between.
・Use a switching hub to connect each Spinning Frame (network board) in the form of star connection.
・Determine the switching hub location so as to limit each network cable length within 100 m.
・Do not increase the number of switching hubs at will by taking possible communication delay into
consideration. (Design cascading with 10 stages as the upper limit.)
・Determine the switching hub ports in consideration of the number of looms, their layout, etc.
・For noise prevention in the plant, pass the network cables in dedicated metal conduits. If metal conduits
cannot be laid, use network cables with shielding wires. Provide a distance of at least 300 mm from the
power line, and ground the shielding wire on the side of the switching hub.
● Terminology
[Switching hub]
・A concentrator for accommodating network cables with a switching function. The switching function
refers to a function for reading the MAC address for the destination terminal in the data frame and
sending the data only to the port where the destination terminal is connected.
[MAC address]
・Hardware address to be set up for identifying the device to be connected in the network.
[100BASE-TX, 10 BASE-T]
・LAN transmission line specifications standardized by 802.3 Sub-committee of IEEE (Institute of Electric
and Electronics Engineers).
[Full/half duplex communication]
・In data communication, full duplex means data transmission in both directions at a time between two data
terminals while half duplex means data transmission only in one direction at a time.
[Router]
・A device for connecting multiple networks.
[Cascade stages]
・The number of stages when increasing the number of devices by connecting switching hubs and other
connecting devices by means of network cables.
72
4.1.3 Network Design

Network design is made for the following purposes:
・To determine the laying routes of network cables and the power line.
・To determine the lengths and quantities of necessary materials.
・To determine the locations for installation of the computer, switching hubs and the router.
The network is designed according to the following steps:

(1) Preparing the plant layout
(2) Determining the locations of the computer, router and switching hubs
(3) Checking the network wiring routes
(4) Network equipment selection and ordering
(1) Preparing the plant layout

・ Prepare the plant layout that allows precise grasp
of dimensional information such as the plant area,
pole positions and computer room position.
・ If Spinning Frame positions are not described I
the plant layout drawing, enter their positions.
Each Spinning Frame may be drawn as a
rectangle. The Spinning Frame length and
positions, however, should be drawn as accurate
as possible.
Plant layout example (Prepare a drawing allowing

precise grasp of space and other dimensions.)
(2) Determining the locations of the computer, router and switching hubs
・ The computer, switching hubs, and the router as
network components are precision electronic
devices. They should be installed in places that
can be protected from fluffs and condensation or
housed in metal boxes.
・ The power supply (100 VAC or 200 VAC) for the
network devices is necessary. Select the locations
where the power supply can be used.
・ Please study while checking the wall and poles to
confirm possibility of actual installation.
Note:
The computer is a precision electronic device.
Select a location where it can be protected from
fluffs and condensation.
・ Determine the place for installation of the router

required for connection with your plant network.
73
Note:
If it is to be installed inside the plant, house it in a
metal box for protection. Set the router according
to the instruction manual for the selected router.
・ Determine the place for switching hub installa-

tion.
Note:
If it is to be installed inside the plant, house it in a
metal box for protection.
・ Determine the places for installing switching hubs for Spinning Frame connection.
・ The number of Spinning Frame to be connected to each switching hub depends on the number of its ports. (8,
16 or 24 ports are general.)
・ The total number of switching hubs will decrease if the number of ports in each switching hub is greater. Such
problems as long wiring path and complicated wiring routes, however, may arise.
・ Determine the switching hub positions on the layout drawing in consideration of the wiring routes.
74
(3) Checking the network wiring route

・ Connect the network cable to the control box side
of each ring frame.
・ Be sure that the planned network devices can be
connected without any problem.
・ Be sure that there is no obstacle in the route to
make wiring impossible.
・ Be sure that the network cable length does not
exceed 100 m in any place. Since actual wiring
requires leading-in from under the floor into the
Spinning Frame and switching hub box, provide a
sufficient margin in length calculation.
・ If the network cable length exceeds 100 m, add a

relaying switching hub (a small one having about
8 ports) for extension within the route.
・ If there is no problem with the network wiring

route, enter all routes in the plant layout drawing
to complete the "network connection diagram".
Network connection diagram example
Note:
Always connect each and switching hub, or between
switching hubs using one independent cable in the
form of star connection.
75
・ Network devices require the power supply. Add

the power cable route, where new power line
installation work is necessary, to the plant layout
drawing to make the "network device power
cabling diagram".
Network device power cabling diagram example
・ Submit the network connection diagram and network device power cabling diagram to the person or company
in charge of installation when requesting the design and installation of actual piping.
(4) Network Equipment Selection and Ordering

・ Select and order equipment and materials based
on the network connection diagram.
Network connection diagram example
・ The necessary equipment and materials for the above figure as an example are as follows:
Ａ：Computer 1 set
Ｂ：Router 1 units
(For connecting your plant network)
Ｃ：Switching hubs 2 units
Ｄ：Network cable Calculate the required length based on the drawing.
Notes:
• For selection standards, refer to “4.1.1 Scope of Your Work.”
• Select each switching hub having the number of ports for connecting the number of devices.
• Metal conduits and power cable are also required.
76
4.1.4 Piping Work

・ The piping work for network wiring is described also in “4.1.2 Network Connection Concept.” Install
exclusive metal conduits for noise prevention. (See the figure below.)
(*) Since the rising length from the trunk line metal conduit to the Spinning Frame varies with the actual piping
method, provide sufficient margin (about 4 to 5 m) when calculating the cable length beforehand.
Note: Install metal conduit to pass the cable from each Spinning Frame to the respective switching hub. The
diameter of the metal conduit rising from the trunk metal conduit to the Spinning Frame must be Dia. 30 mm
or above, and the diameter of the trunk conduit should be determined according to the number of network
cables.
Prepare the power supply (100 or 200 VAC) for each switching hub at each place for installation. If a
shielded cable is used as a network cable, a grounding wire is necessary. Use the common power supply and
grounding for all switching hubs. If the power supply voltage is not stable, use a UPS (uninterruptible power
supply) for stabilized power supply. (See “4.1.5 Wiring Sample Diagram.”)
Note: The computer is a precision electronic device. Select a location where it can be protected from fluffs and
condensation. If it is to be installed inside the plant, house it in a metal box for protection.
77
In case of piping from the ceiling, the network cable should be led in from the inverter box side. Lead the cable to
the control box through the route on the lower R side of the boxes.
78
・ Make a metal box as shown below to fix each switching hub in it.
・ The switching hub should be made removable for easy maintenance.
・ Provide a household power outlet and a grounding connection port in the box.
・ Fix (or bury) each metal box on (or in) the plant wall.
Switching hub box manufacturing example
79
4.1.5 Wiring Sample Diagram

Network wiring example 1
(When a single piece of network cable within 100 m
can be used)
Network wiring example 2

(When a single piece of network cable over 100 m is
required)
80
4.1.6 Network Cable Connector Installation Method

(What must be prepared)
・Network cable (*)
・Connectors (*)
・Nippers
・Special network cable crimping tool
Note:
・*The network cable is available in single core type and multiple core (stranded core) type. Prepare
connectors that match the purchased cable type.
(What should be prepared for easy operation)

・Special network cable holding tool (for neat arrangement of the core conductors.)
・Exclusive network cable tester (to be used upon communication abnormality occurrence.)
Installation procedure
(1) Strip the cable outer insulation with nippers. Operate carefully so as not to damage the core conductors.
81
(2) Arrange the core conductors as illustrated below.
Order
Orange/white
Orange
Green/white
Blue
Blue/white
Green
Brown/white
Brown
(3) Cut the core conductors with nippers for neat arrangement.
(4) With the metal terminals of the connector facing upward, insert the arranged conductors into the connector.
82
(5) After checking if the inserted connectors are in the specified order, crimp them using the special crimping tool.
83
4.1.7 Network Cable Connection to RX300

Connect the network cable on the Spinning side to the daughter board (network interface card) on the control board
in the control box.
84
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RX300 Installation Manual ENG

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Model RX300 RING SPINNING FRAME

Thank you for purchasing the RX300 Ring Spinning Frame.

HEAD OFFICE: TOYOTA INDUSTRIES CORPORATION

INDIA: KIRLOSKAR TOYODA TEXTILE MACHINERY (P) LTD.

, , NOTE:, OUTLINE:, FUNCTION:, OPERATION:, ADJSTMENT:, and

■ Abbreviations and Notations

• Ring spinning frame, model RX300 RX

Chapter S Safe Work ㌀

Chapter 1 Preparation for Installation ㌀

Chapter 2 Procuring Installation Tools ㌀

Chapter 3 PREPARATIONS FOR OPERATION ㌀

Chapter 4 OTHER DEVICE ㌀

CHECK SHEET FOR PREPARATION OF RX

Chapter S Safe Work

S.1 Safe Work

TOYOTA has made every effort to assure as safe work as

It is impossible for the manufacturer to take into account

S.1.1 Rules for Installation Work

1. When foundation bolts, power cable conduits

2. If there is any unstable footing due to any pits

[2] During Installation

(3) Never use gloves if there is the possibility of

(6) Never climb onto a heavy hoisted object nor get

(8) Observe the following rules when conducting a

(4) Never lift the load on the carriers any higher

(8) Always push hand carts when carrying loads.

[2.3] Unpacking and Cleaning

Never apply gasoline or other volatile cleaning agents for cleaning.

(1) Parts are coated with rust-preventive oil.

[2.4] Handling Heavy Components

[2.7] Assembly and Adjustment

[3] Before Trial Running

[4] During Trail Running

S.1.2 Rules for Safe Operation

[1.2] Handling Abnormal Situations

[2] Precautions for Spinning

[2.3] Other Precautions

(2) Put on a gauze mask in the room when the

(3) Put on a pair of ear plugs to protect your ears

(4) Be sure to clean the machine to prevent fire as

S.1.3 Rules for Maintenance

[2] Precautions for Maintenance Personnel

(4) Lubricant, paint, bond, sealing agent or deter-

(5) For any work which could damage the eyes,

[3] During Maintenance Work

S.1.4 Rules for Operating or Checking the Electrical Devices

Chapter 1 Preparation for Installation

1.2 Foundation work

(1) Number of anchor bolts to be used:

1.3 Structure of foundation (2-head version for your reference)

1.4 Structure of foundation (3-head version for your reference)

1.5 Laying the foundation for wiring andpiping

・ For factories which are to use the ever-popular

Required wiring Required piping

When exhaust, piping, wiring and other pits are exposed

1.6 Floor-related Preparations

1.6.1 Floor surface conditions and reference installation height

■ Measuring irregularities and determining the reference installation height

1.6.2 Marking reference lines on the floor

Line A: Installation reference line

1.6.3 Checking before installation

1.6.4 Excavation of holes for anchor bolts

1.6.5 RH and LH sections

1.7.2 Circuit Breakers