btsr IS3, Operating Manual

Page 1: ...SMART 3000TW IS3 YARN CONTROL SYSTEM Operating Manual ENGLISH ...

Page 2: ...nts of this manual without notice For any technical or commercial problem please contact your local BTSR dealer or call directly BTSR customer service centre We will be glad to meet your needs Thank you for your trust and good job The product described herein is compliant with the requirements of 89 336 EEC EMC Directive and 73 23 EEC Low Voltage Directive All BTSR products are covered by patents ...

Page 3: ...al s 3 2 SMART 200 INT TW 485 Interface Board Features 3 4 IS3 Sensors Features 3 5 Types of IS3 sensors for SMART 3000TW 3 5 Function of the IS3 Sensors 3 5 Installation of the IS3 Sensors 3 6 Interpretation of the signalling lights located on the sensors 3 6 Settings that affect the sensor detection features 3 7 Programming examples for F_START F_STOP and relevant sensor delays 3 8 Interface Boa...

Page 4: ...ramming Level 3 35 SENS G Sensitivity global 3 35 DELAY G Reaction Time global 3 36 TEST Functions 3 37 TEST_SE Sensors Test 3 37 COM_B01 Testing the Efficiency Rate over the Communications Line between the SMART 3000TW terminal and all sensors connected to the various Boards 3 37 TEST_BA Bars Test 3 38 BAR_B01 Testing the Efficiency Rate over the Communications Line between the SMART 3000TW termi...

Page 5: ...ity that would normally occur during production in addition it dramatically reduces needle breakages and machine stops thus allowing a rapid pay back of your investment SMART 3000TW combined with IS3 yarn smart control sensors represents a full and effective machine control system How to use this Manual This Operating Manual is divided into 4 Chapters and 1 Appendix Chapter 1 Overview describes th...

Page 6: ...S3 The symbol IS3 generally indicates all the variants of the IS3 sensor For further details please refer to paragraph Types of IS3 sensors In the operating sequences this symbol indicates that to activate the desired function you must press and hold for 3 seconds the button Within the Appendix A Quick Reference the push buttons of SMART control panel are shown as follows Button Button Button Butt...

Page 7: ...n by comparing each production cycle with a sample cycle previously self learnt LEARN function under ideal conditions thus detecting possible deviations with respect to the above mentioned sample cycle and stopping the textile machine when the detected errors exceed the set tolerance Special Features of SMART 3000TW System The SMART 3000TW system has a set of unique features which make it a true m...

Page 8: ...sulting in a simple and fast system configuration Programmable Functions The systems allows programming the sensor detection features Sensor Image Variation Frequency Sensitivity Reaction Time Tolerance etc Production Data The system records during production the machine stops detected by each sensor and by error type Easy Monitoring Besides the information provided on the graphical display of SMA...

Page 9: ... 24 Vdc 10 Maximum Absorption 150 mA Dimensions 140 x 110 x 30 mm Temperature range 0 60 C Signalling LEDs 8 STOP ALARM NEXT CYCLE COM PORT RS485 CONTROL LEARN IDENTIFY SYNCRONISM TIME OUT Protection 1 fuse 5 x 20 1A PSU 10A Power Supply Power supply voltage 24 Vac dc 10 Number of output channels 8 4 4 Output voltage 24 Vdc 5 Max output current 10A peak 6A continuous Dimensions 115 x 135 x 55 mm T...

Page 10: ... connected through Interface Boards Board 1 8 The Boards communicate with SMART 3000TW Terminal using a RS485 Serial Line From the physical point of view the Boards may be installed tens of metres far from the SMART Terminal and they may be included within a special box Bx5040FSST Each box is equipped with a safety switch and cooling fans and it may host up to 4 boards ...

Page 11: ...a and Installation SMART 3000TW 2 3 Connection Example for General Purpose Application Concerning all electrical systems it is a suggested rule to ensure that the ground cable GND is connected to the sensor support ...

Page 12: ...Length 200 cm or 500 cm includes the proximity Multi connector Cables for Connecting IS3 Sensors MA60 60 5CR Ready for 5 sensors with pitch of 60 cm MA75 75 6CR Ready for 6 sensors with pitch of 75 cm MA75 75 7CR Ready for 7 sensors with pitch of 75 cm MA75 75 8CR Ready for 8 sensors with pitch of 75 cm MA60 40 10CR Ready for 10 sensors with pitch of 60 cm MA60 40 12CR Ready for 12 sensors with pi...

Page 13: ...pply with 24 Vdc output 10A Peak 6A continuous PSU 10A The number of Power Supplies required depends on the amount of sensors used and on the application characteristics External RESET Connection RST EXT The external RESET signal is used to reset the system in case of error in the place of terminal s RESET button RESET WITH PUSH BUTTON The RESET input must be provided by a contact which connects t...

Page 14: ...Technical Data and Installation 2 6 SMART 3000TW Page intentionally left blank ...

Page 15: ...tem is working The following picture shows the location of the buttons and display zones that constitute the control panel of the system 1 ENTER button Pressing and holding for 3 seconds the ENTER button when the system is in control condition CONTROL nnnn displayed gives access to P1 programming level Pressing and holding for 3 seconds the ENTER button while the system is at beginning of P1 menu ...

Page 16: ...nking cursor to the next parameter cyclic function 5 REPEAT button During the parameters setting phase within a programming menu it allows you to decrease the numeric value of current field If it is kept continuously pressed the numeric field decreases more quickly When alphanumeric data are entered for instance the Key_cod or K_learn this button allows the decrease of characters pointed by the cu...

Page 17: ...are implemented They display the operating status of the system and the hierarchic level of the menu at which you are operating More specifically the PROGRAM label indicates that you are operating in one of the following modes configuration programming or data transmission to the sensors The CONTROL label indicates that the system is operating normally with all monitor functions enabled and accord...

Page 18: ...s is signalled by 8 red LEDs which light to indicate respectively Board in STOP ALARM condition Error message displayed on terminal screen Next Cycle function active i e NEXT CY and RESET push button pressed on main terminal The system remains disabled for an entire control cycle during which the CONTROL LED stays off both on Boards and on main terminal RS485 communication port inactive System run...

Page 19: ... an unique electronic sensor for yarn control when combined with the SMART series controllers thanks to a patented innovating technique Image Smart Scanning Sensor it does not require complex cabling and long installation time the new multi connector cable allows in fact to control multiple sensors IS3 is full programmable for an easy fitting to the control of any type of yarn application Types of...

Page 20: ... secure the sensor using a M3 screw Check that the yarn runs in the centre of the area shown in the following pictures Interpretation of the signalling lights located on the sensors Green LED ON Normal operation the yarn is running inside the sensor No technical fault detected by the sensor Red LED ON Yarn stopped Green LED FLASHING The system is in automatic numbering phase Red LED FLASHING Durin...

Page 21: ...ide the detection area Finally there are other factors that can affect the detection activity of the sensors like the size and type of yarn silk wool acrylic Lycra single filament nylon as the variation of the image depends on these factors as well That s why the microcomputer embedded in the sensor processes the images provided by the camera by means of the sensor memory which takes into account ...

Page 22: ...dition of optimal detection for that particular article The suggested default values are the following F_START 5 and F_STOP 5 In the presence of frequent errors detected by the sensors it is suggested to gradually change such values until an optimal condition is achieved Sensitivity SENS The SENS settings allow the control of the sensitivity level of the sensor depending on the article to be worke...

Page 23: ...n of Interface Boards by SMART 3000TW terminal occurs by means of three Hardware encoding signals COD_0 COD_1 COD_2 on the 10 pin connector I O SMART 3000TW Computer of each Board When the system is turned on it automatically detects the number of Boards currently connected ...

Page 24: ...The sensors are located inside Logical aways definable by the user according to the machine configuration This allows the user to immediately locate the machine Zone where each individual sensor operates for instance to quickly locate a faulty sensor During the system configuration the user can arrange the Physical Identification of sensors menu P1 by indicating how many and which sensors are conn...

Page 25: ...Operating SMART 3000TW 3 11 Example of 2 sections Machine Side A B Example of 4 sections Machine Side A B C D Example of 8 sections Machine Side A B C D E F G H Sensor Array ...

Page 26: ...nfigured independently from each other by depending a Virtual Array of Rows and Columns Example of creel section with 400 sensors distributed along 40 columns of 10 sensors Columns Priority Example of creel section with 400 sensors distributed along 10 rows of 40 sensors Rows Priority ...

Page 27: ...Operating SMART 3000TW 3 13 Example of creel section with 400 sensors distributed along 40 Bars of 10 Sensors Bars Priority On top of each Bar there s a failure signalling lamp LAMP 485 ...

Page 28: ...ting 3 14 SMART 3000TW Example of creel section physical wiring Side with 100 sensors 5 rows x 20 columns N B All blue wires of MAFE4 cable must be connected to the ground potential of yarn support structure ...

Page 29: ...es For more details on possible machine configurations please refer to Sensor Identification Modes paragraph If the display is blank refer to chapter 4 Troubleshooting If the CONTROL word appears it means that the system correctly started the production control phase All the red Leds inside the buttons of SMART 3000TW and inside the SMART 200 INT TW 485 Boards turn off except the CONTROL leds If t...

Page 30: ...cy is not confirmed it completes the self diagnosys and normally activates the control mode Otherwise if the inconsintency persists it displays again the N_BOARD 00x Y N message If you press Y when the N_BOARD 00x Y N is displayed it means that you want to continue with the number of Boards x actually detected If the problem is due to the fact that one or more Board was added after the last stored...

Page 31: ...uent failures Reading and eventually resetting the BROKE and UNCUT error counters When the system is turned on after the initial diagnostic phase SMART 3000TW immediately gets into monitoring phase CONTROL To access the setting changing menus of system operation parameters press and hold for 3 seconds To activate a learning cycle LEARN press and hold and simultaneously To display the BROKE and UNC...

Page 32: ...n number is shown on the Control screen Both Learn and Control phases start after a programmable delay time D_LEARN in order to allow the machine reaching the rated speed To avoid evaluation mistakes i e to consider a yarn running while it is actually still the Learn phase uses a special BTSR algorithm that makes such phase extremely accurate In case of unstable sensor reading an error message ERR...

Page 33: ...unication Error with Board 0n To restore the normal operating conditions press RESET and refer to Chapter 4 Trobleshooting and Maintenance B If either Rows or Columns priority has been programmed within menu P2 SMART 3000TW under Control phase no failure detected Machine STOP due to broken yarn BROKE on Device located on Row xx Column yy co ordinates of creel side N nnn Total stops occurred on Dev...

Page 34: ...otal stops occurred on Device In this case the Bar Sensor connected to Bar xx will blink Machine STOP due to uncut yarn UNCUT on Device connected to Board xx Side N nnn Total stops occurred on Device In this case the Bar Sensor connected to Bar xx will blink Communication Error with Board 0n To restore the normal operating conditions press RESET and refer to Chapter 4 Trobleshooting and Maintenanc...

Page 35: ...Operating SMART 3000TW 3 21 Summary Diagram of SMART 3000TW Programming Configuration Menu ...

Page 36: ...nus P1 P4 and PX Access password to learning function LEARN While the system is in control condition press and hold for 3 seconds This screen indicates that the P1 programming level has been activated Press to select the first programmable parameter of P1 Level SYNC SYNC Proxy Pulse Divisor The SYNC parameter indicates the divisor of proximity pulses detected during the cylinder rotation used to g...

Page 37: ...Logical level RESET N Press to move to the next parameter D_LEARN D_LEARN Delay time before starting the Learn and Control phases Number of waiting Proximity pulses prior to start the Learning phase LEARN and the Control phase CONTROL This function is used to delay the start of Learn Control phase in order to allow the machine reaching the rated speed Allowed values 001 250 Default 020 increases n...

Page 38: ...s Sensor ready to be numbered With a finger skim the Touch Light area of the sensor to which you wish to assign the number shown by mmm and check that a The sensor LED changes from blinking green to red b The number mmm is increased by 1 unit Repeat the operation on all connected sensors Once the numbering procedure of sensors connected to Board 01 is completed the DEVICES BOARD 02 screen will app...

Page 39: ...85 devices numbering is starting nnn shows the total amount of devices to be numbered mmm shows the number of the first device and subsequently the next one to be numbered Check that the LAMP 485 devices on top of all bars is flashing green to indicate the Bar ready to be numbered condition Press the button of LAMP 485 devices to which you wish to assign the number shown by mmm and check that a Th...

Page 40: ... proceed with the re numbering operation of the involved sensor Press to continue Press until the field mmm will show the actual number of the replaced sensor i e the sensor that must be re numbered With a finger skim the Touch Light area of the replacing sensor and check that the sensor LED goes from flashing green to red The replaced sensor will now be renumbered with the same number of the old ...

Page 41: ...he access code it will be necessary to contact your BTSR reseller K_LEARN Password to Access the Learning Function To access the K_LEARN setting functions press and hold for 3 seconds while the display shows the last P1 menu item KEY_COD This function allows you to setup a secret code to access the learning functions LEARN Enter the code of your choice from 1 to 7 alphanumeric characters using the...

Page 42: ...g Level just pressing the RESET button To leave the P2 menu without completing the configuration for instance when you know you made a mistake on the previous step you will have to either switch OFF and ON again the terminal or wait the expiration of 1 minute time out that brings back the system to the CONTROL status DEFINE SIDE Defining the Number of Sections SIDE Define the number of sections SI...

Page 43: ...depends on the priority choice setup on previous stop Allowed values 01 99 increases the value nn decreases the value nn confirms the display value Start configuration of Row Column or Bar 01 to continue ssss No 1st sensor connected to row column bar 01 of section A eeee No last sensor connected to row column bar 01 of section A increases the eeee number by 1 decreases the eeee number by 1 increas...

Page 44: ... until you complete the numbering of the last row column bar At the end the system will automatically return to the beginning of P2 menu Press if you want to check the logical configuration just defined or press to return to Control condition EXAMPLE System with 4 sections Sides A B C D with Column Priority 10 Columns and 8 Sensors for each column until COL 10 until H 0008 until H 0016 until H 002...

Page 45: ...t column of Section A DEFINE COL 10 L 0073 H 0080 DEFINE SIDE B DEFINE COL 10 DEFINE COL 01 1 st column of Section B L 0081 H 0088 DEFINE COL 02 L 0089 H 0096 Last column of Section B L 0153 H 0160 DEFINE SIDE C DEFINE COL 10 DEFINE COL 01 1 st column of Section C L 0161 H 0168 L 0233 H 0240 DEFINE SIDE D Last column of Section C DEFINE COL 10 ...

Page 46: ...ine is configured with 2 Boards Board 01 160 sensors SIDE A SIDE B Board 02 160 sensors SIDE C SIDE D In case of failure on sensor 254 the error signalling message will be displayed as SIDE D COL 02 In the above example we assumed that the machine had 4 identical sections 80 sensor per section However the SMART 3000TW system allows you to configure the sections differently from each other DEFINE C...

Page 47: ...ble to assign a global tolerance value i e identical to all connected sensors for broken yarn Allowed values 001 050 Default 006 Select the desired values using increases the value decreases the value Example Programming 008 SMART 3000TW will stop the machine after 8 consecutive errors detected within the same cycle Press to communicate the setup value to all the Interface Boards connected to the ...

Page 48: ... detected within the same cycle The UNCUT G function may be disabled or re enabled pressing and holding for 3 seconds the ENTER button When the function is disabled the word OFF appears in place of xxx Press to communicate the setup value to all the Interface Boards connected to the system and return to P3 menu If one of the Boards does not replay correctly for instance Board disconnected or RS485...

Page 49: ... all connected sensors in order to adapt the sensors to any type of application or yarn to be controlled Allowed values 001 010 Default 005 001 minimum sensitivity level suitable for very large yarns 010 maximum sensitivity level suitable for very thin yarns Very thick yarns 1 Thick yarns 3 Medium yarns 5 Fine yarns single filament yarn 6 8 Very fine yarns Lycra 9 10 For more details please refers...

Page 50: ...ed value for high yarn speed 200 ms is the recommended value for normal yarn 500 ms is the recommended value for elastic yarn Choose the desired reaction time selects the next value within the 8 predefined settings selects the previous value Press to communicate the setup value to all the Interface Boards connected to the system and return to P4 menu If one of the sensors does not reply correctly ...

Page 51: ...en operation problems occur which require a check of each sensor individually The test does not send any diagnostic message to the SMART system display You will have to simply select the number of the desired sensor DEV nnn by using the button NEXT CY and checking that the red LED on all sensors identified by number nnn sensor nnn connected to Board 01 sensor nnn connected to Board 02 sensor nnn c...

Page 52: ...ates repeatedly with all connected sensors The test running status is signalled by the flashing red LED embedded in the ENTER button If there are no communication errors detected the display shows the message COM_B01 000 000 If communication errors are detected the display shows the message COM_B01 XXX YYY where the XXX indicates the total number of failed attempts and YYY indicates the total numb...

Page 53: ...rious Boards This function allows to check the perfect operation of the communications line between the SMART 3000TW terminal and LAMP 485 devices connected to the individual Boards It is suggested to run this check during the first testing phase immediately after installation and each time random problems occur in the system operation which may have been caused by inefficient communications betwe...

Page 54: ...T F_START START Frequency This function allows you to program the START frequency applied to all sensors connected to SMART 3000TW terminal The START frequency is the minimum yarn image variation frequency above which the sensor indicates the yarn running condition green LED on For more details please refers to Settings that affect the sensor detection features paragraph Allowed values 001 010 Def...

Page 55: ...chapter 4 Troubleshooting H_SPEED Enabling Disabling the Sensors reading Synchronism with PRX signal This function allows you to choose between two different reading modes of yarn running condition inside the sensors H_SPEED enabled ON The yarn running condition is detected only during the switching edges of PRX pulses H_SPEED disabled OFF The yarn running condition is detected and stored during t...

Page 56: ...BROKE detected by all sensors connected to SMART 3000TW terminal yyyy indicates the overall number of errors due to uncut yarn TOTAL UNCUT detected by all sensors connected to SMART 3000TW terminal Press to leave the function without resetting the counters Press and hold for 3 seconds to clear the counters the display will show for a few seconds the message COUNTER RESET Press to display the broke...

Page 57: ...m battery may be required Message at startup ERROR RAM B0y The self diagnostics detected an error on the Board 0y Press the button The system will reload parameters on Board 0y displaying a PROGRAM RAM B0n message then it will move to Control condition CONTROL nnnn If the problem persists contact your BTSR reseller The replacement of the system s lithium battery may be required The SMART system do...

Page 58: ...Increase Sensitivity and or decrease Start Frequency to optimise the reading The signalling of stopped yarn failed the green led does not turn off Sensitivity Too High Decrease Sensitivity and or increase Stop Frequency The display show the ERROR Dxxx message Sensor XXX of Board 0y disconnected or faulty Power off and on the system If the problem persists replace the sensor See next paragraph Temp...

Page 59: ...lly connected press RESET The system will repeat the detection procedure displaying WAIT READING Check the Board address coding see page 3 9 and the RS485 physical connection Set the number of sensors connected to Board 01 Increases the value decreases the value Set the number of sensors connected to Board 02 Increases the value decreases the value Set the number of sensors for all the other conne...

Page 60: ...id continuous machine stops To disable a faulty sensor operate as follows When the error message appears press and hold for3 seconds Press Y to disable the sensor Press N to clear the error without disabling the sensor Once disabled the sensor will remain excluded until you switch off and on again the system This procedure is very useful in case of defective sensor as the system can still work wai...

Page 61: ...f the system without threading the yarns through the IS3 sensors The SMART terminal must stop the machine when a given yarn starts to work showing on the display the corresponding sensor number Thread the yarn inside the sensor and press RESET to clear the error Repeat the operation on all the yarns Ordinary Maintenance The SMART 3000TW system does not require special maintenance interventions Alt...

Page 62: ...crews and remove the rear cover Fig 1 6 Using the IC extractor remove with care the Integrated Circuit from the socket located on the right top corner of PCB Fig 2 7 Place the Integrated Circuit containing the new software version over the socket paying attention to its correct orientation Fig 3 8 Applying a moderate and progressive pressure with both thumbs push the integrated circuit down into t...

Page 63: ...ance from Box BX5040FSST 5 Using a small screw driver remove the 4 plastic pins and remove the front cover to gain access to the PCB Fig 1 6 Using the IC extractor remove with care the Integrated Circuit from the socket located on the right top corner of PCB Fig 2 7 Place the Integrated Circuit containing the new software version over the socket paying attention to its correct orientation Fig 3 8 ...

Page 64: ...ake note of the defined settings The following table is intended to help you in this task make copy of the form for future use P1 P3 P4 PX SYNC RESET D_LEARN DEVICES KEY_COD K_LEARN BROKEG UNCUT G SENS G DELAY G F_START F_STOP H_SPEED N P BARS BOARD 1 BOARD 2 BOARD 3 BOARD 4 BOARD 5 BOARD 6 BOARD 7 BOARD 8 Sensor No From To SECTIONS A B C D E F G H ROWS COLUMNS PRIORITY BARS ...

Page 65: ...uences which are required to complete all the functions available on the SMART 3000TW system The use of the quick reference guide supposes that the user has already acquired a certain ability in handling the system therefore there are no detailed explanations of each screen shot there is only a global overview of the required steps for each function 4 Symbols Key ...

Page 66: ...Appendix A Quick Reference A 2 SMART 3000TW Symbols Key ...

Page 67: ...Appendix A Quick Reference SMART 3000TW A 3 Symbols Key ...

Page 68: ...Appendix A Quick Reference A 4 SMART 3000TW Symbols Key ...

Page 69: ...Appendix A Quick Reference SMART 3000TW A 5 Symbols Key ...

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Page 71: ...BTSR S p A Via S Rita 21057 OLGIATE OLONA VA Tel 0331 323202 Fax 0331 323282 Internet www btsr com REV 01 06 01 DISTRIBUTOR ...