btsr IS3F-485, Operating Manual

Page 1: ...SMART KNIT IS3F 485 YARN CONTROL SYSTEM Operating Manual Rev 1 0 January 2006 ENGLISH ...

Page 2: ... notice For any technical or commercial problem please contact your local BTSR dealer or call directly BTSR customer service center 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 and adopt exclusive profit...

Page 3: ...ensors 3 6 Interpretation of the sensor signaling lights 3 6 Settings that affect the sensor detection features 3 7 Programming examples for F_START F_STOP and relevant sensor delays 3 8 Automatic adaptation of control parameters to the machine speed 3 9 Preliminary operations for using the SMART KNIT Terminal 3 10 Operating Sequences 3 11 Functions available from SETUP menu CONFIG 3 12 Functions ...

Page 4: ...OW Configuration of Detection Parameters with Slow Ext Input Active 3 23 B3 P_FAST Configuration of Detection Parameters with Fast Ext Input Active 3 24 Display Signalings during the Control Process 3 25 Chapter 4 TROUBLESHOOTING AND MAINTENANCE Troubleshooting 4 1 Ordinary Maintenance 4 4 Repairs 4 4 Updating the Software Version on SMART Terminals 4 5 ...

Page 5: ... control parameters set may also occur automatically through an internal timing related for instance to the initial ramp stage and normal rate stage of the machine respectively SMART KNIT combined with yarn control sensors IS3F 485 represents a complete and effective machine control system How to use this manual This Operation Manual is divided into 4 Chapters Chapter 1 Overview describes the main...

Page 6: ...Introduction I 2 SMART KNIT Page intentionally left blank ...

Page 7: ...fined by the control algorithm P_ABCD thus detecting possible deviations with respect to the above mentioned sequence and stopping the knitting machine when the detected errors exceed the set tolerance Special Features of SMART KNIT System The SMART KNIT system has a set of unique features which make it a true microcomputer dedicated to programming control of production and statistical analysis of...

Page 8: ...tion Programmable Functions The systems allows programming either in global or selective way the sensor detection features Sensor Image Variation Frequency Sensitivity Reaction Time Tolerance etc Easy Monitoring and Fault Detection Besides the information provided on the graphical display of the SMART KNIT terminal each IS3 sensor has a red LED that when flashing indicates the location of the tech...

Page 9: ... levels Signaling With integrated LEDs red green Sensor identification Through Touch Light Dimensions 25 x 35 x 10 mm Temperature range 0 60 C SM DIN KNIT Modules Power supply voltage 15 24 Vac or 24 Vdc 10 Absorption Typical 0 2 A Max 2 A 2 STOP Outputs Stop1 Stop2 NO NC relay contacts 0 24 Vac 3 Inputs Slow Ext Fast Ext Reset Ext NO NC relay contacts 0 24 Vdc Integrated Touch pad 3 push buttons ...

Page 10: ... through SM DIN interface modules up to 8 Each module can manage up to 100 sensors distributed along 4 backbone lines The SM DIN modules communicate with SMART KNIT terminal via RS485 serial line Concerning all electrical systems it is a suggested rule to ensure that the ground cable GND is connected to the device support SM DIN modules Sensors connection ...

Page 11: ...Technical Data and Installation SMART KNIT 2 3 SM DIN Modules Interconnection ...

Page 12: ...ine Interface INPUTS Machine Interface OUTPUTS Chain 1 Sensors Chain 2 Sensors Chain 3 Sensors Chain 4 Sensors Max 100 sensors identified by means of Device function Setup Config menu SM DIN module nn identified by means of Edt function directly on SM DIN module Transformer ...

Page 13: ... signaling the operating status and levels in which the system 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 It allows you to activate the function selected from the menu indicated by the symbol to move to the programming of the displayed function or to confirm the setting value displayed on the m...

Page 14: ...e necessary information to guide the operator step by step through the programming phase and interactive management of the system When the displayed lines refer to the menu items the selected one is indicated with the symbol The presence of a flashing cursor indicates the position where the operator can enter an alphanumeric character or variable setting which will replace the value currently disp...

Page 15: ...e ENTER button while to do the opposite i e going from a lower to an upper level you must press the RESET button The level indication P1 P5 can be particularly useful during the initial phase when one is not yet familiar with the use of the programming functions For example if the system indicates P1 it is useless to press the RESET button as the system is already in the main menu and it is not po...

Page 16: ... modules within the system 1 to 8 Communication speed Baudrate between SMART KNIT and SM DIN 115 2 or 57 6 Kbps Procedure During the normal machine operation Parameter 01 SM DIN module identification number To increase the value max 8 To decrease the value min 1 Parameter P02 Baudrate Always set 115 2 Kbps 3 sec To select 57 6 Kbps or 115 2 Kbps Default 115 2 Kbps ...

Page 17: ...ndition Machine stationary Sensor numbering identification in progress Fault error signaling Signaling LEDS The lighting of respective red leds indicates FAST input inactive SLOW input inactive RESET input active SM DIN module in CONTROL status Communication in progress between SM DIN and SMART KNIT STOP output AL2 active led flashing STOP output AL1 active led flashing SM DIN module powered ...

Page 18: ...o the control of any type of yarn application Optical interface of IS3 sensors The IS3 sensors have two signaling lights green LED red LED and a Touch Light optical button During the automatic numbering of the sensors flashing green LED touch the optical button to give the sensor the number shown in the devices configuration screen Interpretation of the sensor signaling lights Green LED ON Normal ...

Page 19: ...nted by the settings connected to the type of yarn used and to the specific application Non control time D_CNTR Signaling tolerance for broken yarn BROKE Signaling tolerance for uncut yarn UNCUT Sensitivity SENS Reaction Time DELAY Start Frequency F_START Stop Frequency F_STOP Non control time D_CNTR This parameter allows you to delay the beginning of the actual control process after the activatio...

Page 20: ...gnals that the yarn runs normally red LED ON It can be programmed to a value ranging between 1 and 10 Programming examples for F_START F_STOP and relevant sensor delays As the diagram shows if the F_START and F_STOP value is set low e g 2 then the sensor could detect the condition of running yarn even though the yarn is actually still or broken and is undergoing a light oscillation A and B areas o...

Page 21: ...ication advantages such as Possibility of operating always with optimized parameters even if the machine features two different operating speeds for the processing of the same article providing that the machine itself is capable of providing two independent synchronization signals SLOW EXT and FAST EXT Possibility of using two different sets of parameters one for the ramp stage at low speed the ot...

Page 22: ...M DIN Interface Modules must turn On If the display does not light up then refer to Troubleshooting paragraph If the MACHINE message appears it means that the system correctly started the production control phase All the red Leds inside the buttons of SMART KNIT terminal as well as the Leds of SM DIN Interface Modules turn off except the CONTROL Leds If the ERROR RAM message appears on the screen ...

Page 23: ...uncut yarns etc and stopping the machine when the detected errors exceed the set tolerances Performing the sensor test as well as the communication test between SMART KNIT terminal and SM DIN modules and between SM DIN modules and sensors in case of failures When the system is turned on after the initial diagnostic phase SMART KNIT immediately gets into monitoring phase CONTROL To access the setti...

Page 24: ...Operation 3 12 SMART KNIT Functions available from SETUP menu CONFIG Functions available from SETUP menu P_ABCD P_SLOW P_FAST Main Menu Setup Programming Menu Main Menu Setup Programming Menu ...

Page 25: ...ber of SM DIN modules used to control the machine 1 to 8 to activate the function to increase the number of modules used nn to decrease the number of modules used nn to confirm the set value nn The number of configured modules must be consistent with the number of modules actually connected Otherwise the Program and Error labels will blink ...

Page 26: ...e cursor to move the cursor from aa field feeds to bb field sensors per feed or viceversa Allowed values aa 1 120 bb 1 6 to confirm the configured values and return to P3 menu to select the next function DEVICE to return to the P2 configuration menu The result obtained multiplying the number of feeds aa by the number of sensors per feed bb must be consistent with the number of SM DIN modules insta...

Page 27: ...d by the system depending on the values configured with the Feeds function aa x bb YYY shows the number of the first sensor and subsequently the next one to be numbered Check that the sensor being numbered has the green LED FLASHING which indicates 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 YYY and check that a ...

Page 28: ...ET EXT IN 4 Not used IN 5 Not used to activate the function parameter IN 1 FAST EXT to select NC or viceversa to confirm the choice and move to parameter IN 2 SLOW EXT to select NC or viceversa to confirm the choice and move to parameter IN 3 RESET EXT to select NC or viceversa to confirm the choice and move to parameter IN 4 Parameter not used press Parameter not used press to move to the configu...

Page 29: ...r ST 2 to select NO or viceversa to confirm the choice to move to the TEST function to return to CONFIG menu TEST Test Function and Sensor Firmware Update SETUP CONFIG TEST The TEST function allows you to perform 3 diagnostics sub functions COM Communication test between SMART KNIT and SM DIN FEEDS Test of sensors associated with the machine feeds SENSORS Test of individual sensors and a function ...

Page 30: ...d SM DIN modules to activate the Test function to select the Communication Test function to select the SM DIN module whose communication line efficiency is to be checked initially 01 From this moment on the system communicates repeatedly with the selected SM DIN module The running test status is signaled by the flashing red LED inside the ENTER button If no communications errors are detected then ...

Page 31: ...tion to activate the Test of Feeds to run the test of Feed 01 Confirm that the red leds of all sensors associated with Feed 01 are blinking to run the test of Feed 02 Confirm that the red leds of all sensors associated with Feed 02 are blinking Repeat the operation selectively for all the configured Feeds If the red led blinking is inconsistent check the programming of feeds FEEDS function paramet...

Page 32: ...e SMART KNIT system display The operator shall simply select the number of the desired sensor confirming that the red LED of the selected sensor is flashing to activate the function test 2 times to select the Sensor option to access the Test of Sensors to select the next sensor to select the previous sensor Check that the Red LED of the selected sensor is blinking Repeat the operation selectively ...

Page 33: ...tivate the Test function 3 times to access the UPG option nnn number of the first sensor to be upgraded mmm number of the last sensor to be upgraded to move the cursor from nnn field to mmm field or viceversa to increase the number pointed by the cursor to decrease the number pointed by the cursor to leave the function and return to the Test menu ...

Page 34: ...sor to select the type of logical function to be assigned to the sensor AND function OR function blank no function sensor ignored to move the cursor one position to the right to move the cursor one position to the left to confirm the setting and return to the configuration menu P2 How to Set the Control Algorithm Example with 4 feeders 4 sensors per feed The four yarns must always run or not run s...

Page 35: ...aragraph Settings that affect the sensor detection features to activate the function and to select in sequence the following parameters Delay Control Allowed values 100 ms 20 000 ms Broke tolerance prior to signal the broken yarn condition Allowed values 0010 ms 1 000 ms with steps of 10 ms and 1 000 ms 16 000 ms with steps of 100 ms Uncut tolerance prior to signal the uncut yarn condition Allowed...

Page 36: ...aph Settings that affect the sensor detection features to activate the function and to select in sequence the following parameters Delay Control Allowed values 100 ms 20 000 ms Broke tolerance prior to signal the broken yarn condition Allowed values 0010 ms 1 000 ms with steps of 10 ms and 1 000 ms 16 000 ms with steps of 100 ms Uncut tolerance prior to signal the uncut yarn condition Allowed valu...

Page 37: ...volved sensor Example SMART KNIT in control mode no failure detected Machine STOP due to broken yarn BROKE within the feed nn Machine STOP due to uncut yarn UNCUT within the feed nn Communication error between SMART terminal and device nn Inconsistency between number of sensors detected and number of sensors programmed Communication error between SMART KNIT and SM DIN module NN To restore the corr...

Page 38: ...Operation 3 26 SMART KNIT Page intentionally left blank ...

Page 39: ...stem off and on again If the problem persists contact your BTSR dealer The sensors numbering procedure fails the number YYY does not increase in the screen DEVICE YYY ZZZ Communications line problems Check that the sensors are correctly connected Check for locked sensors green and red LED simultaneously ON Turn off and on again the system If the problem persists replace the sensor If the problem p...

Page 40: ...on SM DIN module nn Press If the problem persists turn the system off and on again If the problem persists replace the SM DIN module Message ERROR INPUT on display of SMART terminal The input signal configuration SLOW EXT FAST EXT is not consistent on all the SM DIN modules Check the wiring of input signals Message ERR_COM BOARDNN on display of SMART terminal Communication error between SMART term...

Page 41: ... phase Check the programming parameters of BOARDS and FEEDS functions If the fault is not included in the above table please contact your local BTSR dealer giving a detailed description of the fault and the conditions in which it occurred When the BTSR Technical Service intervention is required before calling you are kindly recommended to take note of the code printed on the defective sensor s on ...

Page 42: ... with an automatic compensation function which allows the detection features to remain unaffected even when some traces of dirt are present However it is suggested to clean the sensors periodically For cleaning purposes do not use solvent but rather a soft cloth dampened with neutral detergent or alcohol Repairs Any repair intervention on the SMART KNIT terminal or the SM DIN modules must be carri...

Page 43: ... the 4 locking screws 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 cir...

Page 44: ...Troubleshooting and Maintenance 4 6 SMART KNIT Page intentionally left blank ...

Page 45: ...BTSR International S p A Via S Rita 21057 OLGIATE OLONA VA Tel 0331 323202 Fax 0331 323282 Internet www btsr com REV 1 0 01 06 DISTRIBUTOR ...